Fluid Connector with Nested Heating Element and Insulated Casing
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Solution Overview
Problem
Existing line connectors for media lines, particularly in motor vehicles, face issues with electrical heating exposure and protection, leading to potential short circuits and complex assembly processes due to loose electrical connections and inadequate protection of heating elements.
Innovation Solution
A casing surrounds the fluid connector with a tubular branch for electrical supply cables, providing protection and thermal insulation, and encapsulating electrical connections within a plastic molding compound to ensure reliable performance and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical heating means are exposed on the outer region of the fluid connector, then the heating function is accessible, but the heating means and electrical connections are unprotected against external influences and mechanical loading
Solution Approach 1:
The heating means are mounted on an intermediate carrier element that is received within the fluid connector. The electrical connections are nested within the same carrier element, which is itself nested within the fluid connector body. This nested arrangement protects the heating means and connections while maintaining their functional accessibility.
Solution Approach 2:
A carrier element is introduced as an intermediary component between the heating means and the external environment. This carrier element provides mechanical support and protection for the heating means and electrical connections, isolating them from direct external influences while allowing the heating function to operate effectively.
2Ease of manufacture
If electrical connections are arranged loosely in a hollow chamber, then assembly is simplified, but the connections are protected only to an insufficient extent against mechanical and other loading
Solution Approach 1:
The carrier element provides a structured framework that guides and protects electrical connections during assembly. While allowing flexible routing of connections, the carrier element's structured design prevents loose arrangements, ensuring connections are properly positioned and protected against mechanical loading throughout the assembly process.
3Shape
If a sleeve-shaped transition piece is provided between the fluid connector and protective tube, then the heating device is positioned, but the heating device remains exposed and unprotected in the outer region
Solution Approach 1:
The carrier element with heating means is nested within the fluid connector, which is itself nested within or protected by the protective tube. This nested arrangement ensures the heating device is properly positioned while being protected by multiple layers of structural protection rather than remaining exposed.
4Reliability
If the casing completely surrounds the fluid connector including the attachment section, then maximum protection is achieved, but the attachment connection to the fluid line is compromised
Solution Approach 1:
The casing is segmented to provide protection in specific regions where needed (around the heating means and electrical connections) while leaving other regions (the attachment section) accessible for fluid line connection. This selective protection maintains both reliability and adaptability.
Solution Approach 2:
The casing provides localized protection specifically in the region where the heating means and electrical connections are located, rather than completely surrounding the entire fluid connector. This local quality approach protects vulnerable components while preserving the attachment connection capability at the fluid line interface.
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 protects electrical connections and heating elements from external influences, ensuring reliable performance and simplifying the assembly process while maintaining uniform temperature distribution and insulation.
Implementation Method 1
electrical heating means being provided at least in regions... for electrical heating means to be activated in order to prevent freezing or to unfreeze the already-frozen medium
Implementation Method 2
additional thermal insulation to the outside is also obtained. It is thus possible, by means of an air gap formed within the casing, to obtain a good and uniform temperature distribution
Data Source
AI summary
A line connector for media lines including a fluid connector having at least one connection section for terminal connection to a fluid line and having a transition section with an inner fluid channel adjoining the connection section. An electric heating element is provided at least in certain areas. The fluid connector is encased by encapsulation at least in the region of the heating element. The encapsulation has a branch for an electric supply conductor for the heating element. A ready-made media line includes the above mentioned line connector and an attached fluid line.