Vehicle Line Connector Heating Wire Fixation
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Solution Overview
Problem
Existing line connectors for vehicles require external rib structures or shaped elements for heating wires, increasing size and manufacturing costs, and lack a universal solution for both heatable and non-heatable variants.
Innovation Solution
A line connector design with a multi-layer insulating sheathing where the inner layer has a higher melting point than the outer layer, allowing for adhesive fixation of heating wires without external shaped elements, enabling both heatable and non-heatable configurations by ensuring reliable electrical insulation and heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external rib structures or shaped elements are provided on the connector for routing heating wires, then the heating wire can be reliably fixed, but the overall size of the connector increases and material requirements increase
Solution Approach 1:
The invention extracts the heating wire fixation function from external rib structures or shaped elements and integrates it into the smooth outer surface of the connector. The heating wire is fixed directly to the smooth outer surface without requiring additional external form elements, thereby eliminating the volume increase while maintaining fixation reliability.
Solution Approach 2:
The invention merges the heating wire fixation function with the connector's outer surface structure. Instead of having separate external ribs or shaped elements for fixation, the smooth outer surface itself serves as the fixation substrate, combining the structural and fixation functions into one integrated design.
2Reliability
If external rib structures or shaped elements are provided on the connector for heating wire routing, then the heating wire can be reliably fixed, but manufacturing effort and expense increase
Solution Approach 1:
The invention removes the need for external rib structures or shaped elements that would complicate manufacturing. The heating wire is fixed directly to the smooth outer surface of the connector, which simplifies the molding process and reduces manufacturing steps while ensuring reliable fixation.
Solution Approach 2:
The connector design is made universal by providing a smooth outer surface that can accommodate heating wires in different configurations (helical winding, meandering winding, or straight routing) without requiring variant-specific molded elements. This single design serves both heated and unheated applications.
3Adaptability or versatility
If a single connector design is used for both heated and unheated applications, then manufacturing complexity and costs are reduced, but the connector must accommodate heating wire fixation without external shaped elements
Solution Approach 1:
The smooth outer surface of the connector serves itself as the fixation substrate for heating wires. No additional external form elements are needed because the connector's own surface provides the necessary attachment area, making the system self-sufficient and universally applicable.
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 allows for a single embodiment variant to function as both heatable and non-heatable, reducing manufacturing complexity and costs while maintaining effective heating and insulation, suitable for various vehicle applications.
Implementation Method 1
a multi-layer insulating sheathing where the inner layer has a higher melting point than the outer layer, allowing for adhesive fixation of heating wires while ensuring reliable electrical insulation
Implementation Method 2
at least one heating strand or heating wire for electrical heating by winding
Data Source
Figure 1~2
Figure 3~5
Figure 6~10
AI summary
The invention relates to a line connector (1) comprising at least one first connection section (10) for connecting to at least one fluid line (5), at least one second connection section (11) for connecting to at least one second fluid line and/or to a unit and at least one central section (12) which is arranged between said lines and which interconnects the connection sections (10,11). Said line connector (1) is designed as a plastic moulding element and comprises at least one wall (14) and at least one inner flow channel (13) is surrounded by thereby. The line connector (1) is provided in at least one partial area of the central section (12) with at least one heating strand (2) or heating wire for electrically heating by winding. The heating strand (2) or the heating wire comprises at least one strand (21) or at least one wire and an insulation covering (20) surrounding one or both. The at least one heating strand (2) or the at least one heating wire is adhesively fixed or secured at least in the central section (12) of the line connector (1) thereto by securing means and after adhesively fixing or securing of the heating strand (2) or the heating wire to the line connector (1), the wall thickness (s,s26) of the at least one single-sheet insulation covering on all sides about the at least one strand (21) or the at least one wire is sufficient for electric insulation,