Flexible Conduit Element with Movable End Portions for Exhaust Systems
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Solution Overview
Problem
Existing flexible conduit elements for exhaust gas systems in combustion engine vehicles face limitations in durability and flexibility due to fixed mesh structures and stationary fixation, which restrict dynamic stiffness and make maintenance difficult, especially under increased engine power conditions.
Innovation Solution
A flexible conduit element design featuring a bellows member with a flexible member that has movable end portions, allowing for radial biasing and movement, and optionally using different stiffness materials or techniques like knitting, braiding, or weaving to enhance dynamic stiffness and maintainability, without the need for additional fixing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flexible member is firmly fixed to the bellows member end portion by welding or pressing, then the connection strength is improved, but the flexibility and dynamic stiffness are reduced
Solution Approach 1:
The flexible member is designed with movable end portions that can dynamically adjust their position relative to the bellows member. The first end portion is movable relative to the first fixing element, and the second end portion is movable relative to the second fixing element, allowing the system to adapt to varying dynamic conditions while maintaining secure connection when needed.
Solution Approach 2:
The flexible member is divided into distinct segments: a first end portion, a middle portion, and a second end portion. Each segment can move independently, with the end portions having different degrees of freedom compared to the middle portion. This segmentation allows the connection to be strong where needed while maintaining flexibility where required.
2Strength
If the mesh structure is used for the flexible member, then the structural integrity is improved, but the traction limit and displacement properties are limited
Solution Approach 1:
Different portions of the flexible member have different structural characteristics. The middle portion maintains a mesh structure for structural integrity, while the end portions are designed with different properties to enable movement and adjustment. This local differentiation allows the flexible member to have both strength and adaptability in different locations.
3Stability of the object's composition
If the flexible member is stationary fixed, then the positioning stability is improved, but the overall flexibility and moveability are reduced
Solution Approach 1:
The flexible member transitions from a stationary fixed design to a dynamic design where end portions can move. The first end portion is movable relative to the first fixing element, and the second end portion is movable relative to the second fixing element, enabling the system to maintain positioning stability when needed while achieving overall flexibility through controlled movement of end portions.
4Reliability
If additional fixing steps are added to secure the flexible member, then the connection reliability is improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The flexible member design allows end portions to self-adjust and self-position within the fixing elements without requiring additional securing steps. The movable end portions naturally maintain their connection through their interaction with the fixing elements, eliminating the need for welding, pressing, or other additional fixing operations.
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 design enhances the durability and flexibility of the flexible conduit element, allowing it to maintain performance under increased engine power and vibration frequencies, while simplifying maintenance and reducing material usage, by allowing end portions to move freely and adjust dynamically.
Implementation Method 1
a bellows member (2) being made of an elastic material, preferably metal
Implementation Method 2
the flexible member is radially movable around the bellows member in particular when the flexible member is knitted/woven or braided around the bellows member
Data Source
Figure 1~1A
Figure 2~2B
Figure 3~3B
AI summary
A flexible conduit element for use in exhaust gas systems of combustion engine vehicles, comprising a bellows member (2) made of metal, a first and a second fixing element (8, 9) partially surrounding a respective end portion of the bellows member (2), a flexible member (4) which at least partially surrounds the bellows member (2), said flexible member (4) comprising a first and a second end portion, wherein one of the first end portion and/or second end portion of the flexible member which is neighboured to one of the fixing elements (8, 9) is separated from the respective fixing elements. Corresponding method of forming the flexible (4) member around the bellows member (2) wherein the texture of the flexible element (4) is biased towards the surface of the bellows member by being formed around the bellows member with a smaller diameter than the outer diameter of the bellows member.