Coiled Heating Conductor Layout for Electrically Heatable Media Lines
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Solution Overview
Problem
Existing electrically heatable media lines face challenges in easy contactability and efficient production, as the random positioning of conductors within the thermal layer leads to increased processing time and potential operational disruptions due to freezing issues, especially in vehicles using aqueous urea solutions.
Innovation Solution
The conductors or heating conductors are coiled in the longitudinal direction and embedded in a radially predetermined position within the thermal layer, allowing for a defined and unambiguous arrangement, which simplifies the connection process and reduces dependence on other layer tolerances, enabling quicker and more reliable connection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductors are randomly positioned within the thermal layer, then the manufacturing process is simpler, but the connection process becomes more time-consuming and less reliable
Solution Approach 1:
The conductors are pre-positioned in a coiled arrangement within the thermal layer at radially predetermined positions before the outer layer is applied. This preliminary positioning eliminates the need for time-consuming location and alignment operations during connection, as the conductor ends are already accessible at known positions on the outer surface.
2Device complexity
If conductors are randomly positioned within the thermal layer, then the device structure is less complex, but the connection reliability decreases
Solution Approach 1:
The coiled arrangement of conductors with predetermined radial positions ensures that conductor ends consistently emerge at specific locations on the outer layer. This preliminary arrangement guarantees reliable connection points without requiring complex positioning mechanisms or increasing overall device complexity.
Solution Approach 2:
The invention changes the positional parameter of conductors from random to predetermined radial positions. This parameter change ensures that conductors are always accessible at known locations, improving connection reliability while maintaining simple device structure through the coiled geometry.
3Power
If conductors are embedded deep within the thermal layer, then the heating efficiency improves, but the accessibility for connection deteriorates
Solution Approach 1:
The conductors are arranged in a coiled configuration within the thermal layer, which allows them to be embedded at optimal depths for heating efficiency while the coiled geometry naturally brings the ends to accessible positions on the outer surface. The curved/coiled path solves both the heating and accessibility requirements simultaneously.
4Productivity
If the exposure area for conductor contact is reduced, then the connection speed increases, but the manufacturing precision requirements increase
Solution Approach 1:
The conductors are pre-positioned in a coiled arrangement with predetermined radial positions during manufacturing. This preliminary action ensures that conductor ends emerge at exact, known locations on the outer layer, allowing for small exposure areas and fast connections without imposing stringent precision requirements on subsequent connection operations.
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
This approach allows for faster and more reliable connection of the media lines, reduces the exposure area needed for contact, and enables targeted heating by knowing the precise position of the conductors, thus improving operational efficiency and reducing the risk of freezing-related disruptions.
Implementation Method 1
The thermal layer of the media line serves to heat the line itself. This thermal layer is an electrically conductive plastic layer that generates heat through its electrical resistance.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a multiple-layer electrically heatable medium line (1) having a medium-resistant inner layer (2), a heating layer (4) which is provided with at least two conductors or heating conductors (30, 31), and an outer layer (5), the layers (2, 4, 5) of the medium line (1) are single-layer or multiple-layer, and the conductors or heating conductors (30, 31) are embedded within the heating layer (4, 4a, 4b) such that they are coiled in the longitudinal direction of the medium line (1), in a radially and/or axially predefined position.