Heated Hose Junction Piece Layout for Urea Freeze Prevention
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Solution Overview
Problem
Existing heatable hoses used in motor vehicle exhaust-gas treatment systems face a risk of freezing in the plug connections and junction pieces, particularly when handling aqueous urea solutions, as these areas are not effectively heated, leading to potential blockages and inefficiencies.
Innovation Solution
A heatable connection apparatus with crimp-connected heating conductors routed through a junction piece, ensuring electrical continuity and direct heating of the hose and connection points, eliminating the need for additional electrical connections and preventing freezing by using existing heating conductors from the hoses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing heatable hoses are used with standardized plug connections, then the hose line can be connected to motor vehicle assemblies, but the plug connections and junction pieces are prone to freezing when handling aqueous urea solutions
Solution Approach 1:
The heating function is merged into the junction piece by integrating heating conductors directly into the connection apparatus. The junction piece housing contains heating conductors that are electrically connected to heating conductors in the hoses, creating a unified heating system that prevents freezing at connection points without requiring separate heating components.
Solution Approach 2:
The heating system uses the existing heating conductors already present in the hoses to provide heating at the junction piece. The heating conductors from both hose ends are routed into the junction piece housing and electrically connected, allowing the system to heat itself at the connection points using its own integrated heating elements without external assistance.
2Reliability
If additional electrical connections are added to heat the junction piece, then freezing prevention is improved, but the device complexity and cost increase
Solution Approach 1:
The electrical heating system is merged with the mechanical connection structure. The heating conductors are integrated into the junction piece housing and connected to the hose heating conductors through crimp connections, combining the electrical heating function with the mechanical junction piece without requiring separate electrical connection components.
Solution Approach 2:
The heating conductors serve multiple functions: they heat the hoses along their length and also heat the junction piece connection points. The same electrical conductors provide both heating functions simultaneously, eliminating the need for dedicated heating elements at the junction piece.
3Temperature
If heating conductors are routed through the junction piece, then direct heating of connection points is achieved, but the structural integrity of heating conductors must be maintained
Solution Approach 1:
The heating conductors are protected by the junction piece housing which acts as a protective enclosure. The housing contains the heating conductors and provides mechanical protection while allowing them to be routed through the connection apparatus without exposure to external damage.
Solution Approach 2:
The crimp connections act as intermediaries that securely join the heating conductors from both hose ends to the junction piece housing. The crimp connections provide reliable electrical and mechanical connection while protecting the heating conductor ends from damage during routing and installation.
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 continuous and direct heating of the hose line branch, preventing freezing in the junction piece and connection points, ensuring reliable operation without additional complexity or cost, and maintaining the structural integrity of the existing heating conductors.
Implementation Method 1
A wide variety of electrically heatable hoses for use in motor vehicles are known. The medium flowing between two connection points in these hoses is heated by these hoses.
Data Source
AI summary
A heatable connection apparatus includes electrically heatable hoses and a junction piece having two nipples for corresponding ones of the hoses. Each hose has two electric heating elements embedded therein. The ends of the heating elements are routed out of the hose for connection. The heating elements from one hose end are connected to corresponding ones of the heating elements from the other hose end to form two heating-element pairs lying diametrically opposite one another. Each heating-element pair is bent downward and guided through with the crimp first from above under a bracket of the housing downward toward the housing bottom, from where it is deflected by 90° along the bottom of the junction piece in tight contact therewith. On the opposite side, the heating-element pair is guided upward and pushed with the crimp first from below and through the bracket.