Thermo-Actuator Sealing Assembly for Planarity Error Compensation
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Solution Overview
Problem
Existing methods for sealing thermo-actuators in internal combustion engine cooling circuits face issues with planarity errors and reliability due to narrow contact surfaces and expensive elastomer coating processes, which lead to poor sealing performance and reduced usage lifetime.
Innovation Solution
A thermo-actuator design featuring a cylindrical body with a stepped diameter structure and a ring-shaped gasket with stage-like form, where the valve is fixed in a shrink-fit manner to compress and crush the gasket between the valve and stepped diameter, ensuring improved sealing through radial and axial compression, preventing back-sliding and exposure to contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sheet press process is used to form a gasket channel and compress the sealing element, then the sealing element is fixed in place, but the narrow contact surface prevents effective compensation of planarity errors on the sealing surfaces
Solution Approach 1:
The sealing element transitions from a traditional flat gasket to a three-dimensional O-ring configuration that wraps around a protrusion. This dimensional change creates multiple contact surfaces (radial and axial directions) instead of a single narrow contact line, enabling effective compensation of planarity errors on the sealing surfaces while maintaining reliable sealing performance
2Reliability
If elastomer material is coated on the valve by over-molding method, then the sealing surface is improved, but the process becomes expensive and the elastomer material separates from the valve due to chemicals in cooling liquids
Solution Approach 1:
The elastomer sealing material is extracted from the valve body and formed as a separate O-ring gasket. This separation eliminates the over-molding process and its associated costs and reliability issues. The O-ring can be independently manufactured from chemically resistant elastomer material and installed separately, avoiding the problem of elastomer separation caused by chemicals in cooling liquids
Solution Approach 2:
The sealing system uses composite construction with the O-ring made from specialized elastomer material that is chemically resistant to cooling liquids. This separate elastomer component works in conjunction with the valve body and housing to create a reliable sealing system without requiring chemical bonding or over-molding processes
3Reliability
If the sealing element is compressed inside the gasket channel preventing removal, then the sealing is improved, but the usage lifetime is reduced due to poor compensation of planarity errors
Solution Approach 1:
The O-ring sealing element uses a three-dimensional configuration that allows it to deform and conform to surface irregularities in both radial and axial directions. This multi-directional compliance enables effective compensation of planarity errors on the sealing surfaces, maintaining sealing performance throughout the usage lifetime without premature failure
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 solution enhances sealing performance and extends the usage lifetime of the sealing element and thermo-actuator by ensuring tight contact without gaps, preventing bending and contamination, thus improving the reliability and durability of the sealing mechanism.
Implementation Method 1
the valve (30) crushes the ring-shaped gasket (20) between the valve (30) and said stepped diameter (12) for improving sealing between them
Implementation Method 2
a valve (30) that is in annular form and fixed onto said cylindrical body (11) in a shrink-fit manner
Data Source
Figure 1~2
Figure 3
AI summary
The present invention is a thermo-actuator (10) in order to be used in cooling circulation circuits of internal combustion engines and comprising a cylindrical body (11 ), a stepped diameter (12) embodied in protrusion form at the continuation of said body (11 ), a ring- shaped gasket (20) positioned in the vicinity of said stepped diameter (12) and providing sealing, characterized in that said gasket (20) comprises a lower lip (23) stopped onto a lower surface (122) of the stepped diameter (12); an upper lip (21 ) extending towards a side surface (121 ) of the stepped diameter (12); a contact knuckle (22) extending between the lower lip (23) and the upper lip (21 ); and the subject matter thermo-actuator (10) comprises a valve (30) having a holder part (31 ) fixed onto the body (11 ) in a shrink-fit manner in a manner tightening and crushing the gasket (20) between the valve (30) and said stepped diameter (12) and extending in a manner encircling the body (11 ) in the longitudinal direction.