Induction Solder Joint for Exhaust Gas System Components
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Solution Overview
Problem
The existing methods for connecting components in exhaust gas systems, such as welding, require significant space, complex devices, and result in stress concentrations and potential cracking due to abrupt changes in cross-section, while soldered connections are believed to be unsuitable for high temperatures.
Innovation Solution
The use of an induction solder joint between exhaust gas system components, allowing for a high-temperature soldered connection that withstands the system's stresses, with a solder gap as large as 1.20 mm, reducing the need for precise gap control and enabling a more compact and efficient connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect exhaust gas system components, then the connection can withstand high temperatures and dynamic stresses, but the floor space requirement increases and complex fixation devices are needed
Solution Approach 1:
The patent replaces the mechanical welding system with an induction heating system that uses electromagnetic fields to heat and melt solder material. This substitution eliminates the need for complex welding robots and fixation devices, significantly reducing floor space requirements while maintaining connection reliability through the solder joint.
Solution Approach 2:
The patent changes the connection method from welding to induction soldering, utilizing phase change of solder material from solid to liquid and back to solid. This parameter change allows the connection to withstand high temperatures and stresses while using simpler equipment with smaller footprint.
2Reliability
If welding is used to connect exhaust gas system components, then the connection can withstand high temperatures and dynamic stresses, but device complexity and space requirement increase
Solution Approach 1:
The patent replaces the complex mechanical welding system with a simpler induction heating system that uses electromagnetic fields. This substitution dramatically reduces device complexity by eliminating welding robots, complex fixation mechanisms, and associated control systems, while the induction soldering process maintains connection reliability.
Solution Approach 2:
The induction heating system enables self-service by allowing the components to be heated and soldered in place without complex positioning or fixation devices. The electromagnetic field automatically concentrates heat at the solder joint location, eliminating the need for complex welding machinery and reducing device complexity.
3Ease of manufacture
If welding is used to connect exhaust gas system components, then the connection can be made, but stress concentration and crack formation occur at the weld seam
Solution Approach 1:
The patent extracts the harmful weld seam from the connection process and replaces it with a solder joint. By removing the welding operation entirely and using induction soldering instead, the source of stress concentration and crack formation is eliminated, while the connection can still be easily manufactured through the soldering process.
Solution Approach 2:
The patent changes the connection method from welding to soldering, which creates a more gradual transition in cross-section and rigidity. This parameter change eliminates the abrupt changes that cause stress concentration and crack formation at weld seams, while maintaining ease of manufacture through the induction soldering process.
4Ease of manufacture
If welding is used to connect exhaust gas system components, then the connection can be made, but welding-provoked distortion occurs requiring straightening
Solution Approach 1:
The patent replaces the welding process with induction soldering, which generates less thermal distortion. This substitution maintains ease of manufacture while significantly improving dimensional accuracy, as the soldering process does not cause the severe heating and subsequent distortion that requires straightening operations.
Solution Approach 2:
The patent changes from welding to soldering, which involves lower temperatures and less thermal input. This parameter change reduces welding-provoked distortion and improves manufacturing precision, while the induction soldering process remains easy to manufacture with proper fixture design.
5Area of stationary object
If soldered connection is used in exhaust gas system, then space requirement and device complexity are reduced, but the connection was believed to be unsuitable for high temperatures
Solution Approach 1:
The patent changes the temperature capability of soldered connections by using induction heating to achieve precise temperature control and by selecting solder materials with appropriate melting points. This parameter change disproves the belief that soldered connections cannot withstand high temperatures, as the induction process maintains temperatures below the solder's melting point while withstanding exhaust system operating temperatures.
Solution Approach 2:
The patent replaces conventional soldering with induction soldering, which provides superior temperature control and eliminates the need for complex heating equipment. This substitution reduces space requirements while enabling the soldered connection to withstand high temperatures through precise thermal management.
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 approach provides a stronger, more durable connection with lower assembly costs and reduced space requirements, as well as eliminating the risk of melting-through during welding, while maintaining mechanical stability at high temperatures.
Implementation Method 1
heating the two components up in the region of the solder material with an inductor to a temperature which lies above the melting temperature of the solder material
Implementation Method 2
fill the solder gap with the solder material which has melted
Data Source
AI summary
An exhaust gas system includes a first exhaust component and a second exhaust component that are spaced apart from each other by a solder gap that can be has great as 1.20 mm. A high temperature solder material is provided near the solder gap and is heated by an inductor to form an induction solder joint between the first and second exhaust components.