Two-State Transmission Cooler Valve for Blockage Bypass
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Solution Overview
Problem
Automotive transmission thermal control systems face issues with inconsistent fluid temperature regulation, leading to overheating, fluid leakage, and potential fire risks due to faulty thermal elements and valves, which can cause damage and require costly maintenance.
Innovation Solution
The development of a two-state thermal bypass valve system that replaces OEM valves, ensuring continuous cooler flow and immediate fluid filling without a warm-up cycle, with designs for installation in various transmission locations, including the pump, case, and cooler lines, to maintain optimal fluid temperatures and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a three-state OEM thermal bypass valve is used to regulate cooler flow based on fluid temperature, then fluid temperature can be maintained within a controlled range, but the system is prone to valve sticking, leakage, and inconsistent operation leading to overheating
Solution Approach 1:
The patent removes the complex three-state thermal bypass valve and its associated thermal element from the system. Instead, it implements a simpler two-state valve system that defaults to allowing cooler flow, extracting the problematic temperature regulation mechanism while maintaining essential cooling function through a more reliable design
Solution Approach 2:
The invention inverts the traditional thermal control approach by defaulting the valve to an open state that allows cooler flow, rather than defaulting to a closed state. The system now actively manages heat through continuous cooler flow unless bypass conditions are met, reversing the conventional thermal regulation philosophy to improve reliability
2Loss of time
If the thermal bypass valve defaults to a closed state to prevent cooler flow, then fluid can be warmed up quickly, but the system is prone to overheating and fire risks when the valve fails or sticks
Solution Approach 1:
The patent implements preliminary anti-action by designing the valve system to default to an open state that proactively allows cooler flow before any failure occurs. This preemptive approach ensures cooling is active by default, counteracting potential overheating risks before they can manifest, rather than relying on a closed default state that requires active opening
Solution Approach 2:
The invention provides beforehand cushioning against overheating by ensuring cooler flow is available by default. The system cushions against thermal runaway risks by having cooling capacity ready and available, creating a safety margin that prevents catastrophic overheating even if control mechanisms fail
3Temperature
If the thermal element is used to control cooler flow, then fluid temperature can be regulated, but the system requires a preheat cycle and immediate fluid filling is delayed
Solution Approach 1:
The patent applies preliminary action by configuring the valve system to be open and allowing cooler flow from the start, before any thermal regulation is needed. This eliminates the need for a preheat cycle by having cooling capacity available immediately, reversing the conventional sequence of warming up before cooling
4Measurement precision
If a complex thermal control system with multiple components is implemented, then temperature control precision can be improved, but the device complexity and maintenance costs increase
Solution Approach 1:
The patent extracts and removes the complex thermal element and three-state valve mechanism from the system. It replaces this complexity with a simpler two-state valve system that maintains adequate cooling function without requiring precise temperature regulation, eliminating unnecessary components and reducing maintenance burden
Solution Approach 2:
The invention inverts the approach to temperature control by accepting less precise thermal management in exchange for significantly reduced system complexity. Rather than using complex components to achieve precise temperature control, it uses a simple binary valve system that prioritizes reliability and simplicity over temperature precision
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 provides consistent cooler flow and reduced maintenance costs by defaulting to a cooler flow ON state, eliminating the need for preheat cycles and ensuring lubricant supply, even in case of cooler blockages, thereby preventing overheating and potential fires.
Implementation Method 1
the transmission cooler offers resistance in the fluid cooling system of the transmission
Implementation Method 2
Sometimes the thermal element itself is designed as a compound part, and functions as a thermally expanding valve
Data Source
AI summary
Methods and valves for providing a continuous flow of cooler fluid in a fluid circuit of a thermal control system between a cooler and automotive transmission such that free flow of cooler fluid between the cooler and transmission exists at vehicle start-up. Fluid flow to and from the cooler is bypassed in case of pressure increases in cooler lines or pressure differentials, for example cause by a blockage in the cooler, such that the cooler fluid flow bypasses the cooler and continues in the fluid circuit through a thermal element of the thermal control system and back to the transmission.