Extruded Polymer Sheathing for Heating Conductor Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for conducting and tempering urea-water solutions are complex and labor-intensive, with low automation and high production costs, due to the use of conventional tape or heat-shrink tubing for heating conductor fixation and insulation, which are inefficient for temperature control and protection against environmental factors.
Innovation Solution
A method using an extrusion process to create a strip-shaped layer of polymer material that is wound around the heating conductor before it hardens, forming a cohesive sheathing that provides effective insulation and protection, allowing for automated production with reduced material costs and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tape or heat-shrink tubing is used for heating conductor fixation and insulation, then the heating conductor can be fixed in place, but the system construction becomes complex and labor-intensive with low automation
Solution Approach 1:
The patent combines the fixation function and insulation function into a single integrated sheath made of polymeric material. This sheath simultaneously secures the heating conductor to the fluid line and provides thermal insulation, eliminating the need for separate tape wrapping and insulation layers, thus reducing construction complexity while maintaining reliability
Solution Approach 2:
The polymeric sheath serves multiple functions: it acts as a mechanical fixture to hold the heating conductor in place, provides thermal insulation to maintain temperature, and protects the heating conductor from environmental factors. This multi-functional design simplifies the overall system construction by replacing multiple components with a single universal element
2Reliability
If conventional tape wrapping method is used, then the heating conductor can be insulated, but the production process becomes labor-intensive with low degree of automation
Solution Approach 1:
The patent replaces the manual mechanical tape wrapping process with an automated extrusion process. The polymeric material is extruded as a continuous layer that automatically forms the insulating sheath around the heating conductor, eliminating labor-intensive manual wrapping operations while ensuring consistent insulation quality
Solution Approach 2:
The invention changes the physical state of the polymeric material during the sheathing process. The material is extruded in a molten or semi-molten state, allowing it to be easily formed and wrapped around the heating conductor, then it cools and solidifies to provide rigid insulation. This parameter change enables automated processing that would be difficult with pre-formed rigid insulation materials
3Adaptability or versatility
If multiple separate components are used for temperature control system, then each component can perform its specific function, but the overall system construction and production becomes very complex
Solution Approach 1:
The patent merges the fixation layer and insulation layer into a single polymeric sheath structure. This integrated design maintains all necessary functions (fixation and insulation) while eliminating the complexity of coordinating multiple separate components during assembly and production, thereby reducing overall system complexity without sacrificing functionality
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 method achieves a simpler, more automated system with reduced production complexity, effective temperature control, and enhanced insulation and protection, enabling even heating and reduced material usage.
Implementation Method 1
A method is specified for producing a sheathing (16) made of polymeric material, in which a strip-shaped layer (26) of polymer material formed by an extrusion process is wound around areas of at least a portion of the fluid line (12) already wrapped with a heating conductor (14)
Implementation Method 2
the heating conductor (14) for heating a urea-water solution contained in the fluid line (12)
Implementation Method 3
at least one sheath (16) of polymeric material surrounding the portion and covering the heating conductor (14)
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for producing a system (10) for guiding and controlling the temperature of a urea/water solution, in which method at least one heating conductor (14) is wound around a section of a fluid line (12), and in which method at least one layer of polymer material (26) is wound around regions of the section, around which the heating conductor (14) has been wound, until the layer of polymer material (26) is wound around the section along the entire predefined length, in order to form a covering (16) of polymer material which surrounds the section, wherein the layer of polymer material (26) is produced by an extrusion process, and wherein the winding around the regions of the sections, around which the heating conductor (14) has been wound, is carried out before the layer of polymer material (26) is cured. Furthermore, the invention relates to an apparatus, in particular for carrying out the method.