Integrated Thermostat Cap with Embedded Temperature Sensor
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Solution Overview
Problem
Conventional thermostat devices for water-cooled internal combustion engine cooling systems are complex, with a high number of components and difficult assembly, particularly when integrating a temperature sensor, which complicates the installation process and increases the overall structure complexity.
Innovation Solution
A streamlined thermostat device design with integrated temperature sensor and compression coil spring, where the sensor is embedded in the cap and the cap is made of resin, reducing the number of parts and simplifying assembly, allowing for easy installation as a single unit without embedding in engine components, and providing diagnostic capabilities through temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is added to the thermostat device to enable temperature detection, then diagnostic capability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The temperature sensor is integrated into the cap structure, merging two separate components (sensor and cap) into one unified part. This reduces the total number of constituent parts while maintaining the temperature detection function, directly resolving the contradiction between improved measurement capability and increased device complexity
Solution Approach 2:
The cap is designed to serve multiple functions: it seals the thermostat container portion, provides mounting for the temperature sensor, and acts as a structural support element. By making the cap multi-functional, the patent avoids adding separate components for each function, thereby improving diagnostic capability without proportionally increasing device complexity
2Measurement precision
If a temperature sensor is added to the thermostat device, then diagnostic capability is improved, but assembly difficulty increases
Solution Approach 1:
By integrating the temperature sensor into the cap as a pre-assembled unit, the patent reduces the number of separate assembly steps. The sensor and cap are treated as one component during installation, simplifying the assembly process while maintaining temperature detection functionality
Solution Approach 2:
The temperature sensor is pre-installed and integrated into the cap before the cap is attached to the thermostat device. This preliminary integration means that during final assembly, the sensor is already in its correct position and orientation, eliminating the need for separate sensor installation steps and reducing assembly difficulty
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 results in a compact, easy-to-assemble thermostat device with reduced component count, improved ease of installation, and enhanced diagnostic capabilities, ensuring proper engine temperature regulation and reduced assembly steps, while maintaining reliability and cost-effectiveness.
Implementation Method 1
a thermostat including a thermo-element that advances and retreats in response to changes in temperature of a coolant that flows through the thermostat container portion
Implementation Method 2
a compression coil spring that biases the thermo-element
Data Source
AI summary
A thermostat device having a first coolant flow path; a second coolant flow path; a casing including a thermostat container portion that communicates with the first and second coolant flow paths; a third coolant flow path that communicates with the thermostat container portion; a cap that covers the thermostat container portion; a thermostat including a thermo-element that advances and retreats in response to changes in temperature of a coolant that flows through the thermostat container portion; a temperature sensor disposed within the thermostat container portion and which detects the temperature of the coolant; a sensor mount in which the temperature sensor is embedded, integrated into an inside end of the cap; and a lead connector extending from the temperature sensor and integrated into an outside end of the cap.