Heated Fluid Line Plug Hinge Structure for Easier Sealing Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heatable fluid lines used in motor vehicles to transport urea face issues with freezing at low temperatures, and the existing solutions for heating the lines require high press-in force for sealing, which complicates assembly and increases the risk of energy loss and damage to heating elements.
Innovation Solution
A heatable fluid line design featuring a plug with a joint section and radially inward projections, allowing for easier assembly and ultrasonic welding to secure the plug to the heating element, reducing the need for high press-in force and minimizing energy loss and damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is pressed into the socket to seal the heating element opening, then sealing reliability is improved, but assembly difficulty increases due to high press-in force requirements
Solution Approach 1:
The plug is divided into two separate parts that are connected by a hinge section, allowing each part to be inserted independently through the socket opening. This segmentation eliminates the need for high press-in force while maintaining sealing reliability through the coordinated positioning of both parts.
Solution Approach 2:
The hinge section enables dynamic movement between the two plug parts, allowing them to flex and adapt during insertion. This dynamic structure permits easy assembly by allowing the parts to move relative to each other during the insertion process, then stabilize in the final sealed position.
2Strength
If ultrasonic welding is used to attach the plug to the heating element, then connection strength is improved, but energy loss and damage risk increase due to high welding energy
Solution Approach 1:
Projections are provided in the through-channel that concentrate the ultrasonic welding energy at specific localized points rather than distributing it across the entire plug surface. This localized energy concentration achieves strong bonding with reduced overall energy input, minimizing energy loss and preventing damage to the heating element.
3Ease of operation
If the plug structure is simplified for easy assembly, then assembly ease is improved, but sealing reliability may deteriorate
Solution Approach 1:
Dividing the plug into two parts connected by a hinge provides both assembly simplicity and sealing reliability. The segmented structure allows easy insertion while the coordinated positioning of both parts maintains the seal integrity.
Solution Approach 2:
The hinge section acts as an intermediary element that connects the two plug parts while allowing relative movement. This intermediary structure enables easy assembly through flexible insertion while maintaining the structural integrity needed for reliable sealing.
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 design simplifies assembly, reduces energy requirements for welding, and ensures reliable sealing and secure attachment of the heating element, preventing vibration and damage during the welding process.
Implementation Method 1
a heating element (12) which is arranged inside the tube (2)
Implementation Method 2
The opening through which the heating element is led out of the connector must be sealed in order to prevent the fluid from escaping from the line to the outside
Implementation Method 3
The plug is preferably welded to the heating element. Once the plug has been inserted into the socket, it can be welded to the heating rod, preferably by ultrasonic welding
Data Source
Figure 1~2
Figure 3~4
AI summary
A heated fluid line is provided, comprising a tube, a connector having a housing located at one end of the tube, and a heater rod located inside the tube and entering the housing through an entry passage having a longitudinal axis and exiting the housing through an opening located in a nozzle, a seal being located in the nozzle which surrounds the heating element and is retained in the nozzle by a plug (21). One would like to be able to accomplish reliable assembly in a simple manner. For this purpose, it is provided that the stopper (21) has at least two parts (22, 23) which are connected to one another by a joint section (24) having a joint axis.