Continuous Heating Wire Layout for Vibration-Resistant Fluid Lines
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Solution Overview
Problem
Existing methods for manufacturing heated media lines with connectors are costly, time-consuming, and prone to connection failures due to vibrations, leading to high material waste and increased labor costs.
Innovation Solution
A continuous heating element with two strands is pre-assembled along the media line and connectors, eliminating joints and crimp points, and is secured with a clamping element or adhesive tape, allowing for efficient heat transfer and reduced material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fluid lines are insulated and wrapped with heating cable to prevent freezing, then the fluid line can be heated effectively, but the system complexity and potential for overheating damage increase
Solution Approach 1:
The heating element is integrated directly into the fluid line wall structure, combining the heating function with the fluid line itself rather than using separate heating cables wrapped around the exterior. This merging eliminates the need for additional insulation layers and wrapping components.
Solution Approach 2:
The fluid line serves multiple functions: it transports fluid and simultaneously acts as a heated conduit. The heating element integrated into the wall allows the fluid line to provide both structural containment and thermal management in a single component system.
2Temperature
If heating cable is wrapped around insulated fluid lines, then heating can be provided, but the fluid line diameter increases and installation space requirements increase
Solution Approach 1:
The heating element is embedded within the fluid line wall thickness rather than added as an external wrap-around component. This integration ensures that the overall outer diameter of the fluid line does not increase significantly compared to a standard insulated fluid line.
Solution Approach 2:
The heating element is nested within the wall structure of the fluid line, similar to placing one object inside another. The heating conductor is positioned within the wall thickness, utilizing the existing structural space rather than adding external layers.
3Temperature
If heating cable is used with insulated fluid lines, then freezing can be prevented, but the risk of overheating and damage to the fluid line increases
Solution Approach 1:
The heating element provides localized heating directly within the fluid line wall where it is needed, rather than external heating that may create uneven temperature distribution. The thermostat is positioned in direct thermal contact with the heating element for precise local temperature control.
Solution Approach 2:
A thermostat is integrated into the system to monitor temperature and provide feedback control to the heating element, preventing overheating by automatically regulating power delivery based on actual temperature conditions within the fluid line wall.
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
The solution reduces manufacturing effort, minimizes connection failures, and lowers costs by using fewer wire variants, ensuring effective heat coupling and durability against vibrations.
Implementation Method 1
The heating element may be disposed within the wall of the fluid line... The heating element and thermostat may be contained within a conduit that is disposed within the wall of the fluid line
Implementation Method 2
The heating element and thermostat may be contained within a conduit that is disposed within the wall of the fluid line... thereby allowing the heating element and the thermostat to remain contained within the wall of the fluid line
Data Source
Figure 1~4
Figure 2~3
Figure 5~7
AI summary
For a heatable medium pipe (1) having at least one pipe connector (11, 110) and heating element (2), wherein the heating element (2) has a few wires (20, 28), in particular one or two wires, wherein said wire(s) (20, 28) extend continuously along the medium pipe (10) and along the at least one pipe connector (11, 110). In a method for producing a heatable medium pipe (1), comprising the medium pipe (10), at least one pipe connector (11, 110), a transition area (12, 120) between the medium pipe (10) and the pipe connector (11, 110), and at least one heating element (2), wherein the heating element (2) has a few wires (20, 28), in particular one or two wires, the medium pipe (10) is pre-assembled with the at least one pipe connector (11, 110), the wire or the few wires (20, 28) of the heating element (2) are pre-assembled as a double-laid, one- or two-part element or as an element connected to form a continuous part, the wire(s) (20, 28) are fastened on the outside of the pipe connector (11, 110), transition area (12, 120), and medium pipe (10), and the ends of the wire(s) are guided into a feed-in connector (24, 25, 27, 32, 33) for connecting to a current source or voltage source.