Fluid Pipe Connector with Radially Spaced Flange
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Solution Overview
Problem
Existing connectors for fluid-carrying tubes, particularly in engine exhaust systems, face issues with high thermal stresses due to temperature differences between the connector and tube ends, leading to potential leaks and plastic deformation.
Innovation Solution
A connector design with radially spaced flange sections that thermally decouple from the intermediate section, allowing ambient air cooling and reducing temperature differences, featuring elastic flange sections for secure coupling and compensation of thermal expansion and assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is made as a one-piece tubular body with thin wall thickness to enable flexible connection, then the connector can be easily manufactured and assembled, but high temperature differences occur during operation leading to thermal stresses and plastic deformation
Solution Approach 1:
The connector is divided into functionally distinct segments: thin-walled connection portions for joining pipes and a thick-walled intermediate portion for thermal insulation. This segmentation allows each part to optimize its wall thickness according to its specific function, reducing thermal stress while maintaining manufacturability.
Solution Approach 2:
Different wall thicknesses are applied to different parts of the connector: thin walls at the connection portions for flexibility and assembly, thick walls at the intermediate portion for thermal insulation. This local differentiation of material properties resolves the contradiction between ease of manufacture and thermal reliability.
2Device complexity
If the connector uses uniform wall thickness throughout to simplify design, then the manufacturing process is simplified, but high temperature differences cause thermal stresses and potential leaks
Solution Approach 1:
The connector structure is segmented into zones with different wall thicknesses: thin-walled connection zones and a thick-walled intermediate zone. This segmentation directly addresses thermal stress by isolating the thin-walled portions from high temperatures while maintaining structural simplicity through a straightforward geometric design.
Solution Approach 2:
The wall thickness is locally optimized: thin at connection points for ease of assembly, thick at the intermediate portion for thermal protection. This local quality variation reduces thermal stress without significantly increasing overall structural complexity.
3Quantity of substance
If the connector uses thin wall thickness to reduce material usage and weight, then cost and weight are reduced, but the connector cannot withstand high thermal stresses during operation
Solution Approach 1:
The connector is segmented into thin-walled connection portions that require minimal material for assembly and a thick-walled intermediate portion that provides thermal stress resistance. This segmentation optimizes material distribution, using material only where structurally necessary.
Solution Approach 2:
Material thickness is locally optimized: thin where needed for connection flexibility and weight reduction, thick where needed for thermal stress resistance. This local quality variation minimizes total material consumption while maintaining sufficient strength.
4Device complexity
If the connector directly contacts pipe ends without thermal insulation to simplify the structure, then the structure is simplified and manufacturing is easier, but temperature differences cause high thermal stresses and plastic deformation
Solution Approach 1:
The connector is segmented into thin-walled connection portions for direct pipe contact and a thick-walled intermediate portion that acts as a thermal buffer. This segmentation provides thermal insulation without requiring separate insulating components, maintaining structural simplicity.
Solution Approach 2:
The wall thickness itself serves as the thermal insulation mechanism: thin at connection points for simplicity, thick at the intermediate portion for thermal protection. This eliminates the need for additional insulating structures while maintaining dimensional stability.
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 effectively reduces thermal stresses, prevents leaks, and ensures secure sealing across varying temperatures and assembly conditions, enhancing the durability and reliability of the connection.
Implementation Method 1
The flange section is spaced from the intermediate section in the radial direction of the connector, expediently for thermal decoupling or insulation (especially the contact surface(s)) from the fluid-carrying parts of the connector
Implementation Method 2
The gaps are open to the ambient air outside the connecting piece, so that the flange sections, in particular their contact surface, can be cooled by ambient air via the gaps
Implementation Method 3
The flange sections are preferably designed to be elastic, and in particular have a spring effect. In this way, in particular, a plug and/or clamp connection with the pipe ends can be achieved
Data Source
Figure 1
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AI summary
The invention relates to a connecting piece (1) for connecting the pipe ends of two fluid-carrying pipes (R1, R2), comprising a first axial end section (A1), a second axial end section (A2), and an intermediate section (Z) extending between the first end section (A1) and the second end section (A2). The connecting piece (1) is characterized in particular by the fact that the first end section (A1) and/or the second end section (A2) comprises a flange section (F1, F2) with a contact surface (K1, K2) for coupling to a pipe end, and the flange section (F1, F2) is radially spaced from the intermediate section (Z).