Flexible Heating Rod for Urea Conduit Anti-Freeze Design
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Solution Overview
Problem
Existing fluid lines used to convey urea in motor vehicles are prone to freezing at low temperatures, leading to transportation issues, and existing heating solutions are either damaged during assembly or inefficient in heat transfer and exposed to external influences.
Innovation Solution
A fluid line design featuring a flexible heating rod with an embedded heating conductor, sealed by an annular ring seal and held in place by a plug, allowing for efficient heat transfer and protection from external damage, with electrical connections made outside the connector for ease of access and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heating wire is wound around the pipe and connector, then heating function is provided, but the heating device is exposed to external damage risk and heat transfer efficiency is low
Solution Approach 1:
The heating conductor is embedded within the heating rod, which is then inserted into the fluid line. This nested configuration protects the heating conductor from external damage while ensuring direct contact with the fluid for efficient heat transfer, eliminating the need for external winding and reducing heat radiation loss.
Solution Approach 2:
The heating rod acts as an intermediary between the heating conductor and the fluid. It protects the heating conductor from direct exposure to external influences while facilitating efficient heat transfer to the fluid through its contact surface, resolving the contradiction between protection and heat transfer efficiency.
2Loss of energy
If a flat heating conductor is shaped as a helix and arranged inside the pipe, then heat transfer area is increased, but the heating device becomes sensitive and difficult to assemble
Solution Approach 1:
The heating device is segmented into a heating conductor embedded within a heating rod structure. This segmentation allows the heating conductor to be protected and easily assembled while maintaining sufficient heat transfer area through the heating rod's design, eliminating the complexity of assembling delicate helical flat conductors.
Solution Approach 2:
The heating rod provides a flexible yet protective structure that encapsulates the heating conductor. This structure is easier to assemble than rigid helical configurations while maintaining adequate heat transfer surface area, resolving the contradiction between heat transfer efficiency and assembly ease.
3Ease of operation
If the heating conductor is led out through the connector opening, then electrical connections are accessible, but fluid leakage occurs at the opening
Solution Approach 1:
The seal ring acts as an intermediary element between the heating rod and the connector opening. It allows the heating rod to pass through for electrical connection accessibility while preventing fluid leakage, resolving the contradiction between ease of operation and prevention of harmful effects.
Solution Approach 2:
The seal ring, as a flexible sealing element, accommodates the heating rod passing through the connector opening while maintaining fluid tightness. This flexible sealing approach enables electrical connections to remain accessible while preventing fluid leakage, solving the identified contradiction.
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 a mechanically stable and efficient heating system that prevents fluid leakage and damage, ensuring reliable urea transport even at low temperatures, while allowing for easy assembly and maintenance.
Implementation Method 1
a heating device which is arranged inside the pipe and is designed as a heating rod that extends from the pipe into the connection piece
Implementation Method 2
the opening is sealed by an annular seal which rests against the heating rod and which is fixed in the connector by a plug
Data Source
Figure 1~3
Figure 4~6
AI summary
The fluid conduit has a pipe (2) and a connector (3) having a connecting piece (4) which is arranged at one end of the pipe, and a heating device which is arranged inside the pipe. The heating device has a bendable heating rod (12) that is fed from pipe in the connecting piece of the connector and is led out by an aperture (11) of the connector. The heating rod has a plastic mass (13) into which heating conductor (14,15) is embedded. The aperture is sealed by an annular seal (20) mounted on the heating rod from the outside to the connector.