Bellows Intake Air Duct With 3D Weld Seam for Transverse Bending
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Solution Overview
Problem
Conventional tubular bodies for fresh air systems in internal combustion engines, equipped with a bellows, are limited in flexibility as they cannot be bent transversely, restricting their use in various installation space situations.
Innovation Solution
A two-part tubular body design with shell-like parts connected by a material bond outside the bellows section, featuring a zigzag or sinusoidal weld seam that intersects the parting plane, allowing for improved bending properties and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tubular body is produced as a single piece with a bellows, then the manufacturing process is simple, but the tubular body cannot be bent transversely and is limited in flexibility
Solution Approach 1:
The tubular body is divided into two separate shell-like parts that are connected by a material bond. This segmentation allows each part to maintain structural integrity while enabling the overall assembly to bend transversely, resolving the contradiction between manufacturing simplicity and bending flexibility.
2Ease of manufacture
If the material connection is arranged in the parting plane, then the connection is simple and direct, but the bending properties are poor and the bellows cannot bend effectively
Solution Approach 1:
The material connection is arranged to extend in three dimensions, protruding from the parting plane into the bellows section. This dimensional extension allows the connection to accommodate transverse bending movements while maintaining structural integrity, resolving the contradiction between connection simplicity and bending capability.
3Ease of operation
If the material connection intersects the parting plane multiple times with a zigzag or sinusoidal course, then the bending properties are improved, but the manufacturing complexity increases
Solution Approach 1:
The material connection geometry is designed with specific parameters including zigzag or sinusoidal courses that intersect the parting plane multiple times. These parameter changes optimize the bending properties by distributing stresses and enabling flexible movement, resolving the contradiction between bending properties and manufacturing complexity.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a tubular body (1), in particular for a fresh air system of an internal combustion engine. The tubular body (1) comprises a first and a second tubular body part (2a, 2b), each of which has a shell-like design and which are bonded together by means of a bonded connection (20) and have a common bellows section (3), wherein the tubular body (1) is designed as a bellows (4) in the bellows section. According to the invention, the bonded connection (20) runs on a separation plane (E) outside of the bellows section (3) and at least partly outside of the separation plane (E) in the bellows section (4).