Segmented Flange Plate Slit Design for Exhaust Thermal Stress
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Solution Overview
Problem
Thermal expansion effects in the connection between exhaust systems and combustion engines lead to stress-induced buckling and leakage due to differing temperature coefficients and heat expansion, causing exhaust gases to escape untreated.
Innovation Solution
A flange plate design with integrally molded connecting sockets and slits that allow for relative movement, reducing thermal stresses by enabling elastic absorption of expansions and preventing buckling, while maintaining secure fixation through strategically placed through openings and pressure plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a common flange is used to fasten exhaust pipes to the combustion engine, then the exhaust system can be securely fastened, but thermal expansion effects cause buckling and leakage due to temperature differences and different heat expansion coefficients
Solution Approach 1:
The flange plate is segmented into multiple independent connecting regions, each surrounded by a slit that separates it from the remaining flange plate. This segmentation allows each connecting region to move independently to accommodate thermal expansion of the exhaust pipes while maintaining the overall structural integrity of the flange plate for secure fastening to the engine.
Solution Approach 2:
The slits with interruptions create a dynamic structure where connecting regions can move relative to the remaining flange plate. This dynamic capability allows the flange plate to adapt to thermal expansion effects in real-time during engine operation, preventing buckling and leakage while maintaining reliable connection.
2Stability of the object's composition
If the flange plate is made rigid to maintain secure fastening, then connection stability is improved, but thermal expansion cannot be absorbed leading to buckling and leakage
Solution Approach 1:
By dividing the flange plate into separate connecting regions through slits, the structure gains localized flexibility while maintaining overall stability. Each segmented region can expand independently with heat while the remaining flange plate maintains its stability for secure engine fastening.
Solution Approach 2:
The flange plate exhibits different mechanical properties in different regions: connecting regions have local flexibility through slits to absorb thermal expansion, while the remaining flange plate maintains rigidity for stable engine mounting. This local quality differentiation resolves the contradiction between rigidity and flexibility.
3Ease of manufacture
If connecting sockets are integrally moulded to the flange plate, then manufacturing simplicity is improved, but thermal expansion causes stresses in the integral structure
Solution Approach 1:
The integral flange plate structure is modified by introducing slits that create separable connecting regions. This maintains the benefit of integral manufacturing while adding stress-relief capability, as each connecting region can now move independently to accommodate thermal expansion without creating excessive stresses in the integral structure.
Solution Approach 2:
The slits with interruptions are pre-formed in the flange plate during manufacturing, creating built-in stress-relief pathways before thermal expansion occurs. This preliminary structural preparation allows the integrally moulded sockets to accommodate future thermal stresses without compromising strength.
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 the risk of component damage and leakage by allowing the connecting sockets to move relative to the flange plate, absorbing thermal expansions and minimizing buckling, thus ensuring a secure and leak-proof connection.
Implementation Method 1
high temperatures develop on the exhaust gas side, which result in thermal expansion effects
Implementation Method 2
thermally induced expansions can be elastically absorbed
Implementation Method 3
the respective connecting region with the respective connecting socket can move relative to the remaining flange plate
Data Source
AI summary
The present invention relates to a flange plate for connecting exhaust pipes to a combustion engine, with at least two connecting sockets integrally moulded on the flange plate, on each of which an exhaust pipe can be fastened, and with a plurality of through openings for fixing the flange plate to the combustion engine. Thermal expansion effects can be better compensated if at least one of the connecting sockets is formed in a connecting region, which is surrounded by a slit penetrating the flange plate, wherein the respective slit comprises at least one interruption and the respective connecting region in the region of the respective interruption is connected to the remaining flange plate.