Modular Thermostatic Valve Sealing via Connector Sleeve
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Solution Overview
Problem
Conventional thermostatic valves for cooling circuits in motor vehicles are complex and costly to produce due to the need for laborious injection molding of the expansion element and its electrical contacting system, with impermeable encapsulation requirements and risk of leakage under extreme conditions.
Innovation Solution
A modular thermostatic valve design where the connector, connector sleeve, and expansion element with a heating resistor form a prefabricated assembly through sealed mechanical connections, allowing for simplified production and reduced material costs, with customizable connector variants and improved sealing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional injection molding is used to encapsulate the expansion element and electrical contacting system, then impermeable shielding is achieved, but production complexity and costs increase significantly
Solution Approach 1:
The thermostatic valve is divided into separate functional components: the expansion element (5) with electrical contacts, the connector (3) for electrical connection, and the connector sleeve (4) for mechanical and sealed connection. This segmentation allows each component to be manufactured independently using simpler processes, eliminating the need for complex multi-cavity injection molding while maintaining impermeable shielding through the sealed connector sleeve assembly.
Solution Approach 2:
The electrical contacting system is extracted from the injection molded housing and implemented as a separate connector assembly. This extraction simplifies the injection molding process by removing the need for complex encapsulation of electrical contacts, while the connector sleeve provides the necessary sealed enclosure for the expanded element and electrical connections.
2Reliability
If high-grade plastics are used for impermeable encapsulation, then protection from environmental influences is improved, but material costs increase
Solution Approach 1:
High-grade plastics are used only where absolutely necessary for environmental protection - specifically for the connector sleeve (4) that encloses the expansion element and electrical contacts. The main thermostat housing can use less expensive materials, as the critical sealing function is localized to the connector assembly rather than requiring expensive materials throughout the entire housing.
3Reliability
If multiple encapsulations are performed to ensure sealing, then impermeability is improved, but production time and complexity increase
Solution Approach 1:
The connector sleeve (4) is pre-assembled with the expansion element (5) and connector (3) in a sealed configuration before final installation. This preliminary assembly ensures proper sealing is achieved in one operation, eliminating the need for multiple subsequent encapsulation steps and reducing production time while maintaining impermeability.
4Adaptability or versatility
If the expansion element is not connected with form fit, then assembly flexibility is improved, but displacement under flow conditions occurs
Solution Approach 1:
The expansion element (5) is nested within the connector sleeve (4), which provides both the flexibility for easy assembly and the stability to prevent displacement. The sleeve acts as a retaining structure that holds the expansion element in place while allowing for simple insertion and removal, solving both the assembly flexibility and position stability requirements.
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 modular construction reduces production complexity and costs, enhances functional reliability, and allows for flexible adaptation to different interfaces and conditions, while ensuring impermeable shielding and effective sealing.
Implementation Method 1
a heating resistor is usually additionally provided, and when an electric current is applied to this resistor it causes the wax element or the expansion element to heat up
Implementation Method 2
it causes the wax element or the expansion element to heat up and thereby expand
Implementation Method 3
a coolant flow is still maintained. This is intended in particular to reduce the reaction time of the switching valve, since the flowing coolant has the effect in particular of helping to cool down a thermostatic operating element
Data Source
AI summary
A thermostatic valve for a cooling circuit of a motor vehicle may include a thermostat housing part, a connector, a connector sleeve and an expansion element including a hearing resistor. The connector and the expansion element may each be insertable into the connector sleeve via a sealed and mechanically plugged-in connection. The connector and the expansion element together with the connector sleeve may define an assembly. The assembly may be insertable into the thermostat housing part via another sealed and mechanically plugged-in connection. The connector and the heating resistor may define an electrically conductive connection when the connector and the expansion element are inserted into the connector sleeve.