Water-Cooled Dosing Module with 360° Heat Sink
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Solution Overview
Problem
Existing dosing modules for internal combustion engines fail to operate effectively in high-temperature environments, such as the engine compartment, due to inadequate cooling of electrical components, leading to potential failure at temperatures above 160°C.
Innovation Solution
A dosing module with a full housing design that includes lateral hydraulic connections and a complete heat sink system, allowing for 360° cooling and utilizing coolant from the vehicle's circuit to cool both the valve tip and electrical components, ensuring the module can withstand temperatures up to 200°C and more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the dosing module is installed in the engine compartment to save installation space, then the installation space utilization is improved, but the electrical components are exposed to temperatures above 160°C causing failure
Solution Approach 1:
The heat sink is divided into a lower heat sink and an upper heat sink, with each serving specific cooling zones. The lower heat sink cools the valve tip area while the upper heat sink cools the electrical contact area, allowing the dosing module to be installed in the high-temperature engine compartment without compromising electrical component reliability.
Solution Approach 2:
The cooling system extends vertically with two stacked heat sinks connected by a connecting piece, creating a three-dimensional cooling structure. This vertical arrangement allows comprehensive cooling of both lower (valve tip) and upper (electrical components) areas, enabling engine compartment installation while protecting temperature-sensitive components.
2Device complexity
If only a lower heat sink is used to cool the valve tip area, then the cooling structure is simplified, but the electrical components in the upper area are not cooled and fail at temperatures above 160°C
Solution Approach 1:
The heat sink system is segmented into lower and upper portions, each targeting specific thermal zones. The lower heat sink addresses valve tip cooling while the upper heat sink protects electrical components, providing comprehensive thermal management without excessive complexity.
Solution Approach 2:
The lower heat sink, upper heat sink, and connecting piece are merged into an integrated cooling assembly. This combined structure functions as a complete thermal management system that simultaneously protects both the valve tip and electrical components, achieving reliable operation in high-temperature environments.
3Reliability
If the dosing module is installed in the underbody area to avoid high temperatures, then the electrical components are protected from overheating, but the installation space requirements cannot be met in the engine compartment
Solution Approach 1:
The cooling system transitions from a single-plane configuration to a vertical three-dimensional structure with stacked heat sinks. This vertical arrangement enables the dosing module to be installed in the constrained engine compartment space while maintaining electrical component protection through comprehensive cooling.
Solution Approach 2:
The integrated heat sink assembly serves multiple cooling functions simultaneously - cooling the valve tip area through the lower heat sink and cooling the electrical contact area through the upper heat sink. This multi-functional design allows the dosing module to operate reliably in the engine compartment, expanding installation location flexibility.
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 reliable operation in high-temperature environments by ensuring comprehensive cooling of the dosing module, preventing electrical component failure and accommodating various installation space constraints with high variability in hydraulic connections.
Implementation Method 1
a complete housing and is provided with lateral hydraulic connections which enable possible contacting almost along its entire circumference, i.e. 360°
Implementation Method 2
coolant coming from the vehicle is first fed into the lower heat sink, so that the greatest cooling capacity is at the hottest point, i.e. at the valve tip of the valve
Data Source
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AI summary
The invention relates to a dosing module (10) for metering a reducing agent into an exhaust system of an internal combustion engine. Said dosing module (10) comprises at least one cooling member (22, 24) through which a cooling fluid flows that is used to cool the internal combustion engine. An electric contact (20) is located in the top region of the dosing module (10). The dosing module (10) is enclosed in a full housing (38) that comprises an upper and a lower cooling member (22, 24, 24) through which a directed cooling fluid stream (34) flows that runs from the valve tip region (18) in the direction of the electric contact (20).