Engine Thermostat Flow Rectifier for Lower Coolant Pressure Loss
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Solution Overview
Problem
The existing thermostat devices for internal combustion engines experience increased flow resistance and pressure loss due to the spring receiving frame and frame support, which impede coolant flow and require larger water pumps, leading to cost and efficiency issues.
Innovation Solution
A thermostat device with a rectifier disposed upstream of the coolant flow at the frame support to prevent collisions and a cone-shaped coil spring that reduces the size of the spring receiving frame, minimizing flow resistance and pressure loss by smoothing coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring receiving frame and frame support are formed in the housing to receive the spring, then the control valve can be biased to close, but the flow resistance and pressure loss of coolant increase
Solution Approach 1:
The patent repositions the frame support from a perpendicular orientation (facing the coolant flow directly) to an orientation where its surface is parallel to the coolant flow direction. This dimensional change in orientation allows the frame support to maintain its structural function while eliminating it as an obstacle to coolant flow, thereby reducing pressure loss and flow resistance.
Solution Approach 2:
The patent introduces a rectifier as an intermediary component between the coolant flow and the frame support. The rectifier guides and smooths the coolant flow before it reaches the frame support area, preventing turbulence and reducing the harmful impact of the frame support on coolant flow, thus reducing pressure loss.
2Reliability
If the spring receiving frame and frame support are placed perpendicular to coolant passage, then the spring can be received and control valve biased, but turbulence and stagnation of coolant occur
Solution Approach 1:
The frame support is reoriented from a perpendicular position relative to coolant flow to a parallel position. This dimensional reconfiguration allows the frame support to maintain its spring-receiving function while eliminating turbulence and stagnation zones that would otherwise form in its wake, thereby improving coolant flow efficiency.
Solution Approach 2:
The rectifier serves as a mediator that conditions the coolant flow before it reaches the frame support. By smoothing and directing the flow, the rectifier prevents the formation of turbulence and stagnation, allowing the frame support to perform its function without hindering coolant circulation.
3Reliability
If the spring receiving frame is enlarged to receive the spring, then the spring can be securely received, but the water pump size must be enlarged to overcome flow resistance
Solution Approach 1:
The frame support is reoriented to be parallel with the coolant flow rather than perpendicular. This dimensional change reduces the projected area facing the flow, minimizing flow resistance. Consequently, the water pump does not need to be enlarged, maintaining its original size and weight while still allowing secure spring reception through the reconfigured support structure.
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 effectively reduces flow resistance and pressure loss by detouring coolant flow around the frame support and spring receiving frame, enhancing coolant flow and reducing the need for larger water pumps, thus lowering costs and improving efficiency.
Implementation Method 1
a thermal expansion body (wax) which expands or contracts due to the temperature change of a coolant
Data Source
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AI summary
Provided is a thermostat device capable of reducing flow resistance due to a thermal-operating unit and a frame support and also reducing the pressure loss in the flow passage. The thermostat device is provided with a control valve which opens and closes a flow passage in a housing based on expansion or contraction of a thermal expansion body in a thermo-sensitive element and a spring that biases the control valve to close and a spring receiving frame that receives one end of the spring. A thermal-operating unit is incorporated into the housing by locking the spring receiving frame to the frame supports formed in the flow passage of the housing. At the upstream side of the coolant flow at the frame support, a rectifier is disposed that prevents water streams from colliding by detouring the flow passage of the coolant heading to the frame support and the spring receiving frame.