Thermostat Device Coolant Rectification and Assembly
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Solution Overview
Problem
Conventional thermostat devices for automobile engines face challenges in assembling efficiency, manufacturing cost, heat transfer accuracy, and coolant temperature control due to design complexities and material limitations, including clearance issues and the need for precise alignment and sealing, which affect the reliability and cost-effectiveness of the assembly process.
Innovation Solution
A thermostat device design featuring a high-temperature-coolant rectification part with protruding ribs for guiding the temperature sensing/operating part, an urging member for valve operation, and a frame for engagement, which simplifies assembly by eliminating the need for external seal members and reduces manufacturing complexity, enhancing heat transfer efficiency and temperature control accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional thermostat device uses a loose insertable state with clearance between the high-temperature-coolant rectification part and temperature sensing/operating part, then heat transfer efficiency is improved, but assembly precision and sealing reliability deteriorate
Solution Approach 1:
The device is divided into modular components: the temperature sensing/operating part, the high-temperature-coolant rectification part, the support guide part, and the receiving part. This segmentation allows each component to be manufactured independently with standard tolerances, improving assembly precision while maintaining the necessary clearance for heat transfer functionality.
Solution Approach 2:
The support guide part acts as an intermediary component between the rectification part and the temperature sensing/operating part. It provides precise positioning and guidance during assembly, ensuring correct alignment without requiring tight tolerances on the main components, thus resolving the conflict between heat transfer clearance and assembly precision.
2Reliability
If a conventional thermostat device requires external seal members and precise alignment, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The receiving part is designed with an integrated engagement structure that automatically engages with the support guide part during assembly. This self-aligning, self-latching mechanism provides reliable sealing and positioning without requiring external seal members or complex alignment procedures, reducing both device complexity and manufacturing cost while maintaining sealing reliability.
Solution Approach 2:
The sealing function and positioning function are merged into the engagement structure between the receiving part and support guide part. This integration eliminates the need for separate seal members and alignment mechanisms, simplifying the device while ensuring reliable sealing through the engaged connection.
3Ease of manufacture
If a conventional thermostat device uses a loose insertable state for the temperature sensing/operating part, then ease of assembly is improved, but temperature detection accuracy deteriorates
Solution Approach 1:
The support guide part serves as a mediator that provides precise positioning and guidance for the temperature sensing/operating part during assembly. It ensures correct alignment and stable positioning, maintaining temperature detection accuracy while allowing the overall assembly process to remain simple and easy to perform.
Solution Approach 2:
The support guide part provides localized precision positioning at the critical interface where the temperature sensing/operating part contacts the rectification part. This localized quality control ensures accurate temperature detection only where needed, while the rest of the assembly maintains ease of manufacture through standard loose fit tolerances.
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 design improves assembling efficiency, reduces manufacturing costs, and enables high-response, high-accuracy coolant temperature detection and control, while simplifying the assembly process and eliminating the need for costly seal members and precise alignment requirements.
Implementation Method 1
incorporating a thermal expansion element which thermally expands or contracts according to a change in a temperature of a coolant
Implementation Method 2
the high-temperature coolant flowing in the high-temperature coolant passage flow out from a discharge opening after being in contact with a periphery (bottom surface/side surface) of the temperature sensing/operating part
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
Provided is a thermostat device which improves the assembling work, reduces the manufacturing cost, and transfers heat to a temperature sensing/operating part more efficiently. The thermostat device includes a cylindrical high-temperature-coolant rectification part which forms a high-temperature coolant passage to bypass a high-temperature coolant heated by an engine, and is communicated and extended so as to partially or entirely cover the temperature sensing/operating part, permitting the high-temperature coolant flowing in the high-temperature coolant passage flow out from a discharge opening after being in contact with the periphery (bottom surface/side surface) of the temperature sensing/operating part, a receiving part provided on the outer periphery side of the high-temperature-coolant rectification part, a spring fitted between the valve body and the receiving part to press the valve body in a valve closing direction and press the receiving part in a direction away from the valve body, and a frame which is continual from an upper end of a piston shaft and engages with the pressed receiving part while receiving urging force thereof.