DIN Rail Heating Cable Mounting for Cold Environments

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Solution Overview

Problem

Electronic components in outdoor environments, especially in extreme cold temperatures, often malfunction or suffer damage due to temperature ratings below −40°C, and conventional heating solutions are costly and inefficient for hazardous locations.

Innovation Solution

A mounting rail with a DIN rail and heating cable channels, formed from extruded aluminum, incorporating self-regulating heating cables and heat transfer fins to maintain safe operating temperatures, with adhesive and heat transfer materials for secure and efficient heat distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional heating units are used to preheat electronics in extreme cold environments, then the electronics can operate at safe temperatures, but the cost becomes excessively high (hundreds of dollars for a small heater)

Engineering Contradiction:

Improveoperating temperatureVSAvoidcost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heating function is segmented from a standalone heating unit and integrated directly into the mounting rail structure. The heating cable is embedded within the rail's internal channel, dividing the heating function into distributed segments along the rail rather than using a centralized expensive heater.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting rail combines multiple functions into a single structure: mechanical mounting (DIN rail), thermal management (heat transfer fins), and heating (embedded heating cable channel). This merging eliminates the need for separate expensive heating units while achieving the same temperature maintenance goal.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If standard mounting rails are used without integrated heating, then the structure remains simple, but electronic components cannot operate reliably in temperatures below −40°C

Engineering Contradiction:

Improveoperation reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mounting rail is designed as a universal structure that performs multiple functions simultaneously: providing mechanical support for electronics, distributing heat through fins, and maintaining operational temperature through the embedded heating cable channel. This multi-functionality ensures reliability in cold environments without requiring separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The heating cable is nested within the internal channel of the mounting rail structure. The heating element is contained within the rail's hollow cross-section, allowing the heating function to be embedded within the existing structural framework rather than adding external complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Stability of the object's composition

If heating cables are secured with adhesive in the mounting rail, then the cables remain firmly positioned, but the adhesive must withstand extreme temperature variations

Engineering Contradiction:

Improvecable positioningVSAvoidtemperature range

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The adhesive's chemical properties are selected to remain stable across extreme temperature ranges. By changing the adhesive's formulation parameters (temperature resistance, flexibility, bonding strength), it can maintain cable positioning stability from extreme cold to heated operating temperatures without degrading or losing adhesion.

Inventive Principle:

Principle #35Parameter changes

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 effectively maintains electronic components within a safe operating range, even in extreme cold, while being cost-effective and safe for hazardous environments by using self-regulating heating cables and heat transfer fins, ensuring reliable operation and reducing heating costs.

Implementation Method 1

self-regulating heating cables

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heat transfer fins

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20230363102A1Apparatus for Electronic Component and Heating Cable Mounting

Publication Date: 2023.11.09 CHEMELEX EUROPE GMBH

AI summary

A mounting rail is provided that includes a DIN rail and one or more heating cable channels. A channel defined by the DIN rail may include one of the heating cable channels. Heating cables may be installed in the heating cable channels using adhesive and/or heat transfer material to form an electronics heating module. The heating cables may be self-regulating heating cables. The mounting rail may include multiple heat transfer fins that transfer heat generated by the heating cables to environment surrounding the mounting rail. A terminal block may be mounted on the DIN rail and may supply electric power to the heating cables.