Exhaust Lining Clamp with Point Contact for Stable Tailpipe Attachment
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Solution Overview
Problem
Existing exhaust linings for motor vehicles face challenges in reliably attaching the second pipe to the first pipe due to temperature and manufacturing fluctuations, leading to inconsistent support and potential detachment.
Innovation Solution
An exhaust lining with a resilient, one-piece connecting element featuring a punctiform contact area and a lever mechanism, where the connecting element is secured via an end claw and a punctiform contact area on the first pipe, providing defined support and enhanced locking through a clamping spring, allowing for secure attachment even with temperature and manufacturing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connecting element with linear or planar contact area is used, then the structure is simple and easy to manufacture, but the support is undefined and unreliable under temperature and manufacturing fluctuations
Solution Approach 1:
The connecting element features a punctiform contact area (point contact) instead of a distributed linear or planar contact area. This localized contact point provides a well-defined, stable support position that remains reliable under temperature and manufacturing fluctuations, resolving the contradiction between attachment reliability and structural simplicity.
Solution Approach 2:
The connecting element incorporates a resilient (elastic) body that can dynamically adapt to temperature changes and manufacturing tolerances. The elastic material allows the connecting element to maintain reliable attachment while accommodating dimensional variations, achieving both reliability and tolerance to fluctuations.
2Reliability
If the connecting element is made resilient with a lever mechanism, then the attachment becomes secure under temperature variations, but the manufacturing complexity increases
Solution Approach 1:
The connecting element is designed as an integrated one-piece component combining the resilient body, lever mechanism, and punctiform contact area. This segmentation into a single molded part simplifies manufacturing compared to assembling multiple separate components, while maintaining the secure attachment functionality under temperature variations.
Solution Approach 2:
The resilient material properties and lever mechanism geometry are optimized to provide consistent attachment force across temperature ranges. By carefully selecting material parameters and geometric dimensions, the design achieves reliable attachment without requiring complex manufacturing processes.
3Reliability
If multiple connecting elements are used to ensure reliable attachment, then the attachment reliability improves, but the device complexity and cost increase
Solution Approach 1:
The single connecting element performs multiple functions simultaneously: it provides structural support, maintains radial positioning, accommodates temperature variations, and ensures consistent attachment. This multi-functional design achieves reliable pipe attachment without requiring multiple separate components, reducing overall system complexity.
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 punctiform contact area and lever mechanism ensure a reliable and secure attachment of the second pipe to the first pipe, effectively addressing the issues of temperature and manufacturing fluctuations, while allowing for cost-effective production using sheet metal components.
Implementation Method 1
an at least partially resilient one-piece first connecting element disposed radially between the first pipe and the second pipe for holding the second pipe to the first pipe
Data Source
AI summary
An exhaust lining for an exhaust system of a motor vehicle has a first connecting element clamped between a first and second pipe. The first pipe forms a tailpipe. The second pipe forms a tailpipe cover. The tailpipe cover has a tubular inner part held on by means of the first connecting element which clings onto the first pipe via by means of a lever mechanism. A load arm of the lever mechanism, having the distance A, is shorter than an effort arm, having the distance B. The length of the effort arm is precisely defined, because the end of the effort arm lies against the first pipe via a punctiform contact area. A first contact surface of a clamping spring is designed offset from the longitudinal extent of a main body of the first connecting element to save space in the longitudinal direction of the main body.