Flexible Conduit Element

Abstract

The present invention relates to a flexible conduit element 1 of an exhaust gas system for vehicles having combustion engines, comprising a bellows member 2 defining within the bellows member 2 a guiding channel 10 guiding the exhaust gas of an inlet opening of the channel 10 to an outlet opening thereof, and a thermal insulation means 80, 80.1, 80.2 which comprises basalt material. Further, the present invention relates to an exhaust gas system comprising the flexible conduit element with said insulation means.

Claims

1. Flexible conduit element of exhaust gas systems for vehicles having combustion engines, comprising a bellows member defining a guiding channel within the bellows member guiding the exhaust gas of an inlet opening of the channel to an outlet opening thereof, and a thermal insulation means which comprises a basalt material.

2. Flexible conduit element according to claim 1, characterized in that the basalt material is provided as a band or fiber, in particular a band or fiber which is drawn out of a melted basalt material.

3. Flexible conduit element according to claim 1, characterized in that the band or fiber from which the insulation means is comprised of is braided or woven to a cloth or fabric matrix and/or non-woven fabric matrix.

4. Flexible conduit element according to claim 3, characterized in that the braided and/or woven matrix, defines recesses and/or loops.

5. Flexible conduit element according to claim 1, characterized in that the insulation means is flexible relative to and movable attached at the bellows member in a floating manner and/or comprises flexible recesses in its outer surface for improving the flexibility and thermal insulation of the insulation means.

6. Flexible conduit element according to claim 4, characterized in that the woven and/or braided matrix is at least partially covered at one side by a fire resistant layer, which covers the recesses.

7. Flexible conduit element according to claim 1, characterized in that the insulation means covers a component of the flexible conduit element such that air pockets and/or air layers are defined.

8. Flexible conduit element according to claim 7, characterized in that, the basalt material of the insulation means comprises basalt, comprising 45-55 wt % of SiO2, 2-6 wt % of total alkalis, 0.5-2.0 wt % of I02. 5-14 wt o of FeO and 14 wt % or more A1203.

9. Flexible conduit element according to claim 1, characterized in that the insulation means is located between the bellows member and the flexible member and/or the insulation means is located between bellows member and the channel for guiding the exhaust gas.

10. Flexible conduit element according to claim 1, characterized in that the insulation means is located on the outside of the bellows member, which outside of the bellows member is opposite to the channel for guiding the exhaust gas.

11. Flexible conduit element according to claim 1, characterized in that the insulation means is located on the outside of a flexible member surrounding the bellows member, such that the insulation means is exposed.

12. Flexible conduit element according to claim 1, characterized in that the insulation means replaces components of the flexible conduit element.

13. Flexible conduit element according to claim 1, characterized in that there is at least one or more than one insulation means provided and/or the insulation means comprises multiple layers.

14. Flexible conduit element according to claim 1, characterized in that the insulation means is a layer, a sheet or a hose.

15. Exhaust gas system for a vehicle comprising a flexible conduit element according to claim 1, wherein the flexible conduit element is mountable between the exhaust gas system and a combustion engine.

Description

[0025] The invention will be now described by several embodiments depicted in the following figures. Other and further objects of the invention together with the features of novelty pertinent thereto will be apparent from the following description. The accompanying drawings, which form a part of the specification, are to be read in conjunction therewith in which like reference numbers are used to indicate like or similar parts:

[0026] FIG. 1 is a schematic sectional view of first and second embodiments of the flexible conduit element according to the invention having an insulation means for maintaining the temperature of the exhaust gas guided in a channel formed by the flexible conduit element, wherein different embodiments are respectively shown in the upper and the lower half, divided by the middle axis,

[0027] FIG. 2 is another schematic sectional view of other embodiments of the flexible conduit element according to the invention having a flexible insulating layer, wherein different embodiments are respectively shown in the upper and the lower half, divided by the middle axis,

[0028] FIG. 3 are further embodiments of the flexible conduit element according to the invention in a schematic sectional view having a flexible insulation means provided at an outside of the flexible conduit element, wherein different embodiments are respectively shown in the upper and the lower half, divided by the middle axis,

[0029] FIG. 4 is another schematic sectional view of other embodiments of the flexible conduit element according to the invention having a flexible insulation means, wherein different embodiments are respectively shown in the upper and the lower half, divided by the middle axis,

[0030] FIG. 5 is a schematic view of a braided matrix of an embodiment of the insulation means,

[0031] FIGS. 6A-6C are schematic section and plan views of different woven and knitted matrixes of the insulation means,

[0032] FIG. 7A-7C are schematic section views of the bellow member on the insulation means showing the position of different air pockets and air layers defined by the insulation means and the components of the flexible conduit element,

[0033] FIG. 8 is a schematic view of a thermal energy exchange without the cover of a flexible conduit element by an insulation means.

[0034] Referring now to the drawings in more detail and initially to FIG. 1, reference sign 1 generally designates a flexible conduit element which is constructed according to an embodiment of the present invention. The flexible conduit element 1 may couple together a pair of pipes not shown via the mounting elements 8, 9, which also are used to stationary fix the further components of the flexible conduit element 1.

[0035] The flexible conduit element 1 comprises in the first embodiment a first and second fixing element 8, 9, which are provided at both sides of a channel 10. The channel 10 can be a tubing of the agraffe type which comprises interlocking rings for providing a high flexibility in a translational, torsional and/or bending direction around a middle axis M of the flexible conduit element 1.

[0036] FIG. 1 shows in a schematic sectional view a first and a second embodiment of the flexible conduit element 1 according to the invention, wherein an insulation means 80, 80.1, 80.2 is provided at different positions with regard to the bellows member 2.

[0037] The upper half and the lower half, which are partitioned by the middle line M, show respectively a first embodiment wherein the insulation means 80 is provided between the bellows member 2 and the flexible member 4.

[0038] The second embodiment is shown in the lower half wherein an additional insulation means 80.2 is provided such that a first or inner insulation means 80.1 and a second or outer insulation means 80.2 surround the bellows member 2 for a better insulation. The additional insulation means 80.1, 80.2 are, for example, two hose-like insulation textures made of volcanic fibers which can have the same or different woven, non-woven matrix as the insulation means 80.

[0039] Further, the flexible conduit element 1 comprises at its outside a flexible member 4 made of a braided or woven fabric for protecting and regulating the dynamic stiffness of the flexible conduit element 1, and a bellows member 2, comprising corrugations 21 and undulations 22 of constant and/or radial extensions.

[0040] The radial extension of the corrugations 21 can increase or may be constant over the length direction of the flexible conduit element 1. Further, the number of corrugations 21 and undulations 22 can be constant or increased depending on the gap between the inlet and outlet pipes to be connected. Additionally, the radial extension of the corrugations 21 and the undulations 22 can be reduced, increased or constant over the length of the flexible conduit element.

[0041] The bellows member 2 is in the embodiment shown in FIG. 1 surrounded by both of the flexible members 4 and insulation means 80, which both have a cylindrical hose-like shape.

[0042] The flexible element 4, the thermal insulation means 80, the bellows member 2 and the channel 10 are provided at both length sides with the fixing elements 8, 9, which preferably hold the respective end portions of the bellows member 2, the channel 10, and the insulation means 80 in place. The respective fixing elements 8, 9 allow mounting of the flexible conduit element 1 to the associated pipe openings, for example of a combustion engine and an exhaust gas system.

[0043] As can be seen in FIG. 1 in the upper half thereof, the insulation means 80 is located on the outer surface of the bellows member 2, which is a flexible and bendable element having sections with frequently positioned corrugations 21 and undulations 22. The corrugations 21 and undulations 22 allow the bellows member 2 to be twisted and flexibly stretched and deformed, such that the vibrations and displacements between an exhaust gas system and a combustion engine are not transferred to the respective end portions such that the connected parts are not harmed by the generated vibrations and displacements.

[0044] The insulation means 80, 80.1, 80.2 is preferably made of a heat resistant material, in particular, basalt or lava-stone which is provided in a braided mesh matrix, for example braided to a hose-insulation means 80, 80.1, 80.2 which can be covered around the bellows member 2. In particular, the insulation means is made of a heat resistant material, like basalt, which also provides as braided matrix a high flexibility in combination with the high heat resistance. The insulation means covers the corrugations of the bellows members 2 and define air pockets 52 and air layer 51. The air contained therein is a perfect insulation.

[0045] Additionally, the thermal insulation means 80 can comprise recesses 81 of a predetermined shape and depth, such that the surrounding air can be contained therein to increase the insulation of the insulation means 80. To achieve this, the insulation means 80, 80.1, 80.2 can made of a braided woven matrix of the volcanic material to define pockets or recesses 81, which are defined by the loops and structure of the braided layer or the recesses 81 are cut into a layer of the thermal insulation means 80, 80.1, 80.2.

[0046] The braided layer or woven layer of the insulation means 80 may be made of a fiber made of basalt or lava-stone which can be strengthened by incorporating support wires of steel or other heat resistance metals to provide a support matrix for the basalt or lava-stone fibers.

[0047] The insulation means 80, 80.1, 80.2 are located between the outer flexible member 4 and the bellows member 2 to insulate and maintain the exhaust gas within the flexible conduit member and also to preferably maintain the temperature of the exhaust gas, such that a purification in a catalysator of the exhaust gas system in a later step can be easily maintained without additional devices for maintaining the temperature of the exhaust gas. In particular, the NOx purification of an exhaust gas should be performed at a relative high temperature Otherwise, the NOx purification will not be performed in an effective manner and the temperature of the exhaust gas must be again heated up to achieve the necessary purification temperature.

[0048] As with regard to FIG. 1, FIG. 2 shows a third and a fourth embodiment of the flexible conduit element 1, wherein the upper half and the lower half respectively show a half of an embodiment divided by the middle line M, wherein each of the upper half and the lower half is a half image of the respective part not shown. However, the embodiments shown in FIGS. 1 to 4 can also be provided with the embodiments shown in the respective other halves, wherein one half has an insulation means 80, 80.1, 80.2 provided at a predetermined position between the tubing of the channel 10 and the bellows member 2 and wherein the other half has an insulation means 80, 80.1, 80.2 between the bellows member 2 and the flexible element 4.

[0049] The insulation means 80, 80.1, and/or a second insulation means 80.2 (lower half) is provided between the bellows member 2 and the exhaust gas channel 10 to directly insulate the channel 10. The pockets 84 formed by the bellows member 2 would also add to a temperature insulation, wherein the insulation means 80, 80.2 and the undulations 22 of bellows member define the shape and size of the additional recesses 84, too. Air has at normal conditions a thermal conductivity A of 0.0261 W/(m*K).

[0050] FIG. 3 shows different embodiments of the flexible conduit element 1, wherein the upper half and the lower half, respectively, show a half of an embodiment divided by the middle line M, wherein each of the upper half and the lower half is a half image of the respective part not shown. The insulation means 80, 80.1, 80.2 is provided on the outside of the flexible conduit element surrounding the flexible element 4, and/or between the bellows member 2 and the channel 10.

[0051] The upper half of FIG. 3 shows a fifth embodiment of the flexible conduit element 1. The insulation means 80 of the flexible conduit element is located at the outside of the same such that it is directed to the environment, for example, of the bottom side of a vehicle, like a passenger vehicle. The insulation means 80, thus, covers the outside of the flexible conduit element 2.

[0052] The embodiment shown in the upper half of FIG. 3 would provide a nearly complete isolated flexible conduit element 1. This embodiment of the insulation means 80 can be upgraded to already existing flexible conduit elements 2.

[0053] The lower half of FIG. 3 shows another embodiment of the flexible conduit element 1, wherein the outer insulation means 80 can be provided with a further inner insulation means 80.1 to enhance the insulation of the flexible conduit element 1. The additional inner insulation means 80.1 can be of the same or of a different braided or woven matrix as the insulation means 80.2 located on the outside of the flexible conduit element 1.

[0054] The lower half of FIG. 3 shows half of a sixth embodiment of the flexible element conduit 1, wherein at least a double layer of a first and a second insulation means 80.1 and 80.2 is provided. It is possible to provide several layers (more than two) at predetermined positions. Further, it is also possible to only surround parts of the cylindrical conduit element 1 with the insulation means 80, 80.1, 80.2. For example, only a middle portion, an end portion, or the opening portions of the flexible conduit element 1 are provided with insulation means.

[0055] FIG. 4 shows further embodiments of the flexible conduit element 1, wherein the upper half and the lower half, respectively, show a half of an embodiment divided by the middle line M, wherein each of the upper half and the lower half is a half image of the respective part of the embodiment not shown. Some components of the flexible conduit element are replaced by the flexible thermal insulation means 80, 80.1, 80.2, for example, the flexible member 4 and/or the agrafe-type tubing which defines the channel 10.

[0056] The insulation means 80, 80.1, 80.2, respectively, replaces parts and components of the flexible conduit element 1. For example, in the upper half of FIG. 1 the flexible member 4 is replaced by the insulation means 80.

[0057] For example, the insulation means can be a composite mesh 90, wherein parts of the fibers are of basalt and other parts of the fibers are metal. The insulation means 80 in the upper half of FIG. 4 can fulfill a double function of insulating and of adjusting the dynamic stiffness of the flexible conduit element 1. Herein, the flexible insulation means 80, 80.1, 80.2 additionally has the function to isolate the flexible conduit element 1, to maintain the overall flexible dynamic and flexibility and to maintain or render the dynamic stiffness of the flexible conduit element over the whole vibration load of the flexible conduit element in an appropriate manner.

[0058] The composite mesh 90 may be made of fibers of different materials which are braided or woven in each other. For example, some of the fibers 82 are made of basalt and some of the fibers 82 are made of metal, which are braided or woven to define the insulations means 80, 80.1, 80.2. The insulation means 80, 80.1 and 80.2 can, therefore, function as a layer for changing the dynamic stiffness and the insulation properties of the flexible conduit element.

[0059] FIG. 5 shows in a schematic plan view a braided matrix of a fiber material, preferably a fiber material of lava stone or basalt, which has a high heat resistance, which fiber material 82 is woven or braided to form recesses 81 in which the surrounding air can be contained. The recesses 81 can contain the surrounding air to increase insulation properties of the insulation means 80. FIG. 5 shows a first embodiment of a braided matrix, wherein the fibers forming insulation means are woven in an oblique manner, wherein the fibers enclose an angle between 100 and 140. The oblique braided fibers give the insulation means a dynamic behavior such that it can be extended without disturbing the thermal and/or dynamic movements of the flexible conduit element.

[0060] Preferably, the insulation means 80 is made of a matrix or texture which is woven or braided of a fiber of volcanic material, in particular a fiber of basalt. The insulation means 80 can be layer made of woven or braided fiber of volcanic material, forming a cloth or fabric which can be brought into a cylindrical shape for surrounding the generally cylindrical bellows member 2, the channel 10 and/or the flexible element 3,

[0061] The manufacturing of basalt-fibers or lava-stone-fibers can be performed as described in the following: About 5 to 10 cm large basalt stones or lava stones are transferred into a furnace. Inside the furnace having temperatures between 1300 C. and 1450 C. the basalt-stones are plasticized, i.e. melted and liquefied to a basalt or lava stone melt. The basalt or lava stone melt is then pressed via a flow feeder, for example a heated tube, into a trough with spinnerets. The flow feeder generates a predetermined melting pressure. The melt is then drawn through the spinnerets to generate a continuous fiber or filaments of basalt or lava-stone. The thickness of the fibers can be of that of a human hair depending on the size of the opening of the spinnerets.

[0062] For ensuring a better processability, the continuous fiber can be coated with a layer which allows the textile processability and serves as a bonding agent between fibers woven into a predetermined braided or woven matrix. Finally, the fibers are drawn and wound by a winder on a so-called spinning cake to form a roving.

[0063] FIGS. 6A-6C show different woven textures of the insulation means 80, 80.1, 80.2, wherein the insulation means 80, 80.1, 80.2 is formed by fibers 82 comprising a volcanic material, like basalt and/or lava-stone. The spaces between the woven basalt and/or lava-stone fibers 82 form and define receiving pockets or recesses 81 for receiving the surrounding air or another insulation material to increase the insulation properties of the insulation means 80.

[0064] FIGS. 6A-6C respectively show different textures of woven structures or matrixes which are formed by a lava-stone and/or basalt fiber 82, wherein the left sectional view, respectively, show a schematic section view of the woven matrix shown as a plan view right to the section view.

[0065] The section views in FIGS. 6A-6C show, respectively, the schematics as how the respective filaments or fibers 82 can be interlayed to each other to form the respective matrixes shown in the plan view of FIGS. 6A-6C.

[0066] It would be also possible to change the fibers 82, which are made of basalt or lava-stone, at predetermined positions with filaments or fibers which are made of another material, for example metal, which is heat resistant. A mix of different materials would lead to a composite insulation means, wherein the respective fibers or bands 82 are woven with fibers preferably of the same size or a different size to form the textures shown in FIGS. 6A-6C.

[0067] However, the shown woven or braided matrixes are examples as how the insulation means 80 can be configured. There are multiple other woven or braided texture matrixes which can be also used for the insulation means 80.

[0068] Preferably, the insulation means 80 is a panel-like or a hose-like woven or braided structure that can be positioned over the cylindrically shaped bellows member 2 or with the channel 10 defined by the bellows member 2.

[0069] FIGS. 7A-7C show in a schematic view the different air pockets which can be defined between the bellows member 2 and the insulation means. For example, when the insulation means covers the undulations located on the outside of the bellows member as insulation means and these undulation form air pockets 52 in which air is contained to increase the insulation behavior and properties of the bellows member. Further, there can be also air layers 25 formed between the insulation means and the other components of the flexible conduit element to further increase the thermal insulation behavior of the flexible conduit element.

[0070] FIG. 8 is a schematic view showing the thermal exchange between the inlet of a flexible conduit element 1 and an outlet of the flexible conduit element 1. An exhaust gas, having a certain amount of heat Q.sub.In, exits the inlet if the flexible conduit element with a certain amount of heat Q.sub.Out. When flowing through the flexible conduit element 1, the exhaust gas, due to heat exchanges between the components of the flexible conduit element, loses a certain amount of heat Q.sub.Loss due to heat conductivity and heat exchange in the uninsulated flexible conduit element 1, such that the exhaust gas will exit the flexible conduit element with a lower amount of heat Q.sub.Out. This means when flowing through an uninsulated flexible conduit element, the exhaust gas will lose a certain amount of heat Q.sub.Loss=Q.sub.In+Q.sub.Out.

[0071] With the insulation means 80 made of basalt according to the invention, the heat amount loss Q.sub.Loss can be at least minimized and at optimal circumstances even clearly prevented such that heat amount of the exhaust gas Q.sub.In is nearly equal to Q.sub.Out. This has the advantage that the exhaust gas needs not to be reheated for a further purification, for example, in a catalysator. Further, the insulation means 80 made of basalt according to the invention has the advantage that the overall dynamic and static stiffness of the conduit element is not disturbed and the flexible conduit element is not negatively affected by the insulation means according to the invention.

[0072] Thus, with the insulation means 80 according to the invention the heat amount Q.sub.In of the exhaust gas can be protected, since the insulation means 80 together with the flexible conduit element defines air pockets and air layers which enhance the insulation of the exhaust gas guided in the flexible conduit element.

[0073] Further, the insulation means enhances the outer surface of the flexible conduit element 1 by covering the bellows member 2 and reducing the surface over which a heat exchange can occur. This means the insulation means, which surrounds and/or covers the bellows member and/or other components of the generally circular flexible conduit element, reduces the surface over which the heat exchange can occur. If there are several layers of insulation means 80, 80.1, 80.2 such a heat exchange can be nearly completely omitted.