Flexible Bellows With Integral Shield And Liner
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Solution Overview
Problem
Existing pipe couplings for exhaust pipes from internal combustion engines face challenges in handling harsh environmental conditions such as heat, noise, vibration, and pressure changes, requiring separate inner liners and outer shields that increase complexity and cost, while lacking flexibility in mounting and durability.
Innovation Solution
A flexible bellows with an integral outer shield and/or inner liner is created by adhering formed discs to form convolutions, allowing for improved thermal compensation, NVH management, and flexible mounting points, while integrating the shield and liner to reduce material constraints and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inner liners and outer shields are used in bellows couplings, then protection against harsh environment and NVH damping is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the bellows, inner liner, and outer shield into a single integrated component formed from a continuous sheet material. The bellows body, convolution liners, and end shields are all formed as one piece through stamping and forming operations, eliminating the need for separate components and reducing assembly complexity while maintaining protective functions.
Solution Approach 2:
The integrated bellows component performs multiple functions simultaneously: it provides thermal expansion compensation through its convolution structure, offers NVH damping through the material construction, protects against harsh environments through the continuous barrier, and enables flexible mounting through integrated features. This multi-functionality in a single component reduces overall system complexity.
2Reliability
If separate inner liners and outer shields are added to bellows, then compression limitation and turbulence reduction are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The inner liner is merged with the bellows body as an integral feature formed during the same stamping process. The convolution structure itself provides the liner function, eliminating the need for separate liner components and reducing manufacturing steps while maintaining compression limitation capabilities.
3Adaptability or versatility
If conventional bellows with separate components are used, then mounting flexibility is limited, but integrating mounting features increases structural complexity
Solution Approach 1:
Mounting features such as hanger loops, tabs, and attachment points are integrated directly into the bellows structure during forming. These mounting features are formed as part of the continuous sheet material construction, allowing flexible mounting configurations without requiring separate mounting brackets or additional structural 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
The integral construction enhances durability, reduces costs, and provides superior NVH compensation, improved cooling, and flexible mounting options, resulting in a more efficient and cost-effective piping system.
Implementation Method 1
compensating for thermal influences
Implementation Method 2
flexible element which is the basis for an elastic connection of pipes
Implementation Method 3
noise, vibration and harshness (hereinafter NVH) are produced by the environment of the exhaust from internal combustion engines must be handled
Data Source
AI summary
A flexible bellows used in a pipe coupling includes composite convolutions having integral extensions forming one or both of an outer shield or inner liner to enhance performance of the coupling. Embodiments incorporate dampers, hangers and convolution modifications. Various embodiments are disclosed.