Single-Piece Sheet Metal Sealing Unit for Exhaust Injection
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Solution Overview
Problem
Existing sealing units for injecting liquids into exhaust systems are complex and costly to produce, requiring individual manufacturing and assembly of shielding pots and sealing plates, which complicates the process and increases costs.
Innovation Solution
A sealing unit formed from a single piece of sheet metal with a cup-shaped portion and a flat mounting area, featuring a plastically deformable bead for gas-tightness, which simplifies production and ensures thermal insulation, with an opening for liquid injection and optional high-temperature-resistant stainless steel and graphite-containing coatings for enhanced reliability and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shielding pot and sealing plates are manufactured individually and assembled, then gas-tightness and thermal insulation are ensured, but production complexity and costs increase
Solution Approach 1:
The patent combines the shielding pot and sealing plates into a single integrated sealing element made from one piece of sheet metal. This merging eliminates the need for separate manufacturing and assembly steps while maintaining the gas-tightness function through the integrated bead structure that provides sealing when compressed between the injection unit and exhaust line.
2Strength
If shielding pot and sealing plates are manufactured individually and welded together, then structural integrity is achieved, but manufacturing costs and production time increase
Solution Approach 1:
The sealing element is formed as a single piece of sheet metal with integrated shielding pot and sealing plate functions. The bead structure is formed as part of the single piece, eliminating welding operations entirely while maintaining structural integrity through the continuous metal structure and plastic deformation of the bead for sealing.
Solution Approach 2:
The patent changes the manufacturing approach from joining separate parts through welding to forming a single piece with integrated features. The bead structure is plastic deformed during assembly to create the sealing action, changing the physical state and properties of the metal locally to achieve the sealing function without additional joining processes.
3Reliability
If multiple separate components are used, then gas-tightness is achieved, but assembly time and production costs increase
Solution Approach 1:
The shielding pot and sealing plates are merged into a single integrated sealing element that is installed as one component. This eliminates multiple assembly steps and reduces installation time while maintaining the gas-tightness function through the integrated bead structure that seals when compressed between the injection unit and exhaust line flange.
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 solution reduces production complexity and costs while maintaining gas-tightness and thermal insulation, ensuring reliable operation in high-temperature exhaust environments.
Implementation Method 1
A bead is formed in the sealing plate. The bead is plastically deformed when the assembly unit that holds the injector is screwed to the flange and thus creates the necessary gas tightness
Implementation Method 2
The air gap thermally insulates the injection valve from the flange and the exhaust gas flowing in the exhaust system
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a sealing unit (2) for mounting between an injection unit and an exhaust strand comprises a cup-shaped region (4) and a flat fastening region (9) designed outside of the cup-shaped region (4). In the fastening region (9), at least one bead (10) is provided, and the sealing unit (2) is formed from a single piece of sheet metal.