Modular Expansion Tank With Reorientable Joints For Coolant Circuits
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Solution Overview
Problem
Conventional expansion tanks for motor vehicle coolant circuits occupy a large volume due to their design, making them costly and inflexible for adaptation to different vehicle types, which increases manufacturing and tooling costs.
Innovation Solution
The expansion tank is designed with an upper and lower part that can be assembled and connected in multiple orientations using complementary joints, allowing for the production of various configurations using the same parts, reducing tooling costs and enabling flexible adaptation to different vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If a conventional expansion tank design is used, then the expansion tank can fulfill its cooling circuit functions, but the volume occupied is large and manufacturing costs are high
Solution Approach 1:
The expansion tank is divided into two separate housing halves (upper and lower parts) that can be manufactured independently using standard injection molds. These segments are then assembled together with complementary joints, allowing the same basic components to create multiple tank configurations and reducing the need for custom tooling for different vehicle types.
Solution Approach 2:
The housing halves are designed with complementary joints that enable multiple assembly orientations (e.g., 0 degrees, 90 degrees, 180 degrees). This universal design allows a single set of housing components to serve multiple vehicle types and space requirements, making the expansion tank adaptable to different engine compartments without requiring entirely different parts.
2Adaptability or versatility
If the expansion tank design is customized for different vehicle types, then the geometric requirements are met, but the manufacturing and tooling costs increase
Solution Approach 1:
By segmenting the expansion tank into standardized housing halves with complementary joints, the design enables flexibility in assembly orientation while maintaining consistent manufacturing processes. The same housing components can be assembled in different configurations to meet various vehicle-specific geometric requirements.
Solution Approach 2:
The complementary joint design creates a universal interface that works across multiple vehicle platforms. A single set of housing halves can be used to produce expansion tanks for different vehicle types by simply changing the assembly orientation, eliminating the need for vehicle-specific tooling while maintaining adaptability.
3Adaptability or versatility
If multiple expansion tank configurations are produced using different parts, then the specific vehicle requirements are met, but the number of tools required increases
Solution Approach 1:
The expansion tank is segmented into modular housing halves that can be assembled in multiple orientations using the same complementary joints. This segmentation allows configuration variety through assembly variation rather than part variation, reducing the number of manufacturing tools needed.
Solution Approach 2:
The complementary joint design creates a universal connection system that enables multiple tank configurations using the same basic parts. This universality reduces device complexity by eliminating the need for different tools and fixtures for producing various tank orientations, as the same housing components can be assembled in multiple valid configurations.
Data Source
AI summary
An expansion tank for a coolant circuit of a motor vehicle includes a housing with an upper part with an upper joint and a lower part with a lower joint. An inlet is arranged on the upper part. An outlet is arranged on the lower part. The upper part is connectable by the upper joint to the lower joint of the lower part in at least two different orientations.