Exhaust Pipe Joint by Radial Deformation Without Clamps
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Solution Overview
Problem
Existing exhaust systems for vehicles with internal combustion engines face challenges in forming reliable mechanical joints between exhaust pipes without the need for welding or clamps, which are costly and complex to implement.
Innovation Solution
A method of joining exhaust system components involves inserting one pipe end into another to create an overlapped section, which is then radially deformed using a tool with moveable jaws to form a pressed engagement and a dimple for mechanical locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join exhaust pipes, then a suitable mechanical joint is achieved, but the joint may not meet leakage specifications and requires costly repair procedures
Solution Approach 1:
The second pipe is inserted within the first pipe to create a nested configuration. This telescoping arrangement allows the pipes to be joined without welding, while the nested structure provides both mechanical strength and leakage resistance through the overlapping configuration
Solution Approach 2:
The patent replaces the welding process with a mechanical deformation process. A tool with radially moveable jaws deforms the overlapped pipe sections radially inwardly to create pressed engagement, substituting thermal welding with cold-forming mechanical joining
2Ease of manufacture
If clamps with mechanical fasteners are used to join exhaust pipes, then the pipes can be connected without welding, but costly equipment and complex assembly line tooling are required
Solution Approach 1:
The joining function is merged directly into the pipe structure itself. The pipes are designed with overlapping ends that can be mechanically deformed to create the joint, eliminating the need for separate clamps and fasteners. The pipe structure serves both as the exhaust component and as the joining element
Solution Approach 2:
The pipe joint is self-forming through radial deformation. The tool with radially moveable jaws deforms the pipe material itself to create the pressed engagement and mechanical lock, allowing the pipe to join itself without requiring external clamps or fastening components
3Weight of moving object
If thin wall thickness pipes are used to minimize exhaust system weight, then weight is reduced, but welding becomes challenging due to limited material in the melt pool
Solution Approach 1:
The patent replaces welding with mechanical deformation joining. The radially moveable jaws deform the thin-walled pipes radially inwardly to create pressed engagement, avoiding the welding process entirely and eliminating the challenges associated with welding thin materials
Solution Approach 2:
The patent changes the joining mechanism from thermal (welding) to mechanical (deformation). This parameter change allows thin-walled pipes to be joined effectively through cold-forming processes that do not require melting or fusing the material
4Strength
If clamps are used to join exhaust pipes, then mechanical connection is achieved, but costly components require shipping, handling and purchasing efforts
Solution Approach 1:
The joining function is merged into the pipe structure itself. The overlapping pipe ends are designed to be mechanically deformed directly, eliminating the need for separate clamp components. This reduces part count and eliminates the costs associated with purchasing, shipping, and handling external clamps
Solution Approach 2:
The pipe structure serves its own joining function. The pipes are designed with overlapping ends that can be deformed to create the joint, allowing the exhaust system components to join themselves without requiring external fastening components
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
This solution eliminates the need for welding or clamps, reducing costs and complexity while achieving a reliable, leak-resistant joint that meets mechanical and sealing requirements.
Implementation Method 1
radially inwardly deforming the overlapped first and second pipes into pressed engagement with one another to define a pipe joint
Implementation Method 2
Both of the first end and the second end are radially inwardly deformed into pressed engagement with one another. The first and second pipes are sealingly engaged with one another at the radial deformation.
Data Source
AI summary
A method of joining components of an exhaust system comprises obtaining a first pipe with a first end and inserting a second end of a second pipe within the first end of the first pipe to provide a length of overlapped first and second pipes. The method includes radially inwardly deforming the overlapped first and second pipes into pressed engagement with one another to define a pipe joint.