FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
PROVISIONAL SPECIFICATION
(See Section 10; rule 13)


TITLE OF THE INVENTION Fusible Plug On Engine Block As A Safety Feature
APPLICANTS
TATA MOTORS LIMITED, an Indian Company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India

INVENTORS
Mrs. Charu Saxena and Mr. Amol Majgaonkar.
Both are Indian Nationals
of TATA MOTORS LIMITED an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION The following specification describes the invention.


FIELD OF INVENTION
This invention relates to the provision of Fusible plug on Cylinder block / Engine Block as a safety feature and is applicable for all vehicles including LCV, MCV, HCV, MUV, passenger Cars.
A fusible plug assembly is thermally responsive to ambient temperature. So a portion will melt to provide a vent opening when a pre-defined temperature is reached. Specially applicable where the clearances are critical between component to component.
BACKGROUND OF INVENTION
Currently all the vehicles are having regular cooling system, i.e. water cooled engine. In this system the cooling jackets are in the cylinder block (around the cylinder), and the coolant flows through these jackets. This system is operated at certain temperature of engine (i.e. by using Thermostat Valve). The complete cooling system is connected by EPDM (material of hoses) hoses (Octopus Hose Assembly), the no. of connections are given to main coolant hose that's why it's called an octopus Hose Assembly.
Octopus hose is the main part of cooling system, if it will damage then the whole system will fail, also in current vehicles the engine overheating and seizing issues are there due any damage of the octopus hose.
To avoid the engine seizing, a fusible plug can be provided on cylinder block with the fusible material which should melt at the critical temperature of engine.
A fusible plug assembly that is thermally responsive to ambient temperature so a portion of it will melt to provide a vent opening when a pre selected temperature is reached. The plug assembly comprising a plug including a portion having a

cylindrical taper bore defining a throughout the passageway of its length. An insert positioned in mentioned bore having around periphery in a radial outwardly directed groove facing the inner wall of the bore. Fusible material will be filled in the groove till the end of the bore, in sealing relationship therewith, fusion material adapted to fuse at predefined temperature to permit the coolant flow to pass through the cooling jackets of cylinder bore. Fusible insert being contoured so that its outermost surfaces conform to the shape of a sphere, that has a radius smaller than the radius of the bore so that when the material fuses, the insert can pass freely out of the passageway.
The present invention relates to a fusible plug assembly that is thermally responsive to ambient temperature to provide a vent opening to a chamber or other device if the ambient temperature becomes high.
In general practice to provide fusible plug assemblies for safety purposes in which the plug has a fusible material of a bismuth alloy. The main component of this alloy is normally bismuth, and the alloys is known to- have low high melting temperatures and low physical strength. They have been used in safety devices associated with sprinkler systems, compressed gas tanks, fire alarm devices, disarmed ordnance projectiles, and now onwards in engines.
As a general rule, bismuth alloys of approximately 50 percent bismuth exhibit little change of volume during solidification, and alloys containing more than this amount expand while those containing less tend to shrink during solidification. Thus when used as the fusible material in a lifting plug for a disarmed ordnance projectile an alloy having bismuth more than 50 percent is desired, and a very suitable alloy is one which contains approximately 52.5 percent bismuth, 32 percent lead and 15.5 percent tin. Lifting plugs of this character are formed by pouring molten alloy into a bore extending axially through the body of the plug and when the alloy solidifies it expands to provide a rigid seal in the bore. The alloy

will melt at a temperature near 210° F to provide a vent opening for a projectile in which the lifting plug is secured if the projectile is subjected to undesired heating.
A fusible plug is a thermally-operated pressure relief device which affords protection against excessive pressure developed by exposure to excessive heat. Once sufficient heat melts the fusible alloy, the entire contents of the cylinder will be vented. The CG-2 fusible alloy has a nominal melt temperature of 165°F (73.9°C); the CG-3 fusible metal has a nominal melt temperature of 212°F (I00°C).
Fusible plugs can be installed on the cylinder as independent devices, or fusible alloy can be cast directly into a suitable orifice in the cylinder valve body. In some cases, a fusible plug may be installed as a separate device like in the case of this invention.
So finally the engine seizure due to any reason is the major problem in vehicles, so to cool the engine before seizing temperature for a short period is necessary, and the given proposal will avoid the engine seizure and finally protect the engine.
OBJECTS OF INVENTION
The main object of this invention is to avoid the engine seizure and protect the engine.
Yet another object of the invention is to alert the driver and provide time to stop the vehicle, which will protect the engine from thermal distortion.
Yet another important object of the invention is that it will avoid thermal distortion of engine and will protect all parts of engine.

Yet another object of the invention is that it is cost effective solution, the engine cost is in thousand rupees but the fusible plug assy, cost will be around hundred rupees only.
Yet another important object of the invention that it will give minimum changes in existing scheme, so anybody can implement it.
Yet another important object of the invention that it will protect the passengers from any damage due to overheating of engine so it can be included in safety items of vehicle.
BRIEF DESCRIPTION OF INVENTION
Referring to fig. 1 shows the current layout of the engine with surrounding components, in this the engine assembly (1) is constructed between RH Crash member (2), LH crash member (3)and firewall (4). the Octopus hose assembly (5) is connected to engine assembly (1) and Auxiliary tank(6) the another end goes to radiator side, the Auxiliary tank(6) is mounted on RH Crash member(2). The section of engine assembly (1) shown in fig., the cooling jacket passage (7) are connected to all four bores of cylinder (i.e. if the coolant will supply at one end it will circulate around all four bores of cylinder.
The various transmission module with crankshaft (12) shown, which may damage Octopus hose assembly (5) due to less clearances or by any other mean it can be damaged.
The coolant tank acts as a make up water for the cooling system, the thermostat valve is provided between engine assy.(l) and Octopus hose assembly (5), and it operate at defined temperature of engine.

Referring to Fig (2) and (3) shows the safety device called fusible plug with sensor assy, to cool the engine and avoid engine seizure, in this the engine assembly (1) is constructed between RH Crash member (2), LH crash member (3)and firewall (4), the Octopus hose assembly (5) is connected to engine assembly (1) and Auxiliary tank(6) the another end goes to radiator side, the Auxiliary tank(6) is mounted on RH Crash member(2). The section of engine assembly (1) shown in flg.l, the cooling jacket passage (7) are connected to all four bores of cylinder (i.e. if the coolant will supply at one end it will circulate around all four bores of cylinder.
The various transmission module with crankshaft (12) shown, which may damage Octopus hose assembly (5) due to less clearances or by any other mean it can be damaged.
The coolant tank acts as a make up water for the cooling system, the thermostat valve is provided between engine assy.(l) and Octopus hose assembly (5), and it operate at defined temperature of engine.
The Auxiliary tank (6) divided in two compartments, safety compartment (9) and mail compartment (6). The safety compartment (9) is connected to inlet of fusible plug assembly (8) by using Bundy tube (10), this assembly contain the Bundy tube, the hollow nut (14) which is provided on tube for locking it in fusible plug assembly (8), the other end of Bundy tube assy, provided to safety compartment (9) with spring band clamp(17). The sensor assembly (11) will be provided at the bottom of main Auxiliary tank (6) and will be connected to alarm system in the driver cabin. The fusible plug assembly (8) fastened on engine assembly (1) and fusible material bismith alloy (13) which is shown and the same will melt at critical temp of the engine.
Referring to fig.4 shows the detailed construction of fusible plug, in this the complete assembly of fusible plug(8) is mounted on engine assembly(l), the fusible plug assembly contain the plug housing(16) with threaded hole at one end and the

through passage is provided for coolant flow, the metallic insert (15) with molded (injected) fusible material(13) is assembled in plug housing (16), the melting of fusible material will allow the coolant to flow through the plug and finally it will go in to the cooling jackets
Working of a engine protection device (Fusible Plug)
When the octopus hose assembly (5) fails due to any reason or engine temperature increases due to any reason, then coolant in the main auxiliary tank compartment (6) will drain out from the hose, and coolant level suddenly decreases, the level sensor(l 1) will give an alert to the driver, but due to high speed it will take some time to off the engine, meanwhile due to sudden increase in temperature the fusible material Bismith Alloy (13) melt at critical temperature and allow the coolant to flow through the cooling jackets (7) which will avoid the engine seizing. During this process driver can easily park the vehicle and switch off the engine, and further damage can be avoided. This invention will help in the failures of the other components also which can increase the ambient temperature of the engine.
BRIEF DESCRIPTION OF DRAWINGS
Figure 1 shows a current position of Engine with variable components. Figure 2 shows the invented position of fusible plug mounted on engine block Figure 3 shows the detailed sectional view of arrangement of fusible plug and
level sensor in assembly. Figure 4 shows the detailed sectional view of fusible plug
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is

intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.
Dated this 26th day of March 2009

TATA Motors Limited By their Agent & Attorney

(Karuna Goleria) of De PENNING & De PENNING