Thermal wax bypass valve utilizing rigid seal carrier

1. A bypass system comprising:

a source of a fluid to be cooled and a heat exchanger for selectively cooling the fluid;

a bypass valve mounted on a line to selectively bypass fluid prior to reaching the heat exchanger if the fluid falls below a predetermined temperature, said bypass valve including a valve poppet and valve seat, said bypass valve further including a piston moveable along an axis allowing movement of said valve poppet toward and away from said valve seat, said piston moving with a rigid seal carrier, said rigid seal carrier carrying a seal at an outer periphery, and said rigid seal carrier and said piston moving within a valve housing, said valve housing having a chamber formed on one axial side of said rigid seal carrier, and a wax portion disposed on an opposed axial side of said rigid seal carrier relative to said chamber, such that said wax portion expands as a temperature of the fluid to be cooled increases, and causes said valve poppet to move against said valve seat and said wax portion cools if the temperature of the fluid to be cooled lowers such that said valve poppet can move away from said valve seat; and

wherein said piston is forced in a first axial direction away from said valve seat as said wax expands, and causes said valve housing to move with said valve head toward said valve seat.

2. The bypass system as set forth in claim 1 , wherein said wax portion includes a wax and a powdered metal.

3. The bypass system as set forth in claim 2 , wherein said rigid seal carrier is formed of a metal.

4. The bypass system as set forth in claim 3 , wherein said seal is formed of one an elastomeric material, a metal, or a carbon material.

5. The bypass system as set forth in claim 4 , wherein said rigid seal carrier has a top hat shape with a forward planer portion extending perpendicularly to an axis of movement of the poppet, a cylindrical portion extending from said forward planar portion and in a direction away from said valve seat and a brim extending radially outwardly from said cylindrical portion.

6. The bypass system as set forth in claim 5 , wherein said seal is received on a radially outer portion of said brim.

7. The bypass system as set forth in claim 1 , wherein said rigid seal carrier is formed of a metal.

8. The bypass system as set forth in claim 7 , wherein said rigid seal carrier is formed of stainless steel.

9. The bypass system as set forth in claim 8 , wherein said seal is formed of one an elastomeric material, a metal, or a carbon material.

10. The bypass system as set forth in claim 9 , wherein said rigid seal carrier has a top hat shape with a forward planer portion extending perpendicularly to an axis of movement of the poppet, a cylindrical portion extending from said forward planar portion and in a direction away from said valve seat and a brim extending radially outwardly from said cylindrical portion.

11. The bypass system as set forth in claim 10 , wherein said seal is received on a radially outer portion of said brim.

12. The bypass system as set forth in claim 1 , wherein said rigid seal carrier has a top hat shape with a forward planer portion extending perpendicularly to an axis of movement of the poppet, a cylindrical portion extending from said forward planar portion and in a direction away from said valve seat and a brim extending radially outwardly from said cylindrical portion.

13. The bypass system as set forth in claim 12 , wherein said seal is received on a radially outer portion of said brim.

14. The bypass system as set forth in claim 13 , wherein said rigid seal carrier is formed of a metal.

15. The bypass system as set forth in claim 14 , wherein said rigid seal carrier is formed of stainless steel.

16. The bypass system as set forth in claim 15 , wherein said seal is formed of one an elastomeric material, a metal, or a carbon material.

17. The bypass system as set forth in claim 1 , wherein said rigid seal carrier is formed of a metal.

18. A bypass valve comprising:

a valve poppet and valve seat, said bypass valve further including a piston moveable along an axis allowing movement of said valve poppet toward and away from said valve seat, said piston moving with a metal seal carrier, said metal seal carrier carrying a seal at an outer periphery, and said metal seal carrier and said piston moving within a valve housing, said valve housing having a chamber formed on one axial side of said metal seal carrier, and a wax portion disposed on an opposed axial side of said metal seal carrier relative to said chamber, such that said wax portion expands as a temperature of the fluid to be cooled increases, and causes said valve poppet to move against said valve seat and said wax portion cools if the temperature of the fluid to be cooled lowers such that said valve poppet can move away from said valve seat;

said metal seal carrier is formed of stainless steel, said seal is formed of one an elastomeric material, a metal, a plastic, or a carbon material, said metal seal carrier has a top hat shape with a forward portion extending generally perpendicularly to an axis of movement of the piston, a cylindrical portion extending from said forward portion and in a direction away from said valve seat and a brim extending radially outwardly from said cylindrical portion, said seal is received on a radially outer portion of said brim; and

wherein said piston is forced in a first axial direction away from said valve seat as said wax expands, and causes said valve housing to move with said valve head toward said valve seat.