Heated Line Connector Structure for Freeze-Prone Media Lines
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Solution Overview
Problem
Media lines in motor vehicles, such as those for windshield washers and urea solutions, are prone to freezing at high ambient temperatures, which can impair vehicle functions, especially at temperatures below -11°C, and existing connectors do not effectively prevent freezing or facilitate defrosting.
Innovation Solution
A line connector with electrical heating means encasing the flow channel, allowing for partial or complete circumference heating, and a modular fixing part that can be easily attached to existing connectors to provide heating, ensuring continuous heating along the media transport path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical heating means are added to the connector, then freezing protection is improved, but device complexity increases
Solution Approach 1:
The heating system is segmented into modular heating sections that can be independently installed on different parts of the connector. The fixing part with guiding elements allows separate installation of heating means on the connector body, media line, or both, enabling selective heating zones rather than requiring a completely integrated heated connector design.
Solution Approach 2:
The heating means are nested around the flow channel in an annular arrangement, with the heating element positioned within a fixing part that attaches to the connector. This nested configuration allows the heating system to be integrated into the existing connector geometry without requiring complete redesign of the connector body.
2Reliability
If heating means are integrated into the connector design, then freezing protection is improved, but manufacturing cost increases
Solution Approach 1:
The connector design is made universal by creating a standardized fixing part with guiding elements that can accommodate heating means while maintaining compatibility with existing unheated connectors. This allows a single base connector design to serve both heated and unheated applications, eliminating the need for separate tooling for different connector types.
Solution Approach 2:
The fixing part with guiding elements is designed and prepared in advance as a separate component that can be attached to the connector before final assembly. This preliminary preparation allows the heating infrastructure to be established without requiring costly post-manufacturing modifications or specialized assembly tooling.
3Reliability
If heating means are added to prevent freezing, then energy consumption increases, but functional reliability improves
Solution Approach 1:
Heating is applied locally only where freezing risk exists - specifically in the connector area and along the media line - rather than heating the entire fluid system. The annular heating arrangement around the flow channel concentrates thermal energy precisely where needed to prevent freezing, minimizing overall energy consumption while maintaining functional reliability.
Solution Approach 2:
The heating system provides sufficient thermal energy to prevent freezing under critical conditions (down to -30°C), using an annular heating arrangement that encloses the flow channel. This partial heating approach targets only the critical zones rather than attempting to heat the entire media system, optimizing energy efficiency while ensuring adequate 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
Prevents freezing and enables efficient defrosting of media within the connector, ensuring functional integrity of vehicle systems even at low temperatures, and allows for a single connector design to serve both heated and unheated applications, reducing tooling costs.
Implementation Method 1
electrical heating means are provided in an arrangement which encloses the flow channel over its circumference at least partially, but preferably completely over 360°
Data Source
Figure 1~2
Figure 3a~5c
Figure 6a~8
AI summary
The invention relates to a line connector (1) for media lines (4), comprising a connector piece (2) with a flow channel (12) and with at least one connection section (4, 8) for connection to a media line (4) or to an aggregate and with at least one transition section (6, 10) proximate to the connection section (4, 8). In such a line connector, in order to prevent the respective medium from freezing in the connection area at low temperatures and in order to enable unfreezing of a frozen medium, it is proposed that heating means (13) be provided in an arrangement that at least partially surrounds the flow channel (12), wherein a fixing part (14) is disposed at the connector piece (2), said fixing part comprising elements (16, 18) for guiding and fixing the heating means (13).