Patent Application
20120112452
None.
As is generally known, some automotive exhaust systems employ a flexible connection member or coupler disposed between two exhaust pipes in order to absorb undesirable vibrations input into the exhaust piping, absorb any thermal expansion or contraction of the exhaust piping, and compensate for any misalignments in the exhaust piping. These couplers are generally formed of a flexible metal bellows member and a braid cover surrounding the outer periphery of the bellows member. Exemplary of such a coupler is U.S. Pat. No. 5,769,463 to Thomas. The couplers may also include an interlock hose member disposed within the bellows member. Exemplary of such a coupler is U.S. Pat. No. 6,230,748 to Krawietz, et al.
The exhaust pipes, which are connected to each other by the coupler, often move and become misaligned with one another due to various circumstances, such as the flexing of the vehicle's frame as it traverses uneven terrain. Thus, a need exists from a coupler having improved flexibility and compressibility so as to absorb such movement and misalignment. Additionally, couplers having interlock hose members may become broken or damaged as a result of the coupler being excessively extended or compressed. Accordingly, a further need exists for a coupler having a means for limiting the extension or compresion of the interlock hose member so that it will not become broken or damaged as a result of the coupler being extended or compressed too far.
The present invention involves the provision of an exhaust connection coupler and a method for manufacturing the same. The coupler may include a flexible bellows member, an axially extendable and contractible interlock member disposed within the bellows member and a braid cover surrounding the bellows member. In one embodiment, the outer braid cover, by its nature, cannot extend or compress without changing diameter. The outer braid cover includes a cross-sectional circumference and an axial length and is constructed such that its circumference constricts radially as its length is extended axially. Such a design results in the outer braid cover becoming constricted against the bellows member when the coupler (and outer braid cover) is extended in length. This constriction against the bellows member serves to limit the amount in which the outer braid cover (and thus the coupler and its components, including the interlock member), may be extended in length. As assembled, the interlock member may generally be at a nearly fully extended length when the bellows member is at a natural, uncompressed and unextended length. Such a design maximizes the amount in which the coupler may be compressed, as the interlock member can be the limiting factor dictating the extent to which the coupler can be compressed. The braid cover may be designed such that it provides resistance limiting the axial growth of the coupler while allowing maximum compression and angular flexibility during installation and use. The braid cover may be constructed of intertwined bundles of wire filaments disposed at a specified angle from a central axis of the coupler.
In one embodiment, the coupler may also include an inner braid member disposed inwardly of the interlock member. Like the outer braid cover, the inner braid member, by its nature, cannot extend or compress without changing diameter. When the coupler is compressed in length axially, the inner braid member expands radially and becomes pressed against the interior of the interlock member. The interior of the interlock member prevents the inner braid member from expanding in diameter any further and thus limits how far the inner braid member (and consequently the coupler and its components, including the interlock member) may be compressed in length. Just as the outer braid cover provides resistance or restriction limiting the axial growth of the coupler, the inner braid member provides resistance or restriction limiting the axial compression of the coupler. The braid cover and braid member may work in tandem to ensure that the coupler will not be stretched or compressed too far thereby aiding to prevent premature failure of the components therein, including the interlock member and bellows member.
Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.
In the accompanying drawing, which forms a part of the specification and is to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:
The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.
The present invention is directed generally toward an exhaust connection member or coupler 10 and a method for manufacturing the same. As illustrated in
The interlock member 12 is generally flexible and able to accommodate relative movement between the exhaust piping (not shown). It is axially extendable and contractible. The interlock member 12 may be of a type generally known in the industry and may be constructed of a single spirally-wound, interlocking formed metal band 28 having interlocking leading and trailing ends 34 and 42. As depicted in
The bellows member 14, which may be formed of a metallic material and may be of a generally cylindrical shape, is comprised of first and second tube-like ends 46 and 48 with a plurality of repeating corrugations 50 extending therebetween. The bellows member 14 is also flexible thereby serving to effectively absorb any linear thermal expansion and contraction of the exhaust piping to which the coupler 10 is connected, absorb undesirable vibrations input into the exhaust piping and compensate for misalignments in the exhaust piping.
As depicted in the figures, the interlock member 12 may be disposed inwardly of the bellows member 14 so as to define a gap therebetween. In one embodiment, there is a circumferential air gap of approximately ⅛ inch between the interlock member 12 and bellows member 14. This gap provides insulation qualities and also permits relative motion and vibration between the interlock member 12 and bellows member 14 without the two creating rubbing against or creating friction between each other.
A braid cover 16 having first and second ends 52 and 54 may surround an outer periphery of the bellows member 14. The braid cover 16 serves to dampen vibrations, protect the bellows member 14 and provide resistance limiting axial growth of the coupler 10 while allowing for maximum compression and angular flexibility during installation and use. As shown in
The braid cover 16 is instrumental in providing resistance or restriction limiting the axial growth of the coupler 10, including the interlock member 12, while allowing for maximum compression and angular flexibility. This promotes prolonged life of the interlock member 12 by restricting it from being stretched too far and potentially breaking or being pulled apart. The construction of the braid cover 16, however, is such that it allows the coupler 10 to be compressed in length and angularly flexed. When compressed, the length of the coupler 10 may be reduced by a length of up to 25% or more of the coupler's 10 naturally uncompressed and unextended length. For example, in one embodiment, the coupler's 10 uncompressed, unextended length is about 12 inches while the coupler 10 has the ability to be compressed to a length of about 10 inches. In some cases, the interlock member 12 is the limiting factor keeping the coupler 10 from being compressed any further. As shown in
As discussed in further detail below, the interlock member 12 is generally at a nearly fully extended length when the coupler 10, including the bellows member 14, is in its natural uncompressed, unextended length. Such a design affords the coupler 10 the ability to maximize the amount in which it may be compressed because, as mentioned above, the interlock member 12 is may be the limiting factor dictating the extent to which the coupler 10 can be compressed. When the interlock member's 12 hook portions 30 and 38 become bottomed out against one another, like demonstrated in
The construction of the braid cover 16, including the angle β at which its bundles 56 are intertwined, affords the braid cover 16 the ability to provide resistance or restriction limiting the coupler's 10 axial growth, while allowing for maximum compression and angular flexibility. As depicted in
As illustrated in the figures, the braid cover 16 is sleeved over the bellows member 14. When the coupler 10 is extended in length, the circumference of the braid cover 16 constricts radially and the braid cover 16 becomes constricted against the bellows member 14. The outer diameter of the bellows member 14 prevents the braid cover 16 from shrinking in diameter any further and thus limits how far the braid cover 16 (and consequently the coupler 10 and its components, including the interlock member 12) may be extended in length.
The combination of the interlock member 12 being at a nearly fully extended length when the bellows member 14 is in a natural uncompressed, unextended length, as described above, and the construction of the braid cover 16, enable the coupler 10 to have improved flexibility and compressibility.
As set forth above, the interlock member ends 22 and 24, the bellows member ends 46 and 48 and the braid cover ends 52 and 54 may be combined together, respectively, with a retainer. The retainer may be comprised of a support ring or end ring 20, a spot weld, a bead of weld 58, a clamping member, any suitable fastener, or any combination thereof. As best illustrated in
Like the outer braid cover 16, the inner braid member 60, by its nature, cannot extend or compress without changing diameter. Thus, when the inner braid member 60 is compressed in length axially, its circumference expands radially, and vice versa. As shown in
It should be understood that one or both of the outer braid cover 12 and inner braid member 60 may be incorporated into a coupler 10 comprising one of more of a bellows member 14, an interlock member 12 or any combinations thereof. For example, in one embodiment, the coupler 10 may be comprised of a bellows member 14, an outer braid cover 16 disposed around the bellows member 14, and retainers coupling the ends parts of the bellows member 14 and outer braid cover 16 together. The coupler 10 need not include all of the components described here and may optionally only include one of either the inner braid member 60 or the outer braid cover 16. Other suitable combinations of the components described herein may also be utilized to form the coupler 10.
Turning attention now to the manner in which the coupler 10 is manufactured, the coupler 10 is an assembly of a number of components, including an interlock member 12 and a bellows member 14. The interlock member 12 is positioned within the bellows member 14. The ends 22 and 24 of the interlock member 12 are coupled with the ends 46 and 48 of the bellows member 14, respectively, such that when the bellows member 14 is at a natural uncompressed and unextended length, the interlock member 12 is generally at a nearly fully extended length. This is best illustrated in
The coupler 10 may also include a braid cover 16 surrounding an outer periphery of the bellows member 14. As set forth above, wire filaments formed into bundles 56, may be intertwined (e.g., interlaced, braided, knitted, woven, looped or the like) together on an elongated mandrel (not shown) to form a flexible, sleeve-like braid cover 16. The bundles 56 may be intertwined on the mandrel such that they are generally disposed of at an angle β relative to a central axis of the mandrel. As set forth above, the angle β can be in a range from about 55° to 80°, and in one embodiment is in a range from about 65° to 75°. Upon the formation of the braid cover 16, it may be assembled with the remainder of the coupler 10. As best shown in
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.
The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.
