Electrically Heatable Media Line With Embedded Conductor Contacting
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Solution Overview
Problem
Existing electrically heatable media lines require complex and costly manual processes for connecting heating conductors to connecting devices, making production expensive and inefficient, with prior art not allowing for automatic connection or heating of the connecting device without additional heating conductors.
Innovation Solution
An electrically heatable media line with a three-layer plastic pipe structure, where the middle layer consists of conductive material and heating conductors are extruded into the pipe wall, allowing the conductive device to extend to the connecting device, enabling complete heating without external heating conductors, and using primary molding or material bonding for connection, facilitating automated exposure and connection of conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating conductors are connected to connecting devices using manual processes as in prior art, then the connection can be made, but the production process becomes complex and expensive
Solution Approach 1:
The heating conductor and the connecting device are merged into a single integrated component. The heating conductor extends directly into the connecting device, eliminating the need for separate connection steps. This integration simplifies the manufacturing process by reducing the number of assembly operations and components, directly addressing the contradiction between ease of manufacture and device complexity.
Solution Approach 2:
The heating conductor is pre-positioned and extended into the connecting device during the pipe extrusion process itself, before the final assembly stage. This preliminary action eliminates subsequent manual connection steps, making the manufacturing process simpler and more automated while reducing overall device complexity.
2Temperature
If additional heating conductors are installed on the outside of the connecting device to enable complete heating, then heating coverage is improved, but the device complexity and production cost increase
Solution Approach 1:
The heating function and the connecting device structure are merged into a single integrated component. The heating conductor is extended directly into the connecting device, providing complete heating coverage without requiring separate external heating elements. This eliminates the need for additional heating conductors on the outside of the connecting device, reducing device complexity while maintaining full heating coverage.
Solution Approach 2:
The heating conductor serves dual functions: it provides heating along the pipe length and extends into the connecting device to provide heating coverage at the connection point as well. This multi-functionality eliminates the need for separate heating systems for the connecting device, reducing overall device complexity while ensuring complete heating coverage.
3Reliability
If manual intervention is required for connecting heating conductors, then connection can be achieved, but productivity decreases and production costs increase
Solution Approach 1:
The heating conductor and connecting device are manufactured as an integrated single component through continuous extrusion. This eliminates all manual connection operations, enabling fully automated production while maintaining connection reliability through the integrated design. The merging of components allows for high-speed automated manufacturing, significantly improving productivity without sacrificing connection reliability.
Solution Approach 2:
The manual mechanical connection process is replaced by a continuous extrusion manufacturing process. The heating conductor is extruded directly into the connecting device in a single automated operation, eliminating the need for manual intervention. This substitution of manufacturing methods dramatically increases productivity while ensuring consistent, reliable connections through process control.
4Temperature
If the heating conductor is extended to the connecting device, then complete heating is enabled, but the manufacturing process becomes more complex
Solution Approach 1:
The heating conductor and connecting device are combined into a single integrated component manufactured through continuous extrusion. This merging allows the heating conductor to extend into the connecting device, ensuring complete and uniform heating coverage. The integrated manufacturing process actually simplifies production compared to separate assembly, as it eliminates multiple manufacturing steps and ensures consistent thermal properties throughout the entire component.
Solution Approach 2:
The connecting device is manufactured as a composite structure with the heating conductor embedded within it during the extrusion process. This composite manufacturing approach allows the heating conductor to extend into the connecting device for complete heating coverage while maintaining manufacturing simplicity through a single continuous process rather than separate assembly steps.
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 the manufacturing process, reduces material and production costs, allows for automated connection and heating of the media line, and ensures efficient heating distribution across the pipe circumference, leading to low power consumption and high efficiency.
Implementation Method 1
the middle layer of the pipe part consists of a plastic material filled with at least one conductive component
Implementation Method 2
the pipe part has at least two electrical conductors or heating conductors extruded into its wall
Data Source
Figure 1~2
Figure 3~3a
Figure 4
AI summary
In a prefabricated electrically heatable media line (1) having at least one pipeline part (4) with an integrated electrically conductive device (100) and having at least one connecting device (2, 3), in particular a plug, screw or coupling device, the pipeline part (4) and the electrically conductive device (100) extend as far as or close to that end (20, 30) of the connecting device (2, 3) which is averted from the pipeline part (4) or close to, in front of or in a connection contour (9). In a method for producing a media line (1), a pipeline part (4) is produced with at least one integrated electrically conductive device (100) and the integrated electrically conductive device (100) is exposed in at least one end region (45, 46) of the pipeline part (4), permanent electrical contact is made with said integrated electrically conductive part by a contact-making device (6, 7), and the contact-making device (6, 7) is routed out at the outer face of the pipeline part (4) in order to form a connection to an electrical energy source.