FLEXIBLE ELEMENT WiTH INTEGRAL OUTER SHIELD AND/OR INHER LINER RELATED APPLICATION

[0001] Applicant claims the benefit of the filing date of United States provisionai patent application Serial No. 61/052,662 filed May 13, 2008, entitled, "FLEXIBLE ELEMENT WITH INTEGRAL OUTER SHIELD AND/OR INNER LINER", the disclosure of which is hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

(0002] This invention relates to flexible piping elements and more specifically to couplings for pipes, particularly useful in, but not limited to, couplings for exhaust pipes from interna! combustion engines.

BACKGROUND OF THE INVENTION

[0003] Couplings for pipes, particularly exhaust pipes, have been known. Prior couplings including bellows with separate inner liners and/or separate outer shields have been used in exhaust pipe environments.

[0004] Such environments are harsh. Heat produces or influences thermal changes in such pipes and couplings. Noise, vibration and harshness (hereinafter NVH) are produced by the environment of the exhaust from internal combustion engines must be handled. Motion, in the form of bending, must be accommodated as well, as pressure changes. Aspects of convection cooing affect such pipes and couplings. Mounting points for support and suspension of such couplings vary between applications but many prior couplings are not generally flexible in the location or placement of mounts.

[0005] Known coupling apparatus deals with such concerns in a variety of ways, leaving room for a great deal of improvement. Such known apparatus typically requires a separate inner liner to limit compression of the bellows, to reduce the impact of the flowing medium to the bellows, and to reduce turbulence and/or an outer shield to limit extension, to protect the bellows from a harsh environment and to add NVH damping properties. These items, i.e. liner and/or shield are usually added at

considerable cost and complexity. Mounting points and hardware require a large variety of designs, adapters and the like.

[0006] In the past, bellows have been edge welded. But edge welded bellows do not have integral liners or outer shields and iack flexibility in provisions for mounting. Hydroformed, elastomeric formed, or mechanically formed bellows have been proposed. But these are limited by the material specifications and forming processes and they require separate outer shields and/or inner liners. The same material limitations evident on conventional bellows, a!so constrains one of its main purposes, that being durability under flexibility. Molded bellows have the same concerns as above. Additional disadvantage of a conventional bellows as described above is the complexity required to mount /hinge support conventional bellows other than on the end of the bellows.

[0007] Accordingly, it is desired to uniquely integrate all components: bellows, outer shield, and/or inner liner, mount/hinge) together to overcome and improve the features in the prior known couplings.

[0008] It is also desired to provide considerable flexibility in the bellows' convolutions so as to better optimize the overall functionality, particularly in the environmental conditions noted above.

SUMMARY OF THE INVENTION

[0009] To these ends, the invention in preferred embodiments includes a flexible element which is the basts for an elastic connection of pipes and which compensates for thermal influences, pressure changes, motion (such as bending}, noise, vibration and harshness (NVH), or provides convection cooling and other such benefits,

[0010] While existing art contains flexible gas tight elements that consist of a bellows provided with a separate inner liner, and/or a separate outer shield, this invention contemplates a bellows having an integral outer shield and/or an integral inner liner. Several components can be added to this bellows with integral outer shield and/or integral inner liner to achieve additional functionality in a unique structure. The invention can be made with a variety of materials and with any number of homogeneous or variant plies thicknesses of the materials.

[0011] The integral construction noted provides a gas tight but flexible connection that is capable of compensating, and performing the benefits of, compensating thermal influences, pressure changes,

motion (such as bending), noise vibration and harshness (NVH), and other such environmental conditions.

[0012] Such a new concept improves piping system life, NVH compensation assembly ease, available cooling surface and provides flexibility in mounting/hinging points. The invention does this at a lower overall cost by integrating the inner liner and/or the outer shield with the bellows.

(0013J Accordingly, the present invention provides a superior and tower cost product with integrated additional functionality like mounting/hinging points.

[0014] In more detail, the integral bellows construction of this invention is achieved by adhering (by welding, chemical bonding, or other such method of adhering) two formed (by stamping, molding, cutting or other such forming method) discs together to form a convolution of the bellows. The overlap at the two adhered ends is used to form the outer shield and/or inner liner. Any number of convolutions can be adhered to form a larger and more flexible bellows with an integral outer shield and/or integral inner liner. The configuration of the bellows can take into consideration the number of plies thickness, the various end configuration, the various materials and thicknesses, the overlap geometry for the outer shield or inner liner, and other such variations. The overlap areas (at the ends of the discs) can be modified to add additional features such as a rod or cable to limit extension or provide mounting. Damping material can be added between the convolutions and trapped by the end features to create a beliows assembly with damping properties.

[0015] These and other objectives and advantages will be more readily apparent from the following written description of the preferred embodiments and from the drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is an isometric view of one embodiment of the invention with the bellows defining an integral outer shield and integral inner liner;

[0017] FIG. IA is a cross-section view of the invention of FIG. 1, along fines IA- IA of FIG. 1 and showing two convolutions of a multiple convolution bellows with the inner liner and outer shield integrated with the beflows;

[0018] FiG. IB is a cross-section view similar to FIG. IA, but of an alternate embodiment of the invention with an alternative bellows disc concept, minimizing the overlap at the ends;

[0019| FIG. 1C is a cross-section view similar to FIG. IA, but of another alternate embodiment of the invention with only an integral outer shield;

[0020] FIG. ID is a cross-section view similar to FIG. IA, but of another alternate embodiment of the invention with only an integral inner liner;

[0021) FIG. IE is a cross-section illustrative view similar to FIG. IA but of one convolution of a bellows with an alternative overlap end to simplify the forming process after the ends are joined;

[0022] FIG. IF is a cross-section view simϋar to FIG. IA but illustrating an alternate embodiment of the invention with integral outer shields and integral inner liner and showing three convolutions of varied height to facilitate the required movement of the bellows;

[0023] FlG. IG is a cross-section view similar to FIG. IA but illustrating an alternate embodiment of the invention with both an integral outer shield and an inner liner, the geometry of the inner liner can be modified to optimize the flow and NVH characteristics of the medium in the piping system, or in the cae of the outer shield, the shielding properties;

[0024] FIG. 2 is an isometric view of a bellows in an alternate embodiment of the invention with an integral inner liner and integral outer shield where the outer shield has a cable or rod threaded through holes in the outer shield to provide a bellows' extension stop;

[0025] FIG. 3 is an isometric view of a bellows in an alternate embodiment of the invention with the integral inner liner and integral outer shield with a damping medium added between the convolutions and fixed by the outer shield to add damping properties to the bellows;

[0026] FiG. 3A is a cross-section along lines 3A-3A of a bellows of FIG. 3 with the integral inner liner and integral outer shield and a damping medium is added between the convolutions and fixed by the outer shield to add damping properties of the bellows;

[0027] FiG. 4 is an isometric view of a bellows in an alternate embodiment of the invention with an integral mounting/hinge support, where one of the convolutions (any across the bellows can be selected depending on the application) has a special inner and outer disc defining the mounting feature;

[0028] FIG. 4A is a cross-section of a bellows of FIG. 4 with an integral mounting/hinge support and showing the invention before bending of the integral inner liner and integral outer shield feature at FIG. IA, excepting the mounting feature convolution;

[0029] FlG. 5 is a perspective drawing illustrating the addition of end caps to an exemplary bellows unit;

[0030] FIG. 6 is a cross-sectional view of a portion of a bellows with end caps as in FlG. 5;

[0031] FIG. 7 is a cross-sectional view similar to FIG. 6 but of a portion of an alternate bellows with end cap;

[0032] FIG. 8 is a cross-sectionai view similar to FIG. 4A but showing the use of end caps in association with the bellows; and

[0033] FSG. 9 is a cross-sectional view illustrating a modification of bellows-forming discs and their outer flanges to promote cooling.

[0034] Center lines "CL" as indicated are shown in selected FIGS, as center lines or axes as appropriate for clarity where the construction is symmetrical thereabout.

DETAILED DESCRIPTION OF THE INVENTION

[0035] It should be readily understood that the components and steps of the invention, as generally described and illustrated in the Figures herein and accompanying text, can be arranged and designed in a wide variety of different configurations while still utilizing the inventive concept.

[0036] For example, the number of disc members and the convolutions of any bellows can be varied as well as their radial and circumferential extension, overlap configuration and the like.

[0037] Thus, the following more detailed description of the preferred embodiments of the system and method for the present invention, as presented in the Figures and accompanying text, is not

intended to limit the scope of the invention, as claimed, but it is merely representative of the presently preferred embodiments of the invention. Moreover, it will be understood that the embodiments described are primariiy referred to as "bellows" but particularly and preferably comprise couplings for pipes.

[0038] The preferred embodiments of the invention will be best understood by reference to the drawings wherein like parts or steps are designated by like numerals throughout. In the FIGS., a dash- dot center line is provided for clarity with the bellows being generally symmetrical thereabout excepting FiGS, 4 and 4A.

[0039] FIG. 1 depicts a unitary bellows unit having a plurality of convolutions, each formed by two discs 10, 20 (FtG. IA).

[0040] Referring to FIGS. 1 and IA, two discs are adhered to form an inner half 10 of a bellows convolution and an outer half 20 of a bellows convolution. Two or more convolutions may be adhered to form a multi-convolution bellows 5. The more convolutions added to the bellows, the larger the range of motion, the longer the durability for set deflections, and the lower the stiffness for NVH compensation properties (among other performance criteria of the bellows).

[0041] Referring to FIG. IA, the overlap of the discs 10 and 20 of one convolution 5a create the integral outer shield 11 and the overlap of disc 20 from convolution 5a and disc 10 from convolution 5b, form integral inner liner 21. The bellows 12 is created by adhering (by welding, chemical bonding, or other such method of adhering) two formed (by stamping, molding, cutting or other such forming method) discs 10, 20 together to form a convolutions of the bellows 12. The overlap at the respective adhered ends is used to form the outer shield 11 and/or inner liner 21. The outer shield 11 serves to provide protection for the bellows 12 from the outside environment and (with additional components) provide extension limits to the bellows. The inner liner 21 serves to protect the bellows 12 from the medium in the piping system, to reduce turbulence and improve NVH properties, and to provide a compression stop.

[00423 Referring to FIG. IB, the inner discs 30 and outer discs 40 and the adhesion method can be designed to minimize the overlap of material and reduce material. A single ply outer shield 31 and a single ply inner shield 41 are provided in a bellows 32.

[0043] Referring to F!6. 1C, the bellows 52 can have inner discs 50 and outer discs 60 to create a bellows 52 with just an outer shield 51.

[0044] Referring to FiG. ID, the bellows 72 can have inner discs 70 and outer discs 80 to create a bellows 72 with just an inner liner 81. One or more concave convolutions 75 (view from outside bellows 72) define bellows 72, each convolution defined in part by disc 70 and disc 80, joined by welding, for example, at the juncture 82 of the respective discs 70, SO forming the respective convolution.

[0045] Referring to FlG. IE, the overlap geometry at 91 of respective inner and outer discs 90, 100 can be optimized in a number of ways to facilitate the forming of it (after adhesion) to the inner liner or outer shield as desired. FlG. IE thus illustrates the intermediate configuration of two discs 90, 100 as initially joined together and awaiting further forming, bending, etc. of the overlap geometry 91.

[0046] FIG. IF illustrates that the size of the convolutions can be altered to change the properties of the bellows. As in this figure, the smaller convolution 111 with inner disc 110 and outer disc 120 form a convolution that can be nested between the larger ones 112, 113 and allow for greater range of motion (i.e. bending) and NVH properties. Each of the convolutions 111, 112, 113 are formed by respective discs 110, 120; 110a, 120a and 110b, 120b. In this configuration, and for example, overlaps 122, 123, 124 form partial outer shields while overlaps 126, 127 and so on form partial inner liners.

[0047] Referring to FiG. IG, the geometry of the ends of the inner discs 130 and outer discs 140 can be made in a variety of ways to optimize the inner liner 131 or outer shield for the best functional purpose, as illustrated.

[0048] in all of FIGS. 1-lG, it will be appreciated the respective shield and liner components are essentially aligned (excepting shields 122-124 and liner 131).

[0049] Referring to FIG. 2, rods or cables or threaded screws 170 can be threaded through holes in the outer shield 171 (formed by discs such as 150, 160), such as suggested in FIG. IE, to provide NVH damping and/or extension limits. Extension limits set at the rods or cables 170 prevent the bellows from extending beyond the elastic limit of the design.

[0050] In this regard, and with attention to FIG. 4A, the support 225 defines an aperture 227 for receiving a hanger 228 in an isolation grommet 229.

[0051] Referring to the bellows 175 of FIGS. 3 and 3A, the inner disc ISO and outer disc 190 are constructed so that the outer shieid 195 formed thereby defines a chamber which captures a damping medium 200 (such as mesh wire or a synthetic material} and provide damping properties of the bellows and between the convoiυtions illustrated. An integral inner shield 196 is formed by interior overlaps of discs 180, 190.

[0052] Referring to FIGS. 4 and 4A, the respective discs 210 and 220 of selected convolutions of bellows 200 can be designed with a feature to define a mounting/hinge support 225 as shown in one such case. The thickness of these discs can be different than the others on the bellows of selected convolutions. Also, this convolution can be located at any point along the beilows. The exact mounting configuration is dependent upon the application.

[0053] Another aspect of this invention includes consideration of and a solution to the interconnection of the elements and structures described above with relatively thicker wall connection pipes or components thereof found in, for example, an exhaust system.

[0054] More specifically, it will be appreciated that the foregoing flexible elements and bellows apparatus described above have particular applicability to, or use in, exhaust systems for internal combustion engines wherein the pipes or conduits of such systems (not shown), or their connecting structures, are relatively thicker than the members comprising the bellows components or stamping described above. In these and other cases, there is here consideration of how the flexible beilows invention described above are operably interconnected within such systems or to specific connection pipes or other exhaust components.

[0055] To this end, the invention further contemplates the combination to the bellows described above of end caps configured for welding or other attachment to the ends of the bellows and more particularly to the end bellows component, disc or stamping. The end caps are somewhat thicker than the bellows discs to facilitate welding both to the bellows and to much thicker conduits or pipe components of an exhaust system.

[0056] This aspect of the invention is illustrated in FIGS. 5-8, where FIG. 5 illustrates in perspective the addition of end caps 250, 251 to a bellows 252, such as that illustrated previously in FIG. IG, for example, but wherein the multiple ply flanges 132a are not formed over as are flanges 132 of FIG. IG. instead, the flanges are left extending radially outwardly as shown in FIG. 5. It will be appreciated that

end caps 250, 251 each have a radial, outwardly extending flange 253, 254, a body 255, 256 and interior, axiaily extending cylindrical bosses 257, 258. Bodies 255, 256 at their outer portions generaily correspond partially to the shape of the outer portions of alternative stampings 130a, 140a respectively as shown. Flanges 253, 254 are welded to the outward radiai flanges 132a of the bellows. End caps 250, 251 are preferably thicker than stampings or discs 103a, 140a for example, but not so thick as to adversely affect their welding to the stampings. At the same time, cylindrical bosses 257, 25S are thick enough for welding to the end connections of pipes, tubes or conduits in an exhaust system, for example.

[0057] Details of FIG. 5 are also shown in FIG. 6, wherein onty the half of the bellows 252 and end caps 250, 251 are illustrated in side view cross-section as shown for clarity. The bellows 252 and end caps 250, 251 are developed about center line CL with inner tiner flanges 131a extending inwardly as shown.

[0058] End caps somewhat similar to these as described are useful on flexible bellows of a variety of configurations as described above.

[0059] For example, FlG. 7 illustrates an end cap 270 used with a bellows 271 of similar configuration to that shown in FIG. IA. In FSG. 7, only one end cap 270 is shown in partial cross-section on the bellows 271, it being understood another end cap is used on the opposite end of the bellows 271.

[0060] In FIG. 7, end cap 270 has a body 272 configured at its upper end like bellows disc or stamping 20a, and a flange 273 along upper flange 11a of disc 10a. The end cap 270 has an interior, axialiy extending cylindrical boss 274 for connection to a pipe tubing or conduit of an exhaust system (not shown), for example.

[0061] The thickness of caps 270 is thicker than discs 10a, 20a, but not so much as to interfere with welding of flange 273 to flange 11a. In addition, its thickness facilitates its welding or connection into the thicker, more robust components of an exhaust system. For clarity, only a portion of bellows 271 end cap 270 are shown about center line CL, similar to FIG. 6.

[0062J FIG. S illustrates a bellows 290 such as that bellows of FSG. 4A, but with end caps 291, 292 all developed about center line CL.

[0063] End caps 291, 292 have radially extending flanges 293, 294 welded respectively to flanges 295, 296 of bellows 290 as shown, with all flanges in this configuration extending radially outwardly from center line CL

[0064] End caps 291, 292 have bodies 297, 298 formed at their upper ends like discs 220a and 210a, respectively, and interior, axially extending cylindrical bosses 299, 230 for interconnection to the components of an exhaust system, for example,

[0065] Other components are numbered and are like that of FIG. 4A,

[0066] In a yet further aspect of the invention, it will be appreciated that the outward extending flanges of the various bellows configurations of the embodiments described herein can be welded together, then fluted or splayed away from one another to present more surface area to the surrounding environment to promote cooling of the bellows and systems in which they are used. Thus, for example, the outward flanges shown in FIGS, IA, 1C, IE, IF, IG, 4A, 5, 6, 7 and 8 couid be so arranged.

[0067] FIG. 9 illustrates this aspect of the invention wherein is shown two discs 310, 312 defining a convolution of a multiple component bellows (such as those shown in various preceding FIGS.), Discs 310, 312 have outwardly extended, but splayed apart, flanges 314, 316 extending beyond weld 317 to present additional surface area exposed to the environment for cooling. Otherwise, the bellows and discs are similar to those described above.

[0068] These and other alternatives, modifications and advantages will become readily apparent to those of ordinary skill in the field to which this invention pertains and applicant intends to be bound only by the claims appended hereto.

WHAT IS CLAIMED IS: