Heated Media Line Braid for Compact Resistance Tuning
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Solution Overview
Problem
Existing heated media lines for selective catalytic reduction (SCR) in the automotive field face challenges in adjusting resistance values over a wide range with small braid outer diameters while maintaining sufficient tensile strength and minimizing installation space, leading to inefficiencies in heating and increased manufacturing costs.
Innovation Solution
The braid comprises at least six individual wires, with at least one wire made from a CuNi alloy and the rest from Cu or NiCr alloy, all having the same diameter, and a plastic support element to enhance tensile strength, allowing for precise resistance adjustment and reduced warehousing and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the braid outer diameter is reduced to minimize installation space, then the installation space is minimized, but the ability to adjust resistance values over a wide range is restricted
Solution Approach 1:
The braid is segmented into multiple individual wires (at least six) that can be made from different materials with different specific resistances. This segmentation allows the resistance to be adjusted by varying the composition and quantity of wires from different material groups (Cu, CuNi, NiCr) while keeping the overall braid diameter small.
Solution Approach 2:
The braid uses composite construction with individual wires made from different materials (Cu, CuNi, NiCr) with different specific resistances. By combining these materials in various proportions and configurations, a wide range of resistance values can be achieved within a compact braid diameter.
2Manufacturing precision
If different materials with different specific resistances are used for individual wires, then resistance values can be adjusted exactly, but the manufacturing complexity and warehousing requirements increase
Solution Approach 1:
The invention changes the material parameter (specific resistance) of individual wires to achieve precise resistance adjustment. By selecting from a limited set of material types (Cu, CuNi, NiCr) with known specific resistances, the total braid resistance can be precisely calculated and controlled based on the number and arrangement of wires from each material group.
3Volume of moving object
If the braid is made with small outer diameter to reduce installation space, then the installation space is minimized, but the tensile strength of the braid is reduced
Solution Approach 1:
The braid employs a composite structure combining multiple wire materials (Cu, CuNi, NiCr) with different mechanical and electrical properties. This composite construction allows optimization of both tensile strength and resistance characteristics within a compact diameter by selecting appropriate material combinations and wire arrangements.
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 enables exact resistance adjustment over a wide range with small braid diameters, reducing manufacturing costs and ensuring precise heating performance while minimizing installation space, with a compact design and efficient production process.
Implementation Method 1
the electric heat conductor includes a braid made of stranded individual wires... For selective catalytic reduction (SCR) lines in the automotive field, the thawing of the lines must be ensured... A specific power is required to meet this requirement
Data Source
AI summary
A heat conductor and a heated media line having an inner tubular fluid line and at least one heat conductor arranged on the periphery thereof. The heat conductor is formed by a braid made of twisted individual wires and, in particular, an outer protective sheath surrounding the heat conductor and the fluid line. The braid is formed by at least six individual wires surrounding a support element, of which at least one individual wire is made of a copper-nickel (CuNi) alloy, and the remaining individual wires are produced from copper (Cu) or from a nickel-chromium (NiCr) alloy. All of the individual wires have the same diameter.