Heated Hose Junction Layout for Freeze-Proof Branch Connections
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Solution Overview
Problem
Existing electrically heatable hoses used in exhaust gas treatment systems for vehicles are prone to freezing issues at connectors and branching points, particularly in extreme applications like SCR systems, where aqueous urea solutions can freeze, and current solutions are either expensive or lack effective heating designs for these areas.
Innovation Solution
A heatable connection arrangement for hoses with branching pieces where the heating conductors from both ends are crimped and routed to ensure electrical continuity, allowing for continuous direct heating of the hose and connection points without additional electrical connections, using existing heating conductors and encapsulating the structure with plastic for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating conductors are extended to connection pieces and branching points, then freezing protection is improved, but device complexity and cost increase due to additional electrical connections
Solution Approach 1:
The heating function is merged with the structural connection pieces by integrating heating conductors directly into the connection pieces and branching points. This eliminates the need for separate heating elements and additional electrical connections, as the connection pieces themselves become the heating elements through integrated conductors.
Solution Approach 2:
The connection pieces serve multiple functions: they provide mechanical connection for hoses and simultaneously act as heating elements through integrated heating conductors. The branching points also serve dual purposes as structural components and heating zones, eliminating the need for dedicated heating devices.
2Temperature
If heating conductors are routed through connection pieces, then heating effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The heating conductors are pre-integrated into the connection pieces during the molding process. The conductors are positioned and secured within the connection piece structure before final assembly, allowing for efficient manufacturing where the heating elements are built-in rather than installed separately.
Solution Approach 2:
The heating conductors are routed through specific paths within the connection pieces and branching points to optimize heat distribution. The conductors are positioned to ensure effective heating of critical areas while maintaining manufacturability through standardized routing patterns.
3Device complexity
If existing heating conductors are utilized without additional connections, then cost is reduced, but heating coverage at connection points may be insufficient
Solution Approach 1:
The heating conductors are routed in three-dimensional paths through the connection pieces and branching points, extending heating coverage to previously unreachable areas. The conductors are positioned to wrap around critical surfaces and penetrate into connection interfaces, providing comprehensive heating without additional electrical connections.
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 provides cost-effective and efficient heating to prevent freezing across the entire line branch, including connectors and branching points, eliminating the risk of ice formation and reducing complexity and costs by utilizing existing heating conductors without additional electrical connections.
Implementation Method 1
each hose having at least two in the respective hose is provided over a portion of the hose length embedded electrical heating conductor
Data Source
Figure 1~3
Figure 4~5
AI summary
A heatable connection apparatus for media-conducting, electrically heatable hoses is configured as a junction piece which has two connection pieces for in each case one hose end and a further connection which communicates with the line interior. Each hose is provided with two electric heating elements which are embedded in the respective hose at least over a part region of the hose length and the ends of which are routed out of the hose for connection to an electric component. The heating elements (21, 22) of one hose end (14) are connected to the heating elements (23, 24) of the other hose end (15) by means of in each case one crimp barrel (20 and 30, respectively) to form two heating-element pairs (21, 23 and 22, 24) which lie diametrically opposite one another. Each heating-element pair (21, 23 and 22, 24) is bent downwards in a compressed manner and is guided through with the crimp point (20 and 30) first of all from above under a lateral bridge web (31 and 32) of the housing (11) downwards in the direction of the housing bottom (33), from where it is deflected by 90° and is laid around the bottom (33) of the junction piece (11) in tight housing contact. On the respectively opposite side, the respective heating-element pair is guided upwards again, and is pushed with the crimp point (20 and 30) first of all from below through the bridge web (31 and 32) of the housing (11) which forms a type of locking bar, and is therefore positioned in this location.