Metal Bellows Linear Seal for Weld-Free Exhaust Pipe Connections
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Solution Overview
Problem
Existing flexible pipe elements in exhaust systems face challenges in creating a gas-tight connection without welded connections, which are problematic due to the need for thin-walled stainless steel and additional costs associated with separate sealing elements, often leading to incorrect assembly and reduced sealing efficiency.
Innovation Solution
The formation of an annular bulge in the contact area of the bellows brim and/or connection element, which projects beyond the average level to create a linear seal, eliminating the need for welded connections and allowing for a gas-tight connection without separate seals, using a method that involves conical widening and corrugated deformation during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded connection is used to connect connection element to bellows brim, then gas-tight connection is achieved, but thin-walled stainless steel bellows cannot be connected and additional costs are incurred
Solution Approach 1:
The sealing function is merged into the bellows brim itself by forming an integrated sealing protrusion, eliminating the need for separate sealing elements. The connection element and bellows brim are directly connected through form-fit connection with the sealing protrusion integrated into the brim structure, combining connection and sealing functions in one component.
Solution Approach 2:
The connection element is divided into distinct functional zones: a connection area for mechanical attachment and a sealing area with the integrated sealing protrusion. This segmentation allows the thin-walled bellows to be connected without welding while maintaining gas-tight sealing through the protrusion design.
2Reliability
If separate sealing element is inserted between connection element and bellows brim, then gas-tight connection is achieved, but additional costs are incurred and assembly errors increase
Solution Approach 1:
The sealing function is merged into the bellows brim itself by forming an integrated sealing protrusion, eliminating the need for separate sealing elements. The connection element and bellows brim are directly connected through form-fit connection with the sealing protrusion integrated into the brim structure.
Solution Approach 2:
The bellows brim provides its own sealing function through the integrated sealing protrusion, eliminating dependency on external sealing elements. The protrusion automatically engages with the connection element to create the seal, making the system self-sufficient.
3Adaptability or versatility
If connection element is made thin-walled to allow mobility, then flexibility is improved, but welding connection becomes problematic
Solution Approach 1:
The welding process is replaced with a mechanical form-fit connection system. The sealing protrusion on the thin-walled bellows brim engages with the connection element through mechanical interference fit, eliminating the need for welding while maintaining connection integrity and gas-tight sealing.
4Reliability
If flange part is provided with convexly curved sealing area, then metallic seal is achieved, but specialty part costs increase and welding is still required
Solution Approach 1:
The sealing function is merged into the bellows brim itself by forming an integrated sealing protrusion, eliminating the need for separate sealing elements. The connection element and bellows brim are directly connected through form-fit connection with the sealing protrusion integrated into the brim structure.
Solution Approach 2:
The bellows brim provides its own sealing function through the integrated sealing protrusion, eliminating dependency on external sealing elements. The protrusion automatically engages with the connection element to create the seal, making the system self-sufficient.
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 solution enables a reliable, cost-effective, and efficient gas-tight connection between the flexible pipe element and continuing pipe parts or connectors, reducing the risk of leaks and assembly errors, while allowing for thinner connection elements and reduced material costs.
Implementation Method 1
an annular bulge is formed in the contact area of the bellows brim and/or the connection area of the connection element in order to form a linear seal between the contact area and the connection area. This annular bulge projects beyond an average level of the contact area and/or beyond an average level of the connection area
Data Source
AI summary
A flexible pipe element is provided formed as a metal bellows with at least one corrugated bellows section and a bellows brim, which forms one end of the metal bellows, and a connection element for connecting the metal bellows to a continuing pipe part or to a connector, with the connection element having a connection area for abutting a contact area of the bellows brim. An annular bulge is formed in the contact area of the bellows brim and/or in the connection area of the connection element projecting beyond an average level of the contact area and/or an average level of the connection area in order to form a linear seal between the contact area and the connection area. A method for producing such a flexible line part is also provided.