Split Cooling System Flow Control Element for Engine Thermal Management
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Solution Overview
Problem
Existing split cooling systems for internal combustion engines are bulky and costly, with complex control systems that increase engine size and cost, and inefficient coolant management leading to higher fuel consumption and emissions.
Innovation Solution
A cooling system with a flow control element that includes a thermostat and a proportional valve, allowing coolant to flow directly from the cylinder head to the engine block, bypassing the heat exchanger, and enabling separate adjustment of coolant flow based on engine operating conditions, reducing the need for a heater bypass line and simplifying the control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a split cooling system with separate coolant circuits for cylinder head and engine block is used, then different cooling zones can be achieved, but the system becomes bulky and increases engine size
Solution Approach 1:
The patent combines the cylinder head coolant outlet directly with the engine block coolant inlet, merging what would traditionally be separate cooling circuits into a integrated flow path. This eliminates the need for separate thermostats and bypass lines for each cooling zone, reducing system bulk while maintaining the ability to provide different cooling conditions to the cylinder head and engine block through a single flow control element
2Adaptability or versatility
If multiple independent coolant passages with separate controllers are provided, then independent flow regulation is achieved, but the control system becomes complex and costly
Solution Approach 1:
The flow control element is designed to perform multiple functions: it regulates coolant flow to the engine block, provides thermal coupling between cylinder head and engine block, and enables different cooling modes (direct cooling, heat transfer mode, bypass mode) through a single integrated component. This multi-functionality eliminates the need for multiple independent controllers, reducing system complexity while maintaining independent flow regulation capability
3Adaptability or versatility
If coolant flow through the engine block is inhibited during warm-up, then cylinder head can be cooled differently, but fuel consumption and emissions increase
Solution Approach 1:
The system dynamically adjusts coolant flow distribution between direct cooling path and engine block heat transfer path based on operating conditions. During warm-up, the flow control element can provide thermal coupling to the engine block to aid warming while still allowing different cooling conditions for the cylinder head. The system transitions between different operational modes (direct cooling, heat transfer, bypass) to optimize both cooling performance and fuel efficiency across the entire operating range
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
This configuration reduces engine size and cost, enhances warm-up efficiency, lowers fuel consumption and emissions, and allows for adjustable cooling of both the cylinder head and engine block, improving engine longevity.
Implementation Method 1
The flow control element may include a thermostat and a proportional valve
Implementation Method 2
a first outlet port in fluidic communication with a heat exchanger
Implementation Method 3
The flow control element may include a thermostat and a proportional valve
Implementation Method 4
allowing coolant to flow directly from the cylinder head to the engine block
Data Source
AI summary
A cooling system for an engine. The cooling system includes a flow control element including an inlet in fluidic communication with an outlet of a cylinder head water jacket, a first outlet port in fluidic communication with a heat exchanger, and a second outlet port in fluidic communication with an inlet of an engine block water jacket.