Internal Insulation for Engine Oil Galleries
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Solution Overview
Problem
Existing lubrication systems for rotating or oscillating components, particularly in engines and transmissions, face challenges in reducing friction and energy consumption during cold-starting phases due to high viscosity of lubricating oils at low temperatures, leading to increased fuel consumption and emissions. Current solutions are complex, costly, and offer only limited reductions in friction losses.
Innovation Solution
A thermally insulated lubrication system with internal insulation in metal housing components and oil galleries, reducing thermal conductivity and surface area-to-volume ratios to minimize heat loss and enhance oil heating efficiency, combined with a thermal reservoir using phase change materials for improved heat storage and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If external insulation is applied to oil lines and housing, then heat loss is reduced, but the surface area increases leading to greater heat loss and fire safety hazards
Solution Approach 1:
The patent applies internal insulation by integrating insulation material within the existing oil lines and housing structure, rather than adding external insulation layers. This nested approach reduces heat loss while avoiding the fire safety hazards and increased surface area associated with external insulation, as the insulation is contained within the existing structural boundaries.
2Loss of energy
If high-quality lubricating oils with reduced viscosity are used, then friction losses are reduced, but the cost increases
Solution Approach 1:
The patent uses thermal insulation to maintain elevated oil temperature, which changes the physical parameter of oil viscosity. By keeping the oil warm, the viscosity remains lower without requiring expensive synthetic oil formulations, thus reducing friction losses while avoiding the high cost of specialized lubricants.
3Use of energy by moving object
If exhaust gas heat exchangers are used to heat engine oil, then fuel consumption is reduced, but the system complexity and fault susceptibility increase
Solution Approach 1:
The patent employs passive thermal insulation that allows the system to self-maintain oil temperature without active heating components. The insulation traps residual heat within the oil lines and housing, enabling the system to sustain adequate lubrication temperatures without complex exhaust gas heat exchangers, thereby reducing fuel consumption while avoiding system complexity.
4Reliability
If additional oil coolers are installed to protect from overheating, then engine protection is improved, but the device complexity and cost increase
Solution Approach 1:
The patent applies thermal insulation selectively to critical oil lines and housing sections where heat retention is most beneficial, rather than insulating the entire system. This partial insulation approach provides sufficient temperature maintenance for engine protection while avoiding the excessive complexity and cost of comprehensive insulation or additional active cooling systems.
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 system achieves significant reductions in friction and energy consumption, particularly during cold-starting, by maintaining low viscosity of lubricating oils, thereby improving fuel efficiency and reducing emissions while maintaining mechanical integrity and cost-effectiveness.
Implementation Method 1
at least one connecting line has inside the oil gallery and upstream from the heat source internal insulation on its inside walls, where the thermal conductivity of the internal insulation is 5% or less than the thermal conductivity of the connecting lines or of the rest of the oil gallery
Implementation Method 2
a heat source and further connecting lines that are integrated into a metal housing, in particular an oil gallery for distributing lubricating oil to the components
Implementation Method 3
combined with a thermal reservoir using phase change materials for improved heat storage and distribution
Data Source
AI summary
The invention relates to a thermally insulated Lubrication system (100) for the lubrication of rotating or oscillating components with at least one oil suction pipe (3) arranged in an oil reservoir (1), an oil pump (4) connected to the oil suction pipe (3), and a heat source (7) connected to the oil pump (4) and downstream from this, further connecting lines (10) for feeding oil to lubrication points (11) that are structurally integrated into a metal structural environment (63) of a metal housing, after which oil is returned to the oil reservoir (1).It is proposed that at least one connecting line (10) between the heat source (7) and the lubrication point (11) downstream from the heat source has internal insulation (13) on its inside walls, wherein the thermal conductivity of the internal insulation (13) is 5% or less than the thermal conductivity of the connecting lines or of the rest of the structural environment (63), and that the heat source (7) is switched off, or at least its heat output is reduced, when a first upper oil limit temperature is reached.By improved insulation, fast heating and hence a lowering of fuel consumption in the cold starting phase is achieved.