Heatable Hose Electrical Connection via Welded Molded Part
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Solution Overview
Problem
Existing heatable hoses in the commercial vehicle and automotive industries face issues with electrical connections that require sealing to IP69K standards, leading to small bending radii which cause insulation damage and broken wires due to thermal stress, and direct welding of stainless steel heating conductors with copper strands is not possible due to different melting points.
Innovation Solution
A U-shaped molded part made of stainless steel provides a welded connection for the heating conductor and a plug-in connection for the copper wire, avoiding crimping issues and using the same material for both connections, with a thermally conductive medium for improved heating and thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small bending radius is used to reduce housing size and meet IP69K sealing requirements, then the housing size is reduced, but the insulation is damaged and wires break due to thermal stress
Solution Approach 1:
A molded part made of heat-resistant material serves as an intermediary component between the heating conductor and the electrical connection. This mediator allows the heating conductor to maintain a larger bending radius while still fitting within the constrained housing space, thereby preventing insulation damage and wire breakage due to thermal stress
Solution Approach 2:
The patent changes the material parameters by using a molded part with a melting point corresponding to the heating conductor material. This parameter change enables the connection structure to withstand high temperatures without deforming, allowing adequate bending radius while maintaining compact housing dimensions
2Reliability
If direct welding is attempted between stainless steel heating conductors and copper strands, then electrical connection is achieved, but welding fails due to different melting points
Solution Approach 1:
The molded part acts as an intermediary connection element between the stainless steel heating conductor and the copper electrical connection. Since the molded part is made of stainless steel with a melting point matching the heating conductor, it can be directly welded to the heating conductor, while the other end provides a positive connection for the copper wire, thus avoiding direct welding between incompatible materials
Solution Approach 2:
The patent applies homogeneity by using the same material (stainless steel) for both the heating conductor and the molded part. This material homogeneity ensures compatible melting points and enables reliable welding between these two components, eliminating the weldability problem caused by material incompatibility
3Reliability
If crimping is used to connect heating conductors, then connection is achieved, but crimping problems occur with steel strands
Solution Approach 1:
The molded part serves as an intermediary that receives the heating conductor through welding rather than crimping. This eliminates the crimping feasibility problem with steel strands, as the welding process is better suited for steel materials. The molded part then provides the connection interface for the copper wire
4Use of energy by moving object
If the contact area is not sufficiently heated, then energy consumption is reduced, but the hose system does not reach required heating performance
Solution Approach 1:
The molded part is designed to concentrate and direct heat locally to the contact area. By improving thermal conduction in the specific region of the connector, the system achieves adequate heating performance at the contact interface without requiring excessive overall energy consumption, thus optimizing the balance between energy use and heating effectiveness
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 reliable, energy-efficient, and environmentally friendly heatable hose with reduced risk of wire damage, improved thermal conduction, and compliance with IP69K standards, suitable for narrow bending radii and easy recycling.
Implementation Method 1
The thermal conduction from the hotspot to the connector is preferably improved by at least one thermally conductive medium which is arranged on the connector and is in thermally conductive connection with the molded part
Implementation Method 2
The heating conductor 14 preferably spirally surrounding the outer wall 12 of the inner hose part 11 is connected at its ends to a first leg 241 of a U-shaped molded part 24 by means of an integral connection, in particular a welded connection 25
Data Source
AI summary
The invention relates to a device for contacting a heatable hose (10) having a fluid-conducting inner hose part (11), the wall (12) of which can be heated by at least one electrical heating conductor (14), wherein the heating conductor (14) is connected by the contacting device to at least one electrical conductor (20) for connection to a voltage source. The invention is characterised in that the contacting device is formed by a moulded part (24) that at one end (241) comprises a bonded connection (25) to the electrical heating conductor (14), and at the other end (242) comprises a positively-connected connection (26) to the electrical conductor (20). The moulded part (24) is advantageously used simultaneously as a "hotspot" for heating a connector (30) connected to the hose (10).