Angled Flexible Coupling with Integral Shield
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Solution Overview
Problem
Existing pipe couplings for exhaust systems, particularly those with bellows, face challenges in flexibility, durability, and complexity due to separate inner liners and outer shields, which increase costs and complexity, and lack integrated mounting solutions to effectively manage thermal changes, noise, vibration, and pressure variations.
Innovation Solution
A flexible pipe coupling with an integral outer shield and/or inner liner, formed by adhering discs to create convolutions, allowing for enhanced flexibility, NVH compensation, and simplified mounting, while reducing material costs and complexity by integrating these components directly into the bellows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inner liners and outer shields are used with bellows, then protection and functionality are improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates the inner liner and outer shield directly into the bellows structure by forming them as integral parts of the same component. This merging eliminates the need for separate protective elements while maintaining their protective functions, thereby reducing device complexity and assembly requirements without compromising reliability
2Reliability
If separate inner liners and outer shields are used with bellows, then protection and functionality are improved, but manufacturing cost increases
Solution Approach 1:
By combining the inner liner, outer shield, and bellows into a single integrated component, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This integration simplifies the supply chain and manufacturing process, leading to cost reductions while maintaining the protective functionality of all elements
3Ease of operation
If conventional bellows are used, then basic flexibility is provided, but flexibility in mounting locations and NVH compensation is limited
Solution Approach 1:
The integrated bellows structure incorporates multiple functions including NVH compensation features, varied mounting point options, and adaptive positioning capabilities directly into the single component. This multi-functionality allows the same component to adapt to different mounting locations and environmental conditions without requiring additional specialized parts
4Ease of manufacture
If edge welded bellows are used, then assembly is simplified, but durability under flexibility and material selection are constrained
Solution Approach 1:
The patent employs composite material construction within the integrated bellows structure, combining materials with different properties to achieve both durability under flexible movement and resistance to thermal and chemical environmental factors. This composite approach allows selection of materials optimized for each specific function while maintaining structural integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, flexible, and durable pipe coupling that effectively manages thermal influences, noise, vibration, and pressure changes, improving system longevity and ease of assembly with integrated mounting options.
Implementation Method 1
compensates for thermal influences, pressure changes
Implementation Method 2
limit compression of the bellows
Implementation Method 3
outer shield to protect the bellows from a harsh environment
Data Source
AI summary
A flexible bellows used in a pipe coupling includes composite convolutions having integral extensions forming one or both of an outer shield or inner liner to enhance performance of the coupling. Embodiments incorporate asymmetric convolution forming discs providing for static angled couplings to accommodate offset or misaligned pipe system components.