Concentric Conduit Connection via Axial Solder Flow
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Solution Overview
Problem
Existing connections between concentrically arranged line elements in motor vehicle exhaust systems, such as those using mechanical pressing or brazing, are prone to loosening under stress and temperature changes, leading to relative movement and premature failure due to frictional wear, and impair liner mobility.
Innovation Solution
A positive-locking structure with a form-fitting cross-sectional enlargement allows solder material to flow axially, creating a secure solder connection between the inner and outer line elements through inductive heating, eliminating the need for expansion and ensuring no relative movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical pressing expansion is used to connect inner pipe and outer pipe, then connection strength is improved, but liner mobility is impaired
Solution Approach 1:
A positive-locking structure is provided on the inner line element and on the outer line element through which the soldering material can flow in the axial direction. This preliminary structural arrangement allows the solder to be positioned automatically during the connection process, eliminating the need for expansion while maintaining connection strength and preserving liner mobility.
2Strength
If mechanical pressing is used to connect inner pipe and outer pipe, then connection is initially secure, but connection can come loose under stress and temperature changes
Solution Approach 1:
The mechanical pressing connection is replaced by a solder connection using a positive-locking structure. The solder material flows axially through the positive-locking structure to create a material bond between the inner and outer line elements. This material connection is more reliable under stress and temperature changes compared to mechanical pressing alone.
3Strength
If brazing material is used without positive-locking structure, then material connection is achieved, but solder cannot be positioned in axial direction
Solution Approach 1:
The positive-locking structure serves as an intermediary between the inner and outer line elements, providing a defined pathway for the soldering material to flow in the axial direction. This intermediary structure ensures precise positioning of the solder while facilitating the material connection process.
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 prevents premature failure by ensuring a secure, friction-free connection and maintaining liner mobility, as the solder connection is stable and evenly applied, reducing wear and enhancing the durability of the decoupling element.
Implementation Method 1
the line element arrangement created from the first line element and the second line element is inductively heated in the area in order to create the desired solder connection
Implementation Method 2
a positive-locking structure is provided on the inner line element and on the outer line element, through which the soldering material can flow in the axial direction of the line element arrangement
Data Source
AI summary
A connection between two concentrically arranged conductor elements (2,3) is proposed, in particular for a decoupling element for the exhaust system of a motor vehicle with an internal combustion engine, which connection is characterized in that a soldering agent is arranged between a first, inner (2) of the two conductor elements and a second, outer (3) of the two conductor elements, which soldering agent creates a materially bonded connection (5) between the two conductor elements (2, 3).