Thermostat Control Module for Motor Vehicle Cooling Systems

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Solution Overview

Problem

Existing motor vehicle cooling systems face challenges in rapidly adapting to temperature setpoints due to the non-negligible reaction time required for the heating of heat-sensitive components to open the thermostat valve, leading to potential overcooling and inefficiencies in temperature regulation.

Innovation Solution

A control module is introduced to limit the heating power of the heating module to a minimum necessary level, allowing for immediate preheating of the heat-sensitive component without fully opening the valve, thereby reducing reaction time and improving temperature control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the heating module delivers maximum heating power to open the valve rapidly, then the valve opening speed is improved, but the reaction time for valve closing increases due to excessive heating of the heat-sensitive component

Engineering Contradiction:

Improvevalve opening speedVSAvoidvalve closing reaction time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The control module performs preliminary heating of the heat-sensitive component to a temperature just below the threshold required for valve opening. This preliminary action reduces the additional heating needed to open the valve, thereby minimizing the thermal energy stored in the component that would otherwise delay valve closing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of applying excessive heating power to rapidly open the valve, the control module applies partial heating power that is sufficient to reach the opening threshold. This avoids over-heating the component and the subsequent delay in closing response.

Inventive Principle:

Principle #16Partial or excessive action

2Productivity

If the heating module delivers maximum heating power to achieve rapid temperature adjustment, then the temperature regulation speed is improved, but the risk of overcooling increases due to excessive cold liquid injection

Engineering Contradiction:

Improvetemperature regulation speedVSAvoidtemperature control precision

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control module continuously monitors the temperature of the heat-sensitive component and adjusts the heating power accordingly. When the component approaches the opening threshold, the control module reduces heating power to prevent overshooting, thereby avoiding excessive valve opening and overcooling of the engine.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The heating power delivered by the heating module is dynamically adjusted based on the current temperature state of the heat-sensitive component. The system transitions from higher heating power when the component is cooler to reduced heating power as it approaches the threshold, enabling precise control and preventing overcooling.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If the heating module delivers high heating power to reduce reaction time, then the system adaptability is improved, but the energy consumption increases

Engineering Contradiction:

Improvesystem response to temperature demandsVSAvoidheating module energy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The control module applies preliminary heating at a moderate power level to bring the heat-sensitive component close to the opening threshold before full valve opening is required. This reduces the need for high-power heating bursts, thereby lowering overall energy consumption while maintaining rapid response capability.

Inventive Principle:

Principle #10Preliminary action

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 enables faster and more precise temperature regulation by ensuring the heat-sensitive component is preheated without unnecessary heating, reducing the risk of overcooling and enhancing the system's ability to adapt to changing temperature demands.

Implementation Method 1

an electrical resistor that heats the wax

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the melting and subsequent expansion of the wax causes displacement

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

the melting and subsequent expansion of the wax

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS10865697B2Thermostat device for motor vehicle cooling system, cooling system equipped with such a thermostat device and method of controlling a heating module

Publication Date: 2020.12.15 HORSE POWERTRAIN SOLUTIONS S L U

AI summary

A thermostat device for a motor vehicle cooling system includes a valve, a heat-sensitive component to induce opening of the valve when the temperature of the sensitive component exceeds a temperature threshold, and a heating module controlled by the sensitive component. The heating module delivers at most a maximum heating power. The heating module includes a regulating module to determine a gross useful voltage based on a measured temperature and of a temperature setpoint, and a correcting module including an electrical resistor connected to an electrode. The correcting module controls the heating module either to limit the heating power delivered by the heating module to a heating power strictly lower than the maximum heating power and sufficient to induce complete opening of the valve, or so that the heating module delivers non-zero heating power that is not sufficient to induce opening of the valve.