Bellows Fluid Duct Structure for Multi-Angle Bending Flexibility
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Solution Overview
Problem
Fluid ducts used in automotive applications face challenges with reduced bending flexibility out of the plane of maximum flexibility due to thermal and mechanical forces, leading to stress and potential rupture or deformation, especially under high temperatures and pressures, while also being difficult to assemble and disassemble.
Innovation Solution
A fluid duct design featuring a tubular base wall with bellows comprising convolutes that wrap around the duct channel by a specific angle, providing high bending flexibility in a range of angles and stiffness in the flow direction, achieved through a combination of convolute arrangement and non-bellows tube portions, allowing for easy assembly and reduced stress on coupling ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bellows are provided with rigidifying sections to prevent elongation in the flow direction, then stiffness in the flow direction is improved, but bending flexibility out of the plane of maximum flexibility is reduced
Solution Approach 1:
The bellows structure implements different mechanical properties at different locations: the convolutes provide flexibility in the bending direction while the connecting sections between convolutes maintain stiffness in the flow direction. This local differentiation allows the tube to exhibit anisotropic mechanical behavior, being flexible when bent sideways but rigid when subjected to axial forces.
Solution Approach 2:
The invention transitions from two-dimensional convolute patterns to three-dimensional spatial arrangements of convolutes. The convolutes are positioned at specific angles and heights, creating a complex 3D structure that provides flexibility in radial directions while maintaining axial stiffness through the spatial configuration and connection geometry.
2Adaptability or versatility
If bellows are designed to provide high bending flexibility, then bending flexibility is improved, but elongation in the flow direction increases under high temperatures and pressures
Solution Approach 1:
Different sections of the bellows are designed with distinct functions: convolutes are optimized for bending flexibility while connecting sections are designed for axial stiffness and dimensional stability. This local specialization allows the structure to tolerate thermal expansion and pressure-induced elongation in specific regions while maintaining overall structural integrity.
Solution Approach 2:
The bellows structure allows for controlled deformation under thermal and pressure loads. The convolutes can expand and contract radially to accommodate dimensional changes, while the connecting sections maintain the structural framework. This dynamic response allows the tube to adapt to environmental conditions without permanent deformation.
3Reliability
If rigidifying sections are added to prevent tube rupture, then reliability is improved, but assembly difficulty increases
Solution Approach 1:
The bellows is divided into discrete convolutes connected by connecting sections. This segmentation allows the structure to achieve rigidity through the arrangement and connection of multiple elements rather than requiring a single rigid component. The modular nature of the segmented structure facilitates easier assembly compared to monolithic rigid components.
Solution Approach 2:
The connecting sections between convolutes provide controlled flexibility that facilitates assembly operations. These sections allow the bellows to flex during installation to accommodate alignment tolerances and reduce assembly forces, while maintaining sufficient rigidity during operation to prevent rupture and detachment.
Data Source
AI summary
Provided herein is a fluid duct 2 comprising a tubular base wall 11 surrounding a duct channel and at least one bellows 10 formed along a section of the tubular base wall 11. The bellows 10 comprises a plurality of convolutes 12 having a profile 14 projecting radially from the base wall 11. At least one convolute 12 wraps around the duct channel at a wrap-around angle Ω of between 180° and 720° from a first end 22a to a second end 22b of the convolute 12, said second end 22b being offset in a flow direction F parallel to a centerline C of the duct channel by a non-zero offset distance D from the first end 22a.