Surge Tank Pneumatic Pressurization for Coolant Pressure Stability
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Solution Overview
Problem
As vehicle cooling systems become larger and more complex, maintaining coolant pressure to ensure the required flow rate becomes increasingly difficult, leading to challenges in achieving a complete fill and managing coolant expansion and contraction.
Innovation Solution
The system employs a pressurized liquid coolant system with a pneumatic compressor to generate compressed air, which is regulated by a reducing valve to maintain a desired operating pressure within the surge tank, thereby ensuring adequate coolant pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional coolant overflow bottle is used to store extra coolant volume, then coolant expansion and contraction can be managed, but it becomes difficult to maintain required coolant pressure and flow rate as cooling systems become larger and more complex
Solution Approach 1:
The patent applies pneumatic principles by introducing a compressed air system into the coolant surge tank. The compressed air acts as a pneumatic pressurization medium to maintain coolant pressure, replacing traditional mechanical pressure maintenance methods. This resolves the contradiction by providing reliable pressure maintenance through gas-liquid interaction without adding complex mechanical pressure regulation devices.
Solution Approach 2:
The patent changes the pressure parameter within the surge tank by introducing compressed air at controlled pressures (typically 8-15 psi). This parameter change enables the system to maintain higher coolant pressure and flow rates. The air pressure can be dynamically adjusted based on system requirements, allowing flexible pressure management in complex cooling systems.
2Manufacturing precision
If a simple tank-based gas compression process is used, then coolant volume management is straightforward, but it is difficult to achieve complete fill and results in more cold fill compressibility than expected
Solution Approach 1:
The compressed air system provides precise pneumatic pressure control to achieve complete coolant fill. The air pressure forces coolant into all system components, ensuring no air pockets remain. This pneumatic assistance overcomes the limitations of simple gravitational filling and achieves complete system fill without complex mechanical filling devices.
Solution Approach 2:
The system performs preliminary pressurization with compressed air before coolant circulation begins. This preliminary action ensures the coolant is completely filled and any air pockets are eliminated before the system operates. The compressed air is then vented or maintained at low pressure, preparing the system for optimal coolant flow from the start.
3Temperature
If coolant pressure is not maintained, then the cooling system is simpler, but the coolant boils at lower temperature and cavitation risk increases
Solution Approach 1:
The compressed air system creates pneumatic pressure in the surge tank, which translates to increased coolant pressure throughout the system. This elevated pressure raises the coolant's boiling point, preventing boil-over conditions. The pneumatic pressure mechanism is simpler than mechanical pressure regulators while achieving the same thermal protection effect.
Solution Approach 2:
The system changes the pressure parameter of the coolant by introducing compressed air. This parameter change directly affects the boiling point of the coolant through the Clausius-Clapeyron relationship. By maintaining pressure at 8-15 psi above atmospheric, the boiling point increases sufficiently to prevent boil-over without requiring complex pressure control systems.
4Productivity
If a pressurized air source is added to the cooling system, then coolant pressure and heat transfer improve, but the device complexity increases
Solution Approach 1:
The compressed air system serves multiple functions: it pressurizes the coolant to prevent boil-over, maintains coolant flow rate through pressure differential, aids in complete system filling, and can provide cooling to air-sensitive components. By consolidating these functions into a single pneumatic system, the patent achieves improved heat transfer efficiency without proportionally increasing device complexity.
Solution Approach 2:
The compressed air system is designed to be self-regulating to an extent. The pressure differential created by the compressed air automatically drives coolant circulation without requiring additional pumps or complex control mechanisms. The system uses the inherent pressure energy of the compressed air to maintain flow and pressure, reducing the need for active control components.
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 approach effectively maintains the desired coolant pressure, reducing the risk of boiling and cavitation, while improving heat transfer and ensuring efficient system cooling.
Implementation Method 1
a pressurized air source configured to supply compressed air
Implementation Method 2
a surge tank for storing a liquid coolant and for pressurizing an interior volume of the surge tank such that a coolant pressure is maintained at the desired operating pressure
Implementation Method 3
a reducing valve for stopping a flow of the compressed air in response to a pressure of the compressed air exceeding a desired operating pressure
Implementation Method 4
a check valve for limiting the flow, either gas or liquid, back into the pressurized air source when the source pressure is reduced below a limit
Data Source
AI summary
Methods and apparatus are provided for pressurizing a liquid cooling system including a pressurized air source configured to supply compressed air and a surge tank for storing a liquid coolant and for pressurizing an interior volume of the surge tank such that a coolant pressure is maintained at the desired operating pressure.