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The targets of this study are: cost reduction of all engine cooling components, gasoline consumption reduction, weight reduction of the engine cooling system, improvement of the thermal comfort in passenger compartment. To reach these targets, Valeo Engine Cooling is developing a new concept in engine cooling. This basic concept consists of adding a small electric water pump, 30 to 60W, instead of the conventional engine driven water pump of up to 1 to 2 KW. This small electric water pump provides a flow rate of approximately 1000L/h. With a liquid flow rate of 1000L/h, this conceptual system can ensure engine cooling at speeds up to 120 Km/h under convective cooling in normal conditions. That is to say, it can supply 95% of the flow requirements (see appendix ) of a vehicle at the same performance level as a conventional cooling system.

In order to reduce the cost of engine cooling systems in particular the turbo Diesel engines with charge air coolers, we want to understand the relationship between oil sump temperatures and engine coolant temperatures and their impact on one another. Several cars have been tested in the climatic wind tunnel. The following are the cooling specifications: hill climbing with 12% grade with or without a trailer at a 20°C ambient max. speed at 35°C ambient. The main results of these studies were: a great variation of oil sump temperature versus coolant temperature a small variation of coolant temperature versus oil sump temperature a very small variation of heat flux in the oil, in the coolant and the output of engine versus oil sump and coolant temperature.

During the cold start of an IC engine, the water temperature and particularly the oil sump temperature rises slowly depending on the outside ambient temperature. At the same time, the engine consumes more gasoline and emits more pollutants in the form of CO, HC, NOX. The thermal comfort in the passenger compartment is also poor. To avoid or minimize some of these problems, Valeo Engine Cooling is developing a new, economical system, the Insulated Expansion Tank (IET), which makes it possible to instantaneously heat the engine coolant by sensible heat from the IET, the volume of this tank has been increased especially for this application. The component actually has two functions: 1. Allows for expansion and degassing of the cooling circuit 2. Thermal storage of sensible heat The IET is installed in the engine cooling circuit according to figure 1.