Description:FIELD
The present invention generally relates to the field of automobiles. Particularly, the present invention relates to a housing for an automotive thermostat.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Presently, a thermostat is used in a vehicle to bring a cold engine to its operating temperature and to continuously maintain the engine temperature at the same operating temperature. The thermostat is generally placed between the cylinder head, the radiator, and the engine, for directing a coolant coming from an outlet of the cylinder head to the engine or the radiator. The thermostat is connected to the cylinder head, the radiator, and the engine via multiple connecting tubes. When the engine is in cold condition, the thermostat is in a closed position allowing the coolant coming from the cylinder head to circulate in the engine. Once the engine has reached its operating temperature, the thermostat switches into its open position and allows the coolant to circulate through the radiator by bypassing the engine.
However, the use of multiple connecting tubes for connecting the thermostat with the cylinder head, the radiator, and the engine, has the following drawbacks:
• low coolant flow efficiency,
• time taken by the engine to attain its operating temperature is large,
• huge inventory size of vehicle manufacturing units,
• increases assembly time of the vehicle,
• increases the maintenance cost of the vehicle,
• increases the size of the vehicle system, and
• increases the production cost of the vehicle.
There is, therefore, felt a need to develop a thermostat housing that alleviates the aforementioned disadvantages.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a compact thermostat housing for a vehicle.
Another object of the present disclosure is to provide a compact thermostat housing that facilitates coolant to flow efficiently.
Another object of the present disclosure is to provide a compact thermostat housing that reduces the inventory size of vehicle manufacturing units.
Still another object of the present disclosure is to provide a compact thermostat housing that reduces the assembly time of an engine cooling system.
Yet another object of the present disclosure is to provide a compact thermostat housing that reduces the maintenance time and cost of the vehicle’s engine cooling system.
Another object of the present disclosure is to provide a compact thermostat housing that reduces the size of the engine cooling system.
Still another object of the present disclosure is to provide a compact thermostat housing that requires lesser manufacturing time.
Another object of the present disclosure is to provide a compact thermostat housing that is produced with a lesser manufacturing rejection rate compared to a traditional sand casting manufacturing process.
Yet another object of the present disclosure is to provide a compact thermostat housing that is economical to manufacture.
Still another object of the present disclosure is to provide a compact thermostat housing that can accommodate multiple parts/components having different functions therewithin.
Yet another object of the present disclosure is to provide a compact thermostat housing that is light-weight.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present invention envisages a compact thermostat housing for a vehicle. The thermostat housing comprises an inlet, a first outlet, a second outlet, a third outlet and a thermostat.
The inlet is configured to receive a flow of coolant. The first outlet is coupled to an engine of the vehicle. The housing consists of a cover having a vent. The second outlet is coupled to a radiator of the vehicle through the vent. A first circuit is present between the inlet and the first outlet, and a second circuit is present between the inlet and the second outlet, wherein the first and second circuits are configured to allow the coolant to flow therethrough. The thermostat is accessible by the first and second circuits. The thermostat is configured to switch the flow of coolant between the first circuit and the second circuit depending on the coolant temperature. In an embodiment, the thermostat is configured to switch the flow of coolant from the first circuit to the second circuit when a coolant temperature is greater than a predetermined threshold temperature and is further configured to switch the flow of coolant from the second circuit to the first circuit when a coolant temperature is less than or equal to the pre-determined threshold temperature. The compact thermostat housing is a single-piece solid housing.
The first circuit consists of an inlet passage and a bypass passage. The inlet passage allows the flow of the coolant from the inlet to the thermostat. The bypass passage allows the flow of the coolant from the thermostat to the first outlet.
The second circuit consists of the inlet passage and the thermostat passage. The inlet passage allows the flow of the coolant from the inlet to the thermostat. The thermostat passage allows the flow of the coolant from the thermostat to the second outlet.
In an embodiment, the housing includes a third outlet coupled to a heating unit of a cabin of the vehicle, and the third outlet is configured to allow the coolant to flow to the heating unit of the cabin of the vehicle. A third circuit is present between the inlet and the third outlet. The third circuit includes the inlet passage and a cabin passage. The inlet passage allows the flow of the coolant from the inlet to the thermostat. The cabin passage allows the flow of the coolant from the thermostat to the third outlet via the thermostat passage.
The housing includes a sensor mount. The sensor mount is communicatively coupled with the first circuit, the second circuit, and the third circuit. The sensor mount is configured to receive a temperature sensor, the temperature sensor configured to sense the temperature of the coolant flowing through at least one of the first circuit, the second circuit, and the third circuit.
The first outlet consists of a thermostat bypass adaptor. The third outlet consists of a plug for the heating unit of the cabin.
The volume of the housing is 184 cm3. The housing is cast aluminium housing. The incoming-to-outgoing diameter ratio of the inlet passage is in the range of 0.90 to 0.92. The incoming-to-outgoing diameter ratio of the bypass passage is in the range of 1.5 to 1.7. The angle of the bypass passage with respect to the vertical axis is 20 degrees. The angle of the inlet passage angle with respect to the vertical axis is 23 degrees.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A compact thermostat housing for a vehicle of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1A illustrates a perspective view of a thermostat housing;
Figure 1B illustrates a perspective view of the housing of Figure 1A, showing a thermostat disposed therewithin;
Figure 1C illustrates a perspective view of the thermostat housing of Figure 1A from a different viewing angle;
Figure 2 illustrates an exploded view of the thermostat housing of Figure 1C coupled to a cylinder head of the vehicle;
Figure 3A illustrates a sectional view of the thermostat housing of Figure 1B, showing a first circuit;
Figure 3B illustrates a sectional view of the thermostat housing of Figure 1B, showing a second circuit; and
Figure 3C illustrates a sectional view of the thermostat housing of Figure 1B, showing a third circuit.
LIST OF REFERENCE NUMERALS USED IN THE DESCRIPTION AND DRAWING:
100 Housing
5 Cylinder head
10 Inlet
12 First outlet
14 Second outlet
14a Bypass adaptor
16 Third outlet
16a Plug
18 Thermostat
20 Sensor mount
20a Temperature sensor
22 Cover
22a Vent
24 Through-holes
25a First set of fasteners
25b Second set of fasteners
26 Threaded-holes
C1 First circuit
C2 Second circuit
C3 Third circuit
P1 Inlet passage
P2 Bypass passage
P3 Thermostat passage
P4 Cabin passage
V Vertical axis
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The present invention envisages a compact thermostat housing 100 for a vehicle. The present disclosure is described with reference to Figures 1- 3.
The thermostat housing 100 comprises an inlet 10, a first outlet 12, a second outlet 14, a third outlet 16 and a thermostat 18.
The thermostat housing 100 is securely coupled to a cylinder head 5 of the vehicle. In an embodiment, the housing 100 includes a plurality of through-holes 24 for allowing a first set of fasteners 25a to securely engage with the cylinder head 5.
The inlet 10 is configured to receive a flow of coolant from the cylinder head 5. The first outlet 12 is coupled to an engine of the vehicle. The housing 100 consists of a cover 22 having a vent 22a. The second outlet 14 is coupled to a radiator of the vehicle through vent 22a. In an embodiment, the housing 100 includes a plurality of threaded holes 26 on its operative top portion, for allowing a second set of fasteners 25b to securely engage the cover 22 with the housing 100.
A first circuit C1 is present between the inlet 10 and the first outlet 12, and a second circuit C2 is present between the inlet 10 and the second outlet 14. The first circuit C1 and second circuit C2 are configured to allow the coolant to flow therethrough. The thermostat 18 is accessible by the first and second circuits (C1, C2). The thermostat 18 is configured to switch the flow of coolant between the first circuit C1 and the second circuit C2 depending on the coolant temperature. In an embodiment, the thermostat 18 is configured to switch the flow of coolant from the first circuit C1 to the second circuit C2 when a coolant temperature is greater than a predetermined threshold temperature and is further configured to switch the flow of coolant from the second circuit C2 to the first circuit C1 when a coolant temperature is less than or equal to the pre-determined threshold temperature.
The first circuit C1 consists of an inlet passage P1 and a bypass passage P2. The inlet passage P1 allows the flow of the coolant from the inlet 10 to the thermostat 18. The bypass passage P2 allows the flow of the coolant from the thermostat 18 to the first outlet 12.
The second circuit C2 consists of the inlet passage P1 and the thermostat passage P3. The inlet passage P1 allows the flow of the coolant from the inlet 10 to the thermostat 18. The thermostat passage P3 allows the flow of the coolant from the thermostat 18 to the second outlet 14.
In an embodiment, the housing 100 includes a third outlet 16 coupled to a heating unit of a cabin of the vehicle. The third outlet 16 is configured to allow the coolant to flow to the heating unit of the cabin of the vehicle. A third circuit C3 is present between the inlet 10 and the third outlet 16. The third circuit C3 includes the inlet passage P1 and a cabin passage P4. The inlet passage P1 allows the flow of the coolant from the inlet 10 to the thermostat 18. The cabin passage P4 allows the flow of the coolant from the thermostat 18 to the third outlet 16 via the thermostat passage P3.
The housing 100 includes a sensor mount 20. The sensor mount 20 is communicatively coupled with the first circuit C1, the second circuit C2, and the third circuit C3. The sensor mount 20 is configured to receive a temperature sensor 20a which is configured to sense the temperature of the coolant flowing through at least one of the first circuit C1, the second circuit C2, and the third circuit C3.
In an embodiment, the first outlet 12 consists of a thermostat bypass adaptor 12a. The third outlet 16 consists of a plug 16a for the heating unit of the cabin.
The thermostat housing 100 is a single-piece solid housing and is made of cast aluminium. The volume of the housing 100 is 184 cm3. The incoming-to-outgoing diameter ratio of the inlet passage P1 is in the range of 0.90 to 0.92. The incoming-to-outgoing diameter ratio of the bypass passage P2 is in the range of 1.5 to 1.7. In a preferred embodiment, the incoming-to-outgoing diameter ratio of the inlet passage P1 is 0.914 and the incoming-to-outgoing diameter ratio of the bypass passage P2 is 1.6. An incoming inlet passage P1 diameter is 32mm, thermostat opening diameter is 35mm and outgoing bypass passage P2 diameter is 20mm. The angle of the bypass passage P2 with respect to the vertical axis V is 20 degrees. The angle of the inlet passage P1 with respect to the vertical axis V is 23 degrees.
Advantageously, the housing 100 of the present disclosure is manufactured using cast aluminium, which is light in weight as compared to the traditional cast iron material. The use of cast aluminium against cast iron reduces the housing weight by 152%. The housing 100 weighs in the range of 0.45 kg to 0.55kg. In an embodiment, the housing 100 weighs about 0.5 kg. The manufactured cast aluminium housing is refined by a machining process, therefore the rejection rate in manufacturing of the housing 100 is comparatively less than the traditional sand casting manufacturing process. As the housing 100 is designed as a single-piece solid housing, there is a reduction of approximately 50% of natural resource utilization in the manufacturing of the housing 100. The present invention includes the inlet passage P1, bypass passage P2, thermostat passage P3 and the cabin passage P4, therefore, it eliminates the need for any connecting tubes between the thermostat 18 and the cylinder head 5/ the radiator/ the engine/ the cabin. Due to the elimination of connecting tubes the coolant flow efficiency increases and it facilitates the engine to attain its operating temperature more quickly. The housing 100 accommodates therewithin multiple parts/components viz., thermostat 18, inlet passage P1, bypass passage P2, cabin passage P4, and sensor 20a each having different functions, as a result, the inventory size of the vehicle manufacturing unit, assembly time of the engine cooling system, and the maintenance time and cost of the vehicle’s engine cooling system is also reduced.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a compact thermostat housing for a vehicle, which:
• facilitates coolant to flow efficiently;
• reduces the inventory size of vehicle manufacturing units;
• reduces assembly time of the engine cooling system;
• reduces the maintenance time and cost of the vehicle’s engine cooling system;
• reduces the size of the engine cooling system;
• requires lesser manufacturing time;
• is produced with a lesser manufacturing rejection rate compared to a traditional sand casting manufacturing process;
• is economical to manufacture;
• can accommodate multiple parts/components having different functions therewithin; and
• is light-weight.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A compact thermostat housing (100) for a vehicle comprising:
• an inlet (10) to receive a flow of coolant;
• a first outlet (12);
• a second outlet (14);
• a first circuit (C1) present between the inlet (10) and the first outlet (12);
• a second circuit (C2) present between the inlet (10) and the second outlet (14), said first and second circuits (C1, C2) configured to allow the coolant to flow therethrough; and
• a thermostat (18) accessible by said first and second circuits (C1, C2), said thermostat (18) configured to switch the flow of coolant between the first circuit (C1) and the second circuit (C2) depending on the coolant temperature.
2. The compact thermostat housing (100) as claimed in claim 1 a single-piece solid housing having volume of 184 cm3, and the housing (100) is a cast aluminium housing.
3. The compact thermostat housing (100) as claimed in claim 1, wherein said first circuit (C1) consists of:
• an inlet passage (P1) to allow the flow of the coolant from the inlet (10) to the thermostat (18); and
• a bypass passage (P2) to allow the flow of the coolant from the thermostat (18) to the first outlet (12).
4. The compact thermostat housing (100) as claimed in claim 3, wherein said second circuit (C2) consists of:
• the inlet passage (P1) to allow the flow of the coolant from the inlet (P1) to the thermostat (18); and
• a thermostat passage (P3) to allow the flow of the coolant from the thermostat (18) to the second outlet (14).
5. The compact thermostat housing (100) as claimed in claim 1, wherein said first outlet (12) is coupled to an engine of the vehicle, and said second outlet (14) is coupled to a radiator of the vehicle through the vent (22a).
6. The compact thermostat housing (100) as claimed in claim 1, consists of a cover (22) having a vent (22a).
7. The compact thermostat housing (100) as claimed in claim 1, wherein said housing (100) includes a third outlet (16) coupled to a heating unit of a cabin of the vehicle, said third outlet (16) configured to allow the coolant to flow to the heating unit of the cabin of the vehicle.
8. The compact thermostat housing (100) as claimed in claim 7, consists of a third circuit (C3) between the inlet (10) and the third outlet (16), said third circuit (C3) including:
• the inlet passage (P1) to allow the flow of the coolant from the inlet to the thermostat (18); and
• a cabin passage (P4) to allow the flow of the coolant from the thermostat (18) to the third outlet via the thermostat passage (P2).
9. The compact thermostat housing (100) as claimed in claim 1, wherein said housing (100) includes a sensor mount (20) communicatively coupled with the first circuit (C1), the second circuit (C2) and the third circuit (C3); and said sensor mount (20) is configured to receive a temperature sensor (20a), the temperature sensor (20a) configured to sense the temperature of the coolant flowing through at least one of the first circuit (C1), the second circuit (C2), and the third circuit (C3), and
wherein said thermostat (18) is configured to switch the flow of coolant from the first circuit (C1) to the second circuit (C2) when a coolant temperature is greater than a predetermined threshold temperature and further configured to switch the flow of coolant from the second circuit (C2) to the first circuit (C1) when a coolant temperature is less than or equal to the pre-determined threshold temperature.
10. The compact thermostat housing (100) as claimed in claim 1, wherein said first outlet (12) consists of a thermostat bypass adaptor (12a), and the third outlet (16) consists of a plug (16a) for the heating unit of the cabin.
11. The compact thermostat housing (100) as claimed in claim 1, wherein the incoming-to-outgoing diameter ratio of the inlet passage (P1) is in the range of 0.90 to 0.92, and the incoming-to-outgoing diameter ratio of the bypass passage (P2) is in the range of 1.5 to 1.7.
12. The compact thermostat housing (100) as claimed in claim 1, wherein the angle of the bypass passage (P2) with respect to the vertical axis (V) is 20 degrees, and the angle of the inlet passage (P1) with respect to the vertical axis (V) is 23 degrees.

Dated this 19th day of May, 2022

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI