Heatable fluid line
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Solution Overview
Problem
Existing heatable fluid lines require a large pressing force to securely lock the plug in place, which complicates assembly and poses a risk of energy loss and damage during ultrasound welding, especially when dealing with fluids that may freeze at low temperatures.
Innovation Solution
A plug with an articulation section and centering projections allows for easier insertion and alignment, followed by ultrasound welding to securely attach the plug to the heating rod, minimizing vibration and energy concentration at specific projections for efficient welding without damaging the heating wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is pressed into the neck to lock the seal in position, then the seal reliability is improved, but the assembly complexity and required pressing force increase
Solution Approach 1:
The plug is divided into two separate parts that can be inserted into the neck independently. This segmentation allows each part to be installed separately without requiring excessive pressing force, while still achieving the same seal-locking function when both parts are in place.
Solution Approach 2:
The plug parts are arranged radially offset from each other around the heating rod, utilizing the circumferential dimension. This spatial arrangement allows the plug to effectively lock the seal from multiple angular positions without requiring a single large pressing force applied axially.
2Strength
If ultrasound welding is used to attach the plug to the heating rod, then the connection strength is improved, but energy loss and damage risk increase
Solution Approach 1:
The plug parts are equipped with localized welding surfaces that are specifically designed for ultrasound welding attachment to the heating rod. These localized welding zones concentrate the welding energy only where needed, rather than requiring energy distribution across the entire plug structure, thereby reducing overall energy loss.
3Ease of manufacture
If a single-piece plug is used to simplify production, then the manufacturing ease is improved, but the insertion difficulty increases due to larger outer circumference
Solution Approach 1:
The plug is segmented into two smaller parts, each with a reduced outer circumference compared to a single-piece plug. This segmentation maintains production simplicity through injection molding of individual parts while significantly facilitating insertion into the neck, as each smaller part encounters less resistance during insertion.
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
This solution simplifies assembly, reduces the risk of energy loss and damage, and ensures a secure seal even under high pressures, allowing for reliable operation of heatable fluid lines in cold conditions.
Implementation Method 1
a heating rod (12) that is arranged in the interior of the tube (2)
Implementation Method 2
a seal (20) which is arranged in the opening (11) and surrounds the heating rod (12)
Implementation Method 3
it can be welded to the heating rod, preferably by means of an ultrasound welding
Data Source
AI summary
A heatable fluid line is disclosed having a tube, a connector that comprises a housing which is arranged at an end of the tube, and a heating rod that is arranged in the interior of the tube and enters into the housing through an inlet channel having a longitudinal axis and exits out of the housing through an opening arranged in a neck, wherein a seal is arranged in the neck, which seal surrounds the heating rod and is held in the neck by a plug (21).The object is to be able to achieve a reliable assembly in a simple manner.For this purpose, it is provided that the plug (21) comprises at least two parts (22, 23) which are connected to one another by an articulation section (24) having an articulation axis.