Patent Publication Number: US-2022228523-A1

Title: Coolant pump module

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 17/070,122, filed on Oct. 14, 2020. The entirety of the aforementioned application is incorporated herein. 
    
    
     BACKGROUND 
     Internal combustion engines are often cooled through circulation of an engine coolant through an engine block, where the coolant absorbs heat from the engine. The coolant can subsequently be circulated through a radiator to dissipate the absorbed heat to the environment before being circulated again through the engine block. A coolant pump associated with the engine drives the coolant through the circuit. The circuit may also include a thermostat configured to restrict flow to the radiator until the coolant reaches a predetermined temperature. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key factors or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
     In one implementation, a coolant pump module for an engine is provided. The coolant pump module includes a module housing having a set of integrated passages. The set of integrated passages include at least a first passage for fluid flow from a radiator, a second passage for fluid flow from the engine, and a third passage for fluid flow to the engine. The coolant pump module also includes a thermostat coupled to the module housing in proximity to the first passage and the second passage. In addition, the coolant pump module further includes a pump mounted to the module housing for moving a coolant through a cooling circuit of the engine. 
     In another implementation, a method controlling a coolant flow through a cooling circuit of an engine is provided. The method includes receiving a first and second coolant flow from the engine and a radiator, respectively, at coolant pump module coupled to the cooling circuit. The method also includes combining the first and second coolant flow via operation of a thermostat integrated with the coolant pump module. In an example, the thermostat is responsive to a temperature of the coolant at the coolant pump module. Further, the method can include outputting a third coolant flow to engine after the combining via a pump integrated with the coolant pump module. 
     In still another implementation, a module is provided that includes a monolithic unit providing a plurality of fluid passages. The plurality of passages include at least a radiator passage, a bypass passage, a coolant output passage, and a pump inlet passage. The module further includes a pump coupled to the monolithic unit. A pump inlet is in fluid communication with the pump inlet passage and a pump outlet is in fluid communication with the coolant output passage. The module also includes a thermostat coupled to the monolithic unit proximate to the radiator passage and the bypass passage. The thermostat is configured to regulate a coolant flow into the coolant pump module from the radiator passage in accordance with a fluid temperature. 
     To the accomplishment of the foregoing and related ends, the following description and annexed drawings set forth certain illustrative aspects and implementations. These are indicative of but a few of the various ways in which one or more aspects may be employed. Other aspects, advantages and novel features of the disclosure will become apparent from the following detailed description when considered in conjunction with the annexed drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various non-limiting embodiments are further described in the detailed description given below with reference to the accompanying drawings, which are incorporated in and constitute a part of the specification. 
         FIG. 1  illustrates an exemplary, non-limiting embodiment of an internal combustion engine according to various aspects. 
         FIG. 2  illustrates a front-right perspective view an exemplary, non-limiting embodiment of a coolant pump module according to various aspects. 
         FIG. 3  illustrates a back-left perspective view of the coolant pump module. 
         FIG. 4  illustrates a back view of the coolant pump module. 
         FIG. 5  illustrates a front view of the coolant pump module. 
         FIG. 6  illustrates a left view of the coolant pump module. 
         FIG. 7  illustrates a right view of the coolant pump module. 
         FIG. 8  illustrates a cross-sectional view of the coolant pump module. 
         FIG. 9  illustrates another exemplary, non-limiting implementation of an engine according to various aspects. 
         FIG. 10  illustrates an exemplary, non-limiting implementation of a coolant pump module according to various aspects. 
         FIG. 11  illustrates an exemplary, non-limiting implementation of a coolant pump module according to various aspects. 
         FIG. 12  illustrates an exemplary, non-limiting implementation of a coolant pump module according to various aspects. 
     
    
    
     DETAILED DESCRIPTION 
     As described above, a typical internal combustion engine may include a coolant pump to circulate a fluid (e.g. an engine coolant) through a fluid circuit that includes an engine block and/or a radiator. In some configurations, the coolant may circulate through the engine block more than once before passing through the radiator to exchange absorbed heat with the environment. To control this bypass of the radiator, a thermostat can be positioned on the fluid circuit. Conventionally, the thermostat is located at an engine coolant outlet and measures a temperature of the coolant after the coolant passes through the engine. 
     In accordance with various embodiments, a coolant pump module for an internal combustion engine is provided. The coolant pump module includes an inlet thermostat and an exhaust gas recirculation (EGR) passage integrated into a single unit. Thus, the coolant pump module provides inlet and outlet of coolant to various cooling circuits and inlet and outlet for an EGR gas circuit. Coolant flow and gas flow in the module are through separate internal passages. The coolant pump module, in one aspect, is constructed of light weight material. 
     With this module, coolant from a radiator, for example, is circulated to an engine with a pump integrated with the module. In one aspect, the thermostat is positioned upstream of the pump at the inlet of the module for coolant. The thermostat may be dimensioned to provide a sufficient cross-sectional area to reduce a pressure drop and reduce a pump cavitation risk. In addition, placement at the inlet allows coolant flow from the engine (e.g. via a bypass) to mix with coolant flow from the radiator to be mixed near the thermostat, which facilitates maintaining a consistent coolant flow temperature to the engine. The consistent coolant flow temperature helps minimize a possibility of thermal shock, reduces system pressure, and reduces temperature cycling. 
     According to a further aspect, the coolant pump module accommodates coolant return from other engine components and/or a surge tank. Such coolant may flow to a pump inlet via a mixing chamber. The mixing chamber, in an embodiment, reduces coolant flow turbulence in the pump inlet passage. 
     During operation, coolant enters through a passage of the module coupled to an engine block. If a temperature of the coolant is less than a predetermined temperature (e.g. a start-to-open temperature) configured for the thermostat, the coolant flows through the passages in the module to coolant pump and back to the engine. If the temperature of the coolant is greater than the predetermined temperature, the coolant flow to the radiator for cooling and returns to the module (and, subsequently, the pump) after cooling. 
     The claimed subject matter is now described with reference to the drawings, wherein like reference numerals are generally used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to facilitate describing the claimed subject matter. 
     Referring briefly to  FIG. 1 , an exemplary, non-limiting embodiment of an internal combustion engine  100  is illustrated. As shown in  FIG. 1 , a portion of a cooling circuit is depicted. In particular,  FIG. 1  shows engine  100  with a coolant pump module  102 . The coolant pump module  102  includes a pump cartridge  104  and a module inlet  106 . The module inlet receives a coolant flow from a radiator (not shown). The engine  100  includes a coolant outlet  108  providing coolant flow to a surge tank (not shown) and/or the radiator after passing through engine  100 . 
     Turning now to  FIGS. 2-8 , an exemplary, non-limiting embodiment of coolant pump module  102  (also referred to herein as module  102 ) is illustrated in accordance with various aspects. Module  102  includes a housing  220 , which may be a monolithic unit composed of a lightweight material. Module  102  further includes a pump cartridge  202  and a thermostat  204 , which may be mounted to or integrated with housing  220 . According to an embodiment, pump cartridge  202  may be a pump having a two-speed electro-magnetic clutch. Further, thermostat  204  may be a wax motor configured according to a predetermined temperature, referred to as a start-to-open temperature. Thus, in one example, thermostat  204  remains closed until a temperature reaches the predetermined temperature (e.g. predetermined temperature), which may be a fluid temperature of a coolant at an inlet of module  102 . 
     Module  102  includes a plurality of inlets and outlets. These include, for example, a radiator inlet  206  that receives flow from the radiator, a surge tank port  208  that receives a return flow from a surge tank, and an exhaust gas recirculation (EGR) inlet  210  as shown in  FIGS. 2, 6 and 7 ; and, as best shown in  FIGS. 3 and 4 , a module outlet  212  from which an output of pump  202  flows, an EGR outlet  214 , and an engine return inlet  216  that receives a return flow of coolant after circulating through the engine. 
     Module  102  further includes a plurality of passages in fluid communication with the plurality of inlets and outlets described above. The passages are best seen in the cross-sectional view of  FIG. 8 . In  FIG. 8 , the cross-section is along an axis of module  102  as shown in  FIGS. 6 and 7 . 
     The plurality of passages include an EGR passage  222  that extends between EGR inlet  210  and EGR outlet  214 . The EGR passage  222  is integrated with module  102 , but is separate and isolated from other passages containing coolant flow. A bypass passage  224  is externally accessible (e.g. with respect to module  102 ) via the engine return inlet  216 . The bypass passage  224 , as described above, carries a coolant flow after circulation through the engine. The bypass passage  224  is in fluid communication with a pump inlet passage  234 , which extends between thermostat  204  and pump  202 . 
     A radiator passage  228  is externally accessible via the pump inlet  206  and carries a coolant flow after circulation through the radiator. The radiator passage  228  carries coolant to thermostat  204 , which regulates the coolant flow from the radiator passage  228  to the pump inlet passage  234 . For example, thermostat  204  may be configured according to a desired start-to-open temperature suitable for the engine and/or vehicle in which the module  102  is installed. In an aspect, the thermostat  204  reacts to a temperature of the fluid proximate to the exit of the bypass passage  224 , where the coolant returning from the engine enters the pump inlet passage  234 . When the fluid temperature reaches the start-to-open temperature, the thermostat  204  reacts by allowing coolant flow from the radiator passage  228  to the pump inlet passage  234 , where it mixes with the coolant flow returning from the engine. 
     As described above, coolant returning from a surge tank may be received by module  102  via the surge tank port  208 . The surge tank port  208  is in fluid communication with a mixing chamber  230 . The mixing chamber  230  is also in fluid communication with the pump inlet passage  234  via one or more openings or apertures  232 . Thus, the pump inlet passage  234  allows coolant returning from the engine, coolant returning from the surge tank, and coolant arriving from the radiator to mix prior to intake by pump  202 . Accordingly, module  102  provides a more consistent coolant flow temperature to an engine and reduces a possibility of engine thermal shock. 
     As shown in  FIG. 8 , pump  202  includes a pump impeller inlet  236  positioned on one side of pump inlet passage  234  opposed from thermostat  204 . A pump impeller outlet  238  is in fluid communication with a coolant output passage  226 , which leads to module outlet  212  and, then, to the engine. In one example, coolant output passage  226  is a volute shape. In addition, the volute is integrated into module  102 . 
     Turning now to  FIGS. 9-12 , another exemplary implementation of a coolant module is depicted. According to this implementation, the coolant module is a monolithic unit providing a plurality of fluid passages. The plurality of passages include, for example, one or more of a radiator intake passage, an engine return passage, a coolant output passage, and an internal passage. A pump can be coupled to the monolithic unit. An inlet of the pump is in fluid communication with the internal passage and an outlet of the pump is is in fluid communication with the coolant output passage. A thermostat can be coupled to the monolithic unit proximate to the radiator intake passage and the engine return passage. The thermostat is configured to regulate a coolant flow into the coolant pump module from the radiator intake passage and engine return passage in accordance with a fluid temperature. 
     Further to this implementation, the coolant pump module may include a check valve and a check valve passage that allows air to be vented from the radiator intake passage during a cooling system fill operation. The coolant pump module may also include a passage for installation of a pressure sensor. 
     Referring briefly to  FIG. 9 , an exemplary, non-limiting implementation of an engine  300  is illustrated. As shown in  FIG. 9 , a portion of a cooling circuit is depicted. Similar to  FIG. 1 , for example,  FIG. 9  shows engine  300  with a coolant pump module  302 . 
     Referring now to  FIGS. 10-12 , an exemplary, non-limiting implementation of coolant pump module  302  (also referred to herein as module  302 ) is illustrated in accordance with various aspects. Module  302  includes a housing  420 , which, like module  102  and housing  220 , may be a monolithic unit. As described herein, unlike module  102 , module  302  does not have integrated EGR passages. 
     Module  302  may include a pump  402  and a thermostat  404 , which may be mounted to or integrated with housing  420 . According to various examples, pump  402  may be a pump having a two-speed electro-magnetic clutch. Further, thermostat  404  may be a wax motor configured according to a predetermined temperature, referred to as a start-to-open temperature. Thus, in one example, thermostat  404  remains closed until a temperature reaches the predetermined temperature (e.g. the start-to-open temperature), which may be a fluid temperature of a coolant at an inlet of module  302 . 
     Module  302  includes a plurality of inlets and/or outlets. The inlets include, for example, a radiator inlet  406  that receives flow from the radiator, a surge tank port  408  that receives a return flow from a surge tank, an auxiliary inlet  410  that receives return flow from auxiliary components of the cooling system, and an engine return inlet  416  that receives a return flow of coolant after circulating through the engine. The outlets include, for example, a module output  412  from which an output of pump  402  flows out to other portions of the cooling system (e.g. engine, radiator, auxiliary components, etc.). 
     The module  302  further includes a plurality of passages in fluid communication with the plurality of inlets and/or outlets described above. The passages are best seen in the cross-sectional view of  FIG. 12 . The plurality of passages include an engine return passage  424 , which is externally accessible (e.g. with respect to module  302 ) via the engine return inlet  416 . The engine return passage  424  carries a coolant flow after circulation through the engine. The engine return passage  424  is in fluid communication with an internal passage  434  (or pump inlet passage  434 ), which extends between thermostat  404  and pump  402 . 
     A radiator passage  428  is externally accessible via the radiator inlet  406  and carries a coolant flow after circulation through the radiator. The radiator passage  428  carries coolant to thermostat  404 , which regulates the coolant flow from the radiator passage  428  to the internal passage  434 . For example, thermostat  404  may be configured according to a desired start-to-open temperature suitable for the engine and/or vehicle in which the module  302  is installed. In an aspect, the thermostat  404  reacts to a temperature of the fluid proximate to the exit of the engine return passage  424 , where the coolant returning from the engine enters the internal passage  434 . When the fluid temperature reaches the start-to-open temperature, the thermostat  404  reacts by allowing coolant flow from the radiator passage  428  to the internal passage  434 , where it mixes with the coolant flow returning from the engine via the engine return passage  424 . 
     Coolant returning from a surge tank may be received by module  302  via the surge tank port  408 . As shown in  FIG. 12 , the surge tank port  408  is in fluid communication with the internal passage  434 . Thus, the internal passage  434  allows coolant returning from the engine, coolant returning from the surge tank, coolant arriving from the radiator to mix prior to intake by pump  402 , and coolant received from auxiliary components via auxiliary port  410 . 
     Similar to the implementation described in connection with  FIG. 8 , pump  402  may include a pump impeller inlet positioned on one side of internal passage  434  opposed from thermostat  404 . A pump impeller outlet is in fluid communication with a coolant output passage  426 , which leads to module outlet  412  and, then, to the engine and/or other components of the cooling system. In one example, coolant output passage  426  is a volute shape. In addition, the volute is integrated into module  302 . 
     Further, as shown in  FIG. 12 , the module  302  further includes a check valve  432  and a check valve passage  430 . The check valve  432  allows air to be released from radiator passage  428  and facilitates draining coolant from the cooling system. For instance, the check valve  432  allows air to be released through an orifice in the valve. When the radiator passage  428  is filled with coolant, the check valve  432  is closed due to a differential pressure. When closed, the check valve  432  prevents coolant flow through the valve. As shown in  FIG. 12 , one side of the check valve  432  is in fluid communication with the surge tank port  408  via the check valve passage  430 . The other side of the check valve  432  is in fluid communication with the radiator passage  428 . 
     As shown in  FIG. 10 , module  302  includes a port  418  where a pressure sensor is received. 
     The word “exemplary” is used herein to mean serving as an example, instance or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. Further, at least one of A and B and/or the like generally means A or B or both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims may generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. 
     Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter. 
     Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure includes all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above described components (e.g., elements, resources, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the disclosure. 
     In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” 
     The implementations have been described, hereinabove. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.