Multi-Channel Fluid Duct With Stable Heating Wire Placement
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Solution Overview
Problem
Existing ducts for fluid transportation in automotive systems face issues such as wall collapse during thermoforming and non-uniform heating due to resistive wires not being in intimate contact with the sheath, leading to manufacturing challenges and lack of homogeneity in heating.
Innovation Solution
A duct design featuring an outer tube with auxiliary channels that are extruded directly around the inner tube, providing structural integrity and allowing for thermal insulation or heat exchange, with a resistive wire wound outside the inner tube for heating, and made from a flexible thermoplastic elastomer material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the duct is manufactured by thermoforming with inner grooves in the covering sheath, then the duct can be formed, but the walls defining the groove tend to collapse during manufacturing
Solution Approach 1:
The resistive wire is applied to the inner tube before the outer tube is formed, establishing the heating element position in advance. This preliminary action ensures the wire is securely positioned before the thermoforming process, preventing collapse of groove walls during manufacturing.
Solution Approach 2:
The inner tube serves as an intermediary structure that provides support during the formation of the outer tube. By having the inner tube in place during thermoforming, it acts as a mold or support structure that prevents the outer tube walls from collapsing while maintaining the groove geometry.
2Temperature
If resistive wires are placed inside the duct sheath, then heating can be provided, but the wires can move from their initial position and create lack of homogeneity in heating
Solution Approach 1:
The resistive wire is applied to the outer surface of the inner tube before the outer tube is formed, establishing the heating element position in advance. This preliminary positioning ensures the wire remains in a fixed, homogeneous position relative to the inner tube, preventing movement that would cause heating non-uniformity.
Solution Approach 2:
The resistive wire is combined with the inner tube by applying it to the outer surface of the inner tube, creating a fixed association between the heating element and the fluid-conducting component. This merging ensures the wire moves with the inner tube as a unified structure, maintaining position stability.
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 duct exhibits improved resistance during manufacturing and adaptability to various systems, offering effective thermal insulation or heating capabilities depending on the fluid and auxiliary fluid used, enhancing manufacturing efficiency and system performance.
Implementation Method 1
the duct has a device for heating the fluid to be transported, in particular a heating resistor wire
Implementation Method 2
the auxiliary channels can be used to obtain, relative to the environment on the outside of the duct, an effective thermal insulation of the fluid to be transported, for example by closing them at their axial ends and containing air
Implementation Method 3
the auxiliary channels can be used to heat the fluid to be transported, for example by causing the auxiliary channels to be flown through by an auxiliary fluid suited to carry out a heat exchange with the fluid to be transported
Data Source
Figure 1
Figure 2
AI summary
The duct (10) comprises an inner tube (12) configured to be flown through by a fluid to be transported and an outer tube (14) surrounding the inner tube (12). The outer tube (14) defines, in its interior, a plurality of auxiliary channels (16), which extend in the longitudinal direction of the outer tube (14) and are designed to contain or be flown through by a further auxiliary fluid, which is suited to thermally interact with the fluid to be transported.