Motor Vehicle Connector With Embedded 3D Heating Conductor
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Solution Overview
Problem
Existing motor vehicle connectors face challenges in precisely positioning and reliably fixing heating wires for uniform heating, often resulting in uneven heating and increased assembly time due to the complexity of winding the wires around the connector.
Innovation Solution
A motor vehicle connector with a three-dimensional heating conductor unit made of strand-shaped heating conductors, where at least 30% of the conductor is embedded in the connector wall, with sections extending radially and ending in reversal points, allowing for precise and efficient embedding within the connector's thermoplastic material during injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating wires are positioned and fixed using shaped elements on the outer surface of the connector, then the heating wire can be guided between these elements, but exact winding in the intermediate areas is not possible resulting in uneven heating and undesirable short circuits
Solution Approach 1:
The heating conductor is pre-formed into a three-dimensional structure with predetermined sections extending in the radial direction before being embedded in the connector wall. This preliminary shaping allows the heating conductor to be precisely positioned at specific locations (intermediate areas between shaped elements) without requiring manual winding, thereby achieving exact positioning and reliable heating while avoiding short circuits.
Solution Approach 2:
The heating conductor transitions from a two-dimensional winding approach (wrapping around the connector) to a three-dimensional structure with sections extending radially into the connector wall. This dimensional change enables precise positioning at multiple depths and locations within the wall, ensuring uniform heating and eliminating the limitations of surface-level wire routing.
2Reliability
If the heating wire is wrapped around the connector between shaped elements, then the heating wire can be arranged on the outer surface, but this process is relatively time-consuming
Solution Approach 1:
The heating conductor is pre-formed into a complete three-dimensional structure with all necessary radial sections and reversal points configured before assembly. This eliminates the time-consuming step of manually winding and securing the wire during assembly, as the pre-formed structure can be directly embedded into the connector wall in a single operation, significantly improving productivity while maintaining reliable fixation.
Solution Approach 2:
The heating conductor structure integrates multiple functions into a single component: the radial sections provide heating, the reversal points enable directional changes, and the embedded portions provide fixation. This merging of functions into one pre-formed unit eliminates the need for separate winding, positioning, and securing operations, thereby accelerating assembly while ensuring reliable fixation.
3Ease of manufacture
If heating conductors are embedded in the connector wall, then positioning can be simplified, but at least 30% of the conductor must be embedded with specific radial extensions to ensure proper heating
Solution Approach 1:
The heating conductor is divided into distinct segments: portions embedded in the connector wall for fixation and heat distribution, and radial sections extending outward for active heating. This segmentation allows each portion to fulfill its specific function while maintaining precise control over embedding depth and radial extension length, satisfying the requirement that at least 30% be embedded without compromising manufacturing simplicity.
Solution Approach 2:
Different sections of the heating conductor have different configurations tailored to their specific functions: deeper embedding in certain areas for structural support and heat distribution, and radial extensions in other areas for optimized heating. This local differentiation ensures that each portion meets its specific requirements while maintaining overall manufacturing simplicity through the pre-formed structure.
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 solution enables simple, rapid, and reliable positioning of heating conductors, reducing the risk of short circuits and assembly time, while ensuring optimal stability and efficient heating of the connector's inner channel.
Implementation Method 1
the connector wall or the inner channel can be heated electrically
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
The application relates to a connector (1) for connecting at least one pipeline for conveying a fluid medium, wherein the connector (1) has at least two connection ends (3, 4), at least one of which connection end (3) is provided for connecting a pipeline (2), wherein a connector wall (6) extending between the connection ends surrounds an inner channel (5) for conveying the fluid medium, wherein the connector wall (6) or the inner channel (5) is electrically heatable, wherein for the electrical heating of the connector wall (6) or the inner channel (5)of the inner channel (5) at least one three-dimensionally formed heating conductor assembly (7) consisting of a strand-shaped heating conductor (8) is present, wherein at least 30% of the length of the strand-shaped heating conductor (8) is embedded in the connector wall (6) and wherein at least one heating conductor section (9) of the strand-shaped heating conductor (8) extends radially over 25% of the radial thickness d of the connector wall (6). The application also relates to a method for manufacturing a connector.