Integrated Thermal Bypass Valve for Heat Exchanger Weight Reduction
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Solution Overview
Problem
Existing heat exchanger systems in automotive applications are space-intensive and add weight, potentially degrading fuel economy, and are sensitive to environmental conditions affecting oil temperature readings, leading to inefficient coolant flow.
Innovation Solution
A heat exchanger apparatus with an integrated thermal bypass valve (TBV) that includes a sleeve with slots, a movable drum, and a thermal actuator, allowing fluid to bypass the heat exchanger based on temperature, reducing space requirements and improving flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a thermostat is used to control coolant flow in response to oil temperature, then the flow rate can be regulated, but the system takes up considerable space and adds weight
Solution Approach 1:
The patent combines the thermostat and bypass valve functions into a single integrated thermal bypass valve assembly that is directly mounted on the heat exchanger. This merging of components eliminates the need for separate thermostats and valve mechanisms, thereby reducing overall system weight while maintaining the ability to control coolant flow in response to oil temperature.
Solution Approach 2:
The thermal bypass valve assembly is nested within or directly integrated with the heat exchanger structure. The valve body incorporates internal passages and moving parts that are contained within the overall heat exchanger assembly, allowing the control mechanism to be housed within the existing structural envelope rather than adding external components.
2Ease of operation
If a thermostat is used to control coolant flow, then flow rate regulation is achieved, but the system occupies considerable space
Solution Approach 1:
The thermostat and bypass valve are merged into a single integrated assembly that is mounted directly on the heat exchanger. This combination eliminates the need for separate control components and reduces the overall space required for the temperature control system while maintaining full flow regulation capability.
Solution Approach 2:
The integrated thermal bypass valve serves multiple functions: it acts as both the temperature-sensing thermostat and the flow-control valve, and also serves as part of the heat exchanger mounting structure. This multi-functionality reduces the number of separate components needed and minimizes the total space occupied by the system.
3Measurement precision
If the thermostat is positioned upstream to measure oil temperature, then early detection is possible, but environmental conditions affect the temperature reading accuracy
Solution Approach 1:
The temperature-sensing element is extracted from the upstream position and repositioned to be in direct thermal contact with the oil passage within the heat exchanger. This extraction from the environmental exposure zone eliminates the harmful effects of ambient temperature on the reading, while the sensing element still detects oil temperature accurately through direct thermal coupling with the oil-flowing passages.
4Ease of operation
If separate thermostat and valve systems are used, then flow control is achieved, but the system adds weight degrading fuel economy
Solution Approach 1:
The separate thermostat and valve systems are merged into a single integrated thermal bypass valve assembly. This consolidation reduces the total weight of the temperature control system, thereby improving fuel economy while maintaining the ability to regulate coolant flow in response to oil temperature conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated thermal bypass valve reduces the overall size and weight of the heat exchanger system while optimizing fluid flow by adapting to temperature changes, enhancing efficiency and fuel economy.
Implementation Method 1
a thermal actuator engaging the drum and actuating the drum to move from the first position to the second position in response to the temperature of the first fluid
Data Source
AI summary
A heat exchanger apparatus containing a heat exchanger and a thermally actuated bypass valve is described. The heat exchanger has a plurality of plates defining a first, a second and a bypass channels. A first fluid inlet manifold is in fluid communication with the first and the bypass channels. The bypass valve is positioned in the first fluid inlet manifold, and contains a sleeve having a first slot and a second slot, that permit fluid flow from a first fluid inlet to the bypass channel and to the first fluid inlet manifold, respectively. A drum is positioned within the sleeve and is movable from a first position to a second position. The drum has an aperture permitting first fluid flow to the first slot in the first position and to the second slot in the second position. An actuator engages the drum and actuates it to move from the first position to the second position.