Heatable Media Line Assembly Using High-Temperature Fixing Film
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Solution Overview
Problem
Existing heatable media lines in vehicles face issues with adhesive residue from fixing devices, necessitating complex and costly cleaning processes before laser welding, which prolongs assembly time and increases costs.
Innovation Solution
A high-temperature-resistant film element made of polymer material, such as PET, is applied over the heating element on the tubular media line to prevent adhesive residue from adhering, thereby eliminating the need for additional fixing devices and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a fixing device with adhesive is used to secure the heating element on the media line, then the heating element position is fixed, but adhesive residue remains on the media line requiring complex cleaning before laser welding
Solution Approach 1:
A release film is introduced as an intermediary layer between the adhesive fixing device and the media line. This film prevents direct contact between the adhesive and the media line surface, thereby eliminating adhesive residue contamination while maintaining effective fixation of the heating element.
Solution Approach 2:
The fixing system is segmented into distinct functional layers: the adhesive layer is separated from the media line by the release film. This segmentation allows the adhesive to perform its fixation function without transferring residue to the media line, simplifying subsequent welding operations.
2Productivity
If adhesive fixing devices are removed after use, then the media line can be assembled, but adhesive residue remains requiring additional cleaning steps
Solution Approach 1:
The release film serves as a mediator that prevents adhesive transfer to the media line during the entire fixation process. This eliminates the need for cleaning operations, allowing the media line to proceed directly to assembly operations without time loss.
3Reliability
If cleaning processes are implemented to remove adhesive residue, then laser welding quality is improved, but production time and costs increase
Solution Approach 1:
The release film is applied in advance to prevent adhesive residue formation before any welding operations occur. This preliminary protective action ensures that the media line surface remains clean and ready for high-quality laser welding without requiring subsequent cleaning steps.
Solution Approach 2:
By placing the release film as an intermediary barrier, the system prevents adhesive contamination at the source, ensuring welding quality is maintained while eliminating time-consuming cleaning operations that reduce productivity.
4Stability of the object's composition
If multiple fixing devices are used to secure the heating element, then fixation reliability is improved, but the complexity of removal and cleaning increases
Solution Approach 1:
The release film is applied as a continuous layer across all fixation points, providing a unified barrier that prevents adhesive residue formation regardless of how many fixing devices are used. This simplifies the overall system by creating a consistent solution across multiple fixation locations.
Data Source
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AI summary
In a heatable media line (1) with a tubular media line (2), at least one heating element (4, 5) arranged externally on the tubular media line (2) and at least one fixing device for fixing the position of the at least one heating element (4, 5) on the outside (20) of the tubular media line (2), at least one high-temperature resistant film element (3) made of a polymer material that can withstand temperatures of 150 °C and more without damage is provided and arranged on the outside (20) of the tubular media line (2) wound with the at least one heating element (4, 5), wherein the high-temperature resistant film element (3) serves as a fixing device for fixing the at least one heating element (4, 5) on the outside (20) of the tubular media line (2).In a method for producing a heatable media line (1), wherein at least one tubular media line (2) is provided with at least one heating element (4, 5) on its outer surface, in particular wound, at least one high-temperature resistant film element (3) made of a polymer material that can withstand temperatures of 150 °C and more without damage is applied to the outside (20) of the tubular media line (2) above the winding of the at least one heating element (4, 5) in order to enable a comparatively simple and quick assembly of the heatable media line without the need to remove fixative residues from the outside of the media line before assembly.