Compact Thermo Valve Integrating Actuator and Spring Nesting
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Solution Overview
Problem
Existing thermo valves are not compact enough to fit within small compartment spaces, limiting the arrangement of engine and oil pan components, and they do not effectively manage oil pressure variations with temperature changes.
Innovation Solution
A compact thermo valve design featuring a thermo actuator with a large-diameter portion that integrates the actuator body and valve body within a case, utilizing a return spring with a smaller outer diameter than the case, allowing the actuator body to be housed inside the spring and reducing the overall size, while maintaining functionality across temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thermo valve uses a conventional design with separate components for actuator body and valve body, then the assembly and manufacturing are straightforward, but the overall size of the thermo valve becomes large, limiting the arrangement of components in small compartment spaces
Solution Approach 1:
The actuator body and valve body are integrated into a single unified structure. The valve body is formed as an integral part of the actuator body, eliminating the need for separate components and reducing the overall size of the thermo valve while maintaining functional independence of each component
Solution Approach 2:
The return spring is positioned to surround the actuator body, with the spring's inner diameter being larger than the outer diameter of the actuator body. This nested arrangement allows the spring to provide biasing force while occupying minimal space, further reducing the overall volume of the thermo valve assembly
2Reliability
If the outer diameter of the return spring is made larger to ensure sufficient biasing force, then the reliability of the valve operation improves, but the overall size of the thermo valve increases
Solution Approach 1:
The return spring is designed with non-uniform coil spacing, featuring tighter coils at the ends and wider spacing in the middle section. This localized variation in spring geometry optimizes the distribution of biasing force, ensuring reliable valve operation at critical positions while minimizing the overall spring diameter and maintaining compact dimensions
3Ease of manufacture
If the actuator body and valve body are kept as separate components for ease of manufacturing, then the manufacturing process is simpler, but the total length of the thermo valve increases
Solution Approach 1:
The actuator body and valve body are formed as integral components through a single manufacturing process, eliminating the need for assembly operations and reducing the total length of the thermo valve. The unified structure maintains the functional characteristics of separate components while achieving compact dimensions
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 compact design facilitates easier assembly and reduces the total length of the thermo valve, maintaining consistent oil pressure in the main flow passage regardless of temperature, while allowing bypass flow at low temperatures to manage pressure effectively.
Implementation Method 1
When the temperature of the oil is high, wax inside the thermo actuator expands to move the valve body forward
Implementation Method 2
The valve body is retracted by the biasing force of a return spring inside the thermo actuator
Data Source
AI summary
A thermo actuator includes an actuator body and a large-diameter portion (54) that projects from the actuator body outward in the radial direction. The outer diameter of a return spring is smaller than the inner diameter of a case. The outer diameter of the actuator body and the outer diameter of a valve body are smaller than the inner diameter of the return spring. The outer diameter of the large-diameter portion is smaller than the inner diameter of the case and is larger than the average diameter of the return spring. One end of the return spring is in contact with the large-diameter portion.