Flanged Connector Air Gap for SCR Injector Thermal Management

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Solution Overview

Problem

Existing injector systems for Selective Catalyst Reduction (SCR) in engines face overheating issues due to engine exhaust heat, leading to solid deposits and clogging, and current solutions like V-band clamps are cumbersome and prone to premature degradation, causing exhaust leakage.

Innovation Solution

A flanged connector system with a stand-off creating an air gap between the injector and exhaust duct flanges, incorporating a seal within the gap to reduce heat transfer and facilitate a robust, efficient, and easy assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a V-band clamp is used to connect the injector to the mounting structure, then the injector is insulated from engine exhaust heat reducing solid deposit buildup, but the connection becomes cumbersome requiring special tools and may degrade prematurely causing exhaust leakage

Engineering Contradiction:

Improvesolid deposit buildupVSAvoidassembly ease

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent introduces a flanged connector as an intermediary component between the injector and exhaust duct. This connector includes a first flange connected to the exhaust duct and a second flange connected to the injector mounting structure, with a stand-off creating an air gap between them. The intermediary connector provides both thermal insulation and easy assembly through standard flanged connections with bolts and seals.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connection system is segmented into separate components: the exhaust duct with its flange, the connector with stand-off and air gap, and the injector mounting structure. This segmentation allows each component to be optimized independently and assembled using standard procedures, eliminating the need for special tools while maintaining thermal insulation.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

Engineering Contradiction:

Improvesolid deposit buildupVSAvoidconnection reliability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The flanged connector serves as a reliable intermediary that distributes mechanical and thermal stresses away from the injector. The connector's robust flanged design with multiple bolt holes and integrated seal provides consistent, reliable connection without the premature degradation issues of V-band clamps.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The air gap created by the stand-off acts as a thermal cushion before heat can reach the injector. This pre-established thermal barrier protects the injector from heat-related degradation and solid deposit buildup, enhancing long-term reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If a flanged connector with stand-off and air gap is used to connect the injector, then heat transfer is reduced and assembly is simplified, but the device complexity increases

Engineering Contradiction:

Improveassembly easeVSAvoidconnector structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The flanged connector is designed as a universal component that performs multiple functions: mechanical connection, thermal insulation through air gap, and sealing. By consolidating these functions into a single standardized component, the overall system complexity is reduced despite the added protection features.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Temperature

If a flanged connector with stand-off and air gap is used to connect the injector, then heat transfer is reduced and assembly is simplified, but the device complexity increases

Engineering Contradiction:

Improveinjector temperatureVSAvoidconnector structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The stand-off acts as a thermal intermediary that blocks direct heat conduction paths from the exhaust duct to the injector. The air gap it creates provides passive thermal insulation, reducing injector temperature without requiring active cooling systems or complex thermal management devices.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 flanged connector system provides a reliable, efficient, and time-saving connection that reduces heat transfer and minimizes solid deposit buildup, preventing clogging and exhaust leakage while allowing for single-hand mounting and hand-free fastening.

Implementation Method 1

a stand-off separating the first flange from the second flange to form an air gap therebetween

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS8695327B2Liquid injector assembly with a flanged connector connection

Publication Date: 2014.04.15 FORD GLOBAL TECH LLC

AI summary

A system for injecting from an injector into a duct of an engine system is provided. The system may include a first flange on a duct connection side, a second flange on an injector connection side, a stand-off separating the first flange from the second flange to form an air gap therebetween, and a seal offset from at least one of the first and the second flanges and located within the airgap and between the first flange and the second flange.