Spherical Duct Connection for Thermal Misalignment Sealing
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Solution Overview
Problem
Existing connections between ducts in internal combustion engines, particularly those made of different materials like metal and thermoplastic, face issues with deformation due to thermo-mechanical stress, leading to leakage and loss of sealing compression, especially in air intake systems where relative movement and alignment challenges are prevalent.
Innovation Solution
A duct connection design featuring a bracket with a ring-segment shaped body and complementary spherically curved interface segments that allow for rotational and limited tilting movements while maintaining axial sealing, using thermoplastic materials for durability and ease of assembly, with a sealing gasket for enhanced leakage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat flange connection with screws and axial sealing gasket is used between metallic and thermoplastic parts, then mechanical assembly is ensured, but deformation due to pressure, temperature, and mechanical stresses generates loss of sealing compression and leakage risk
Solution Approach 1:
The invention replaces the flat flange connection with a spherical interface connection. The first duct end is formed with a spherical outer surface that cooperates with a complementary spherical inner surface in the second duct, allowing the connection to accommodate thermal expansion and mechanical deformation while maintaining sealing contact. This curved geometry enables the ducts to move relative to each other without compromising the seal integrity.
Solution Approach 2:
The invention changes the geometric parameters of the connection interface from flat to spherical, and allows for parameter variations due to thermal and mechanical stresses. The spherical geometry provides a degree of freedom for movement while maintaining contact, and the sealing element is designed to accommodate these parameter changes without losing sealing effectiveness.
2Stability of the object's composition
If rigid flange connections are used between ducts, then structural stability is improved, but relative movement and misalignment between ducts cause sealing failures
Solution Approach 1:
The spherical interface geometry inherently provides adaptability to relative movement and misalignment. The curved surfaces allow for rotational and angular adjustments while maintaining contact, enabling the connection to accommodate installation tolerances and operational movements without requiring rigid precision alignment.
Solution Approach 2:
The invention transitions from a static rigid connection to a dynamic connection that can adapt its configuration. The spherical interface allows the ducts to move relative to each other within certain limits while maintaining sealing contact, making the connection flexible and adaptable to operational conditions rather than fixed and rigid.
3Strength
If traditional screw connections are used between different material ducts, then mechanical fastening is achieved, but thermal and mechanical stresses cause deformation and leakage
Solution Approach 1:
The spherical interface design eliminates the need for screw connections between different materials. The curved surfaces provide mechanical interlocking and pressure distribution that prevents deformation, while the sealing element accommodates any minor relative movement caused by thermal expansion differences between materials.
Solution Approach 2:
The sealing element acts as an intermediary between the two ducts with different materials. It compensates for the dimensional changes and deformation that occur due to thermal and mechanical stresses, maintaining the seal without transmitting these stresses to compromise the structural integrity of either duct.
Data Source
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AI summary
The invention relates to a duct connection (100) between a first duct (10) and a second duct (20) of an internal combustion engine, in particular where at least one of the two ducts (10, 20) is made of a plastics material, comprising a flange (22) located on one end of said second duct (20), a sealing means (40) for sealing the connection between the two ducts (10, 20); a bracket (50) mounted to the first duct (10) and fastened to the flange (22) of the second duct (20); and a duct interface segment (12) located on one end of said first duct (10), the interface segment (12) being configured to cooperate with a complementary bracket interface segment (52). The invention further relates to a bracket (50) for such a duct conneciton (100) and an air duct (110) with such a duct connection (100).