Transmission Cooler Bypass Valve for Continuous Startup Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal bypass systems in automotive transmissions suffer from issues such as overheating, inconsistent temperature control, valve malfunctions, and the need for preheat cycles, leading to potential damage and increased maintenance costs.
Innovation Solution
A two-state thermal bypass valve system is introduced, replacing OEM valves with improved designs that ensure continuous cooler fluid flow by default, allowing bypass only under pressure differentials, and eliminating the need for preheat cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a three-state OEM thermal bypass valve is used to control cooler flow, then temperature control is attempted, but valve sticking and malfunction occur leading to inconsistent temperature control and overheating
Solution Approach 1:
The patent extracts the thermal regulation function from the valve mechanism itself and replaces it with a dedicated thermal element (wax pellet or silicone bulb) that expands/contracts with temperature changes. This separates the temperature sensing function from the flow control function, eliminating valve sticking issues caused by thermal expansion of valve components.
Solution Approach 2:
The patent introduces a thermal element as an intermediary between the temperature变化 and the valve operation. The thermal element physically expands or contracts in response to temperature changes, which then actuates the valve through a pushrod or direct mechanical connection, providing reliable temperature-based control without thermal stress on the valve itself.
2Temperature
If a three-state thermal bypass valve is used to prevent cooler flow during cold operation, then preheat cycles are required, but this increases time loss and reduces productivity
Solution Approach 1:
The patent designs the thermal bypass system to automatically open the cooler flow path as soon as the fluid reaches operating temperature, eliminating the need for predetermined preheat cycles. The thermal element begins expanding during normal operation and progressively opens the cooler flow, allowing the system to transition to optimal temperature control without idle waiting time.
3Temperature
If a three-state thermal bypass valve is used to regulate cooler flow, then temperature control is attempted, but the complex valve mechanism increases device complexity and maintenance requirements
Solution Approach 1:
The patent removes the three-state regulation complexity from the valve and replaces it with a simple two-state thermal element that either expands or contracts based on temperature. This extracts the complex control logic from the mechanical valve and replaces it with a passive thermal-mechanical response, significantly reducing system complexity.
Solution Approach 2:
The patent changes the control parameter from multi-position valve actuation to continuous thermal expansion/contraction. The thermal element's physical dimension changes with temperature, providing a simple, fail-safe control mechanism that eliminates the need for complex three-state valve mechanisms and their associated control systems.
4Temperature
If a three-state thermal bypass valve is used to control cooler flow, then temperature regulation is attempted, but the valve requires maintenance and replacement due to sticking and malfunction
Solution Approach 1:
The patent extracts the temperature-sensitive function from the valve mechanism and places it in a dedicated thermal element (wax pellet or silicone bulb). This allows the valve itself to remain a simple, passive component that cannot stick or malfunction, while the thermal element becomes a easily replaceable item if it degrades over time.
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 new system maintains consistent cooler fluid flow, prevents overheating, and reduces maintenance costs by ensuring continuous lubrication and cooling without requiring preheat cycles, enhancing transmission performance and reliability.
Implementation Method 1
The actual physical location of the thermostatic switch device, or thermal element, in principal can be anywhere these two circuits can be physically bridged... The thermal element itself is designed as a compound part, and functions as a thermally expanding valve.
Implementation Method 2
the converter out line, which is a line directly away from the torque converter to the cooler... the most logical destination for liquid coolant, or fluid, flow is away from the torque converter is through a converter out line, which is a line directly away from the torque converter to the cooler.
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.