Connecting Flange Heat Protection Sleeve
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Solution Overview
Problem
The existing fastening arrangements between engine blocks and exhaust manifolds face thermal overload issues due to the high thermal loads from exhaust gases, leading to potential failure of the connecting flange elements, which requires the use of cost-intensive and thermally resilient materials to prevent thermal failure.
Innovation Solution
A heat protection sleeve is arranged within the passage openings extending from the engine-side flange surface to the exhaust manifold-side flange surface, creating an air gap for thermal insulation and reducing direct heat transfer, while a coolant channel further cools the connecting flange element, and the sleeve elements are designed to prevent exhaust gas leakage with overlapping and crimping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting flange element is made of cost-intensive and thermally resilient material to prevent thermal failure, then the thermal reliability is improved, but the manufacturing cost increases
Solution Approach 1:
A heat protection sleeve is introduced as an intermediary component between the exhaust gas and the connecting flange element. The sleeve extends through the passage opening and is radially spaced from the peripheral surface, creating an air gap that acts as thermal insulation. This mediator protects the connecting flange element from direct thermal exposure, allowing the use of less expensive materials while maintaining thermal reliability.
Solution Approach 2:
The heat protection sleeve is made of sheet steel, a cost-effective material compared to the thermally resilient materials previously required for the connecting flange element itself. The sleeve acts as a sacrificial or replaceable component that absorbs thermal exposure, protecting the more expensive connecting flange element from thermal damage.
2Temperature
If a heat protection sleeve with air gap is arranged in the passage opening to reduce heat transfer, then the thermal insulation is improved, but the device complexity increases
Solution Approach 1:
The heat protection sleeve is divided into a first sleeve element and a second sleeve element that are assembled separately. The first sleeve element is inserted into the passage opening from one side, while the second sleeve element is inserted from the other side, with their ends overlapping to form the complete heat protection assembly. This segmentation simplifies the installation process and reduces the complexity of fitting a single large sleeve into the passage opening.
Solution Approach 2:
The first and second sleeve elements are nested together through overlapping, with one sleeve element partially inserted into the other. This nested arrangement creates the complete heat protection structure while allowing for simplified assembly and positioning of the individual sleeve elements within the passage opening.
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 effectively prevents thermal failure of the connecting flange element in a simple and cost-effective manner by reducing heat transfer and ensuring reliable thermal insulation and coolant distribution, thereby extending the lifespan of the components.
Implementation Method 1
The air gap is radially defined by the outer peripheral surface of the heat protection sleeve and the peripheral surface of the passage opening and serves to thermally insulate the exhaust duct and the connecting flange element
Implementation Method 2
The connecting flange element has at least one coolant channel through which a coolant flows. The connecting flange element is additionally cooled by the coolant
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Mounting arrangement comprising an engine block (14), an exhaust manifold (70), and a connecting flange element (72), which is attached to the engine block (14) via an engine-side flange surface (74) and to the exhaust manifold (70) via an exhaust manifold-side flange surface (76), wherein the connecting flange element (72) has several through-openings (77, 79, 83, 85) which extend from the engine-side flange surface (74) to the exhaust manifold-side flange surface (76) and each radially delimit an exhaust channel (78, 80, 84, 86), wherein a heat protection sleeve (110; 112) is arranged in at least one through-opening (77, 79, 83, 85) which extends axially from the engine-side flange surface (74) to the exhaust manifold-side flange surface (76).