Wave-Shaped Spring Mounting for Exhaust Tailpipe
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Solution Overview
Problem
Existing tail pipe mounting systems for automotive exhaust pipes face challenges such as misalignment, deformation, high assembly force, and the need for tools, which complicate the mounting process and increase the risk of errors and theft.
Innovation Solution
A spring-based mounting system with specifically designed wave-shaped spring elements that attach to the tail pipe, featuring varying bending radii and angles to reduce assembly force while maintaining a high pull force, allowing for tool-free mounting and enhanced security against theft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used to fasten the tail pipe to the exhaust pipe, then the tail pipe can be securely mounted, but misalignment and deformation may occur during tightening
Solution Approach 1:
The spring elements automatically adjust and distribute the mounting force evenly around the tail pipe circumference, eliminating the need for manual screw tightening and preventing misalignment. The elastic deformation of springs provides self-aligning capability during assembly.
Solution Approach 2:
The spring elements utilize elastic deformation parameters to provide mounting force, allowing the system to adapt to slight variations in pipe dimensions and alignment while maintaining secure attachment without causing deformation.
2Strength
If pipe clamps are used to mount the tail pipe, then secure mounting is achieved, but the mounting process becomes time-consuming and complex
Solution Approach 1:
The spring elements are pre-attached to the tail pipe and automatically engage with the exhaust pipe during assembly, eliminating the need for separate clamp installation and tool-based tightening operations.
Solution Approach 2:
The mounting function is segmented into multiple spring elements distributed around the circumference, allowing parallel engagement with the exhaust pipe and reducing overall assembly time compared to sequential clamp installation.
3Device complexity
If springs with uniform bending radius are used, then the spring structure is simple, but extremely high assembly force is required
Solution Approach 1:
Different bending zones of the spring elements have different bending radii optimized for their specific functions: smaller radii in gripping zones for high local force concentration, and larger radii in transition zones for stress distribution, reducing overall assembly force requirements.
Solution Approach 2:
The bending radius parameter varies along the spring element length, creating zones of different stiffness that facilitate gradual engagement with the exhaust pipe and reduce peak assembly forces compared to uniform bending radius springs.
4Strength
If a high pull force is required to prevent theft, then mounting security is improved, but the risk of spring failure and pipe deformation during assembly increases
Solution Approach 1:
The spring elements have varying bending radii that create zones of different stiffness: softer zones for gentle engagement during assembly, and harder gripping zones for high pull force resistance during service, preventing both spring failure and pipe deformation.
Solution Approach 2:
The bending radius parameter is optimized to provide progressive engagement: initial contact with larger effective radius reduces assembly force, while the gripping portions with smaller effective radius provide high pull force resistance, decoupling assembly force requirements from service strength requirements.
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 system effectively aligns and secures the tail pipe with reduced assembly force, minimizing deformation risks and enabling tool-free installation, while providing a high pull force that prevents unintentional dismounting, including by theft, and facilitates automation.
Implementation Method 1
Previously known spring based tail pipe mounting systems uses three springs arranged equally around the inner circumference of the tail pipe
Implementation Method 2
The barb-like members grips into the surface of the exhaust pipe
Data Source
AI summary
An exhaust tailpipe mounting system for mounting on an exhaust pipe end includes a tailpipe and a ring member attached to the tailpipe. At least three spring elements are attached to the ring member, wherein each spring element extends generally along a longitudinal axis and is bent into a wave shape. Each spring element has a proximal end opposite a distal end, where the proximal end is attached to the ring member and the distal end has at least one pointed end configured to grip into an outer surface of the exhaust pipe end. Each spring element has a first, second, third, fourth, fifth, sixth and seventh bend zone starting from the proximal end and respectively going to the distal end. The at least one pointed end of is angled at an angle of 75° to 85° in relation to the longitudinal axis of the spring elements.