Connecting Flange Structure for Gas-Tight Thermal Isolation
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Solution Overview
Problem
Existing connecting flanges for tubular components in exhaust systems of internal combustion engines often fail to provide a reliable and gas-tight connection while also addressing thermal insulation and thermal expansion issues.
Innovation Solution
A connecting flange with axially separated flange contact regions and an insulating recess, featuring a sealing element and conical surfaces for stable, thermally insulated connection, using materials like graphite and a connecting clip for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single continuous contact surface is provided on the connecting flange, then a stable contact interaction and defined positioning with the tubular component is achieved, but the connecting flange becomes thermally overloaded in high-thermal-load regions
Solution Approach 1:
The connecting flange is divided into multiple contact regions (first and second contact regions) separated by a gap region. This segmentation allows the flange to maintain stable contact with the tubular component through distributed contact points while the gap region provides thermal insulation, preventing excessive heat transfer from high-thermal-load areas to the connecting flange body.
2Volume of moving object
If the connecting flange is positioned close to the exhaust gas outlet to utilize the available space, then compactness is achieved, but the connecting flange is exposed to high thermal loads that compromise connection reliability
Solution Approach 1:
The gap region acts as a thermal intermediary between the tubular component and the connecting flange body. This intermediary zone reduces direct thermal coupling, allowing the connecting flange to be positioned in high-thermal-load regions near the exhaust gas outlet while maintaining connection reliability by limiting heat transfer to the flange structure.
3Reliability
If a gas-tight connection is achieved using a sealing element between connecting surfaces, then gas-tightness is ensured, but thermal expansion and mechanical stress affect the sealing effectiveness
Solution Approach 1:
The connecting flange features different local properties: the contact regions provide stable mechanical support and positioning, while the gap region provides thermal insulation. This local differentiation allows the sealing element to be protected from excessive thermal stress while maintaining gas-tight connection, as the gap region shields the sealing area from direct thermal exposure.
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
Ensures a stable, gas-tight, and thermally insulated connection suitable for high-thermal-load environments, minimizing mechanical stress and maintaining connection integrity under thermal expansion.
Implementation Method 1
the insulating recess or the air contained therein or another thermally insulating material creates an insulating effect, by which the connecting flange is thermally relieved
Data Source
AI summary
A connecting flange for mutually connecting two tubular components including a flange body annularly surrounding a flange longitudinal axis with a first flange contact region and a second flange contact region, which is arranged in the direction of the flange longitudinal axis at a distance from the first flange contact region. At the first flange contact region, a first inner circumferential contact surface for contact of the flange body against an outer circumferential surface of one of the components to be connected to each other via the connecting flange is provided, and, at the second flange contact region, a second inner circumferential contact surface for contact of the flange body against the outer circumferential surface is provided. An insulating recess extending radially outward with respect to the first inner circumferential contact surface or/and the second inner circumferential contact surface and open radially inward is provided in the flange body.