Heatable Pipe Connector with Spiral Heating Conductor
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Solution Overview
Problem
Electrically heatable hoses used in motor vehicles face issues with exposed heating conductor ends being unprotected and prone to freezing, especially in applications like exhaust gas aftertreatment systems where aqueous urea solutions can freeze, leading to connectivity issues and increased complexity with existing solutions.
Innovation Solution
A connection device that integrates the heating conductor into standard quick connectors, using a cylindrical heat conductor seat and protective sleeve to secure and insulate the heating elements, ensuring continuous direct heatability of the hose and connection points without additional electrical connections, thus protecting against freezing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating conductor ends are exposed outside the hose for electrical connection, then electrical connectivity is enabled, but the exposed ends are unprotected and prone to freezing
Solution Approach 1:
A connection device acts as an intermediary component between the hose and the electrical connector. This device includes a receptacle that receives the heating conductor ends and provides both electrical connectivity and thermal protection. The intermediary structure allows the heating conductors to be electrically connected while being physically protected from freezing conditions.
2Object-affected harmful factors
If additional protective structures are added to protect the heating conductor ends, then freezing protection is improved, but device complexity increases
Solution Approach 1:
The connection device merges multiple functions into a single integrated component: it provides mechanical support for the heating conductor ends, electrical connectivity through the receptacle, and thermal protection against freezing. By combining these functions into one device rather than adding separate protective structures, the solution avoids increasing overall device complexity.
Solution Approach 2:
The connection device is designed as a multi-functional component that simultaneously serves as a mechanical support structure, an electrical connector, and a thermal protection element. This universal design approach allows a single component to address multiple requirements (structural support, electrical connectivity, and freezing protection) without requiring additional separate parts.
3Ease of operation
If the heating conductor is integrated into standard quick connectors, then ease of operation is improved, but continuous heating capability may be compromised
Solution Approach 1:
The connection device is segmented into distinct functional zones: a receptacle portion that receives and protects the heating conductor ends, and an outer shell that provides additional protection and structural support. This segmentation allows the device to maintain quick connection capability while ensuring continuous heating through proper thermal contact and protection.
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 cost-effective and technically simple continuous heating of the entire line branch, including hose and connection points, preventing freezing and maintaining functionality without cold bridges, while ensuring the heating conductor's protection and insulation.
Implementation Method 1
Electrically heatable hoses for use in motor vehicles are widely known. The medium flowing in these hoses between two connection points is heated by these hoses.
Implementation Method 2
A connection device that integrates the heating conductor into standard quick connectors, using a cylindrical heat conductor seat and protective sleeve to secure and insulate the heating elements
Data Source
Figure 1
Figure 2
AI summary
Disclosed is a connecting device for media-conducting, electrically heatable pipes. Said connecting device is designed as a plug-in connection in which at least one pipe end is fitted with a plug-in connector that can be plugged onto a mating plug-in connector piece mounted on a motor vehicle unit. The electrically heatable pipe comprises an embedded electrical heating conductor, the ends of which are brought out of the pipe in order to be assembled with a plug. The plug-in connector (6; 26) at the pipe end has a cylindrical housing section (8) onto which a cylindrical heating conductor fixture (7) can be slid, the surface of said heating conductor fixture (7) being provided with a helical groove (11). The heating conductor is inserted into the helical groove (11) in a spiraling manner in such a way as to cover the cylindrical housing section (8) in a spiral-shaped fashion.