Flexible Heater Connection Protection via Liquid Casting
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Solution Overview
Problem
Existing flexible heaters used in urea tanks for SCR systems face challenges in corrosion protection of electrical connections, particularly in wet conditions, with existing solutions being either inefficient or economically unviable for industrial-scale production.
Innovation Solution
A method involving a flexible heater with a resistive track enclosed in electrically insulating plastic sheets, where electrical connections are protected using a liquid casting formulation in an open mould, cured to form a thermosetting resin, which is faster and more material-efficient than traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flow-coating silicone rubber is used to protect electrical connections, then corrosion protection is provided, but material waste is excessive and curing time is long
Solution Approach 1:
The patent applies preliminary action by pre-attaching a protective cap to the electrical connection before the curing process. This cap serves as a mold that defines the exact amount of insulation material needed, preventing excess material application and waste while ensuring complete coverage for corrosion protection.
Solution Approach 2:
The patent implements local quality by providing corrosion protection only where needed - specifically at the electrical connection point - rather than coating the entire heater assembly. The protective cap confines the insulation material to the precise location of the electrical connection, reducing material waste while maintaining effective protection.
2Reliability
If traditional flow-coating silicone rubber is used to protect electrical connections, then corrosion protection is provided, but curing time is excessively long
Solution Approach 1:
The protective cap is attached beforehand to the electrical connection, creating a pre-defined mold cavity. This preliminary preparation allows for controlled, precise application of insulation material and enables faster curing by limiting the material volume and ensuring uniform thickness, thereby reducing overall curing time.
Solution Approach 2:
The patent segments the protection process into distinct steps: first attaching the protective cap as a mold, then injecting the insulation material, and finally curing. This segmentation allows for optimized material injection and controlled curing, reducing the total curing time compared to traditional flow-coating methods.
3Ease of manufacture
If electrical wires are soldered to resistive track for connection, then electrical connection is established, but corrosion protection of connections becomes problematic
Solution Approach 1:
The patent introduces an intermediary protective cap that acts as a barrier between the corrosive urea environment and the electrical connection. This cap prevents direct contact between corrosion-causing substances and the soldered connections, maintaining both the ease of electrical connection and the reliability of corrosion protection.
Solution Approach 2:
The patent employs composite materials by combining the conductive resistive track with insulating and protective materials. The protective cap made of corrosion-resistant material complements the electrical components, creating a composite structure that provides both electrical functionality and corrosion protection.
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 provides effective corrosion protection for electrical connections of flexible heaters, suitable for industrial-scale production, ensuring reliable operation in wet conditions like those encountered in urea tanks, while minimizing material waste and curing time.
Implementation Method 1
curing said composition
Implementation Method 2
resistive track inserted between two flexible films or affixed to a flexible film
Data Source
AI summary
Method for manufacturing a flexible heater comprising a resistive track enclosed in two sheets of electrically insulating plastic material, said track comprising electrical connections to which electrical wires are connected, the method comprising the steps of: -enclosing the resistive track in the two sheets of electrically insulating plastic material - connecting the electrical wires to the electrical connections of the resistive track - putting an open mould around the connection area - injecting a liquid casting formulation into said mould - curing said composition - removing the mould.