Plastic Heatable Liquid Container With Floating Heater Support
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Solution Overview
Problem
Existing heatable liquid containers for urea solutions in vehicles face issues with thermal expansion and material deformation, leading to internal stresses and potential leaks due to fixed bracing of heating elements, which are exacerbated by temperature fluctuations and operational vibrations.
Innovation Solution
A floating bearing system where the heating element is supported by a bracing element made from the same material as the container, allowing for horizontal movement and compensating for material expansion, eliminating the need for additional fixing means and preventing leaks by creating a homogeneous, leak-proof bond through sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the heating element is fixed to the container wall, then the heating element remains in a fixed position during vibrations, but thermal expansion causes internal stresses and potential leaks
Solution Approach 1:
The heating element is designed with a floating mounting system that allows dynamic adjustment of its position. The element can move horizontally within the container to accommodate thermal expansion and contraction, while vertical positioning is maintained through gravity and container geometry. This dynamic adaptation eliminates internal stresses during temperature cycles while preventing leaks through proper sealing at the connection points.
2Strength
If the heating element is fixed immovably, then attachment strength is maximized, but repeated heating and cooling cycles create alternating stresses leading to cracks
Solution Approach 1:
The mounting system combines fixed and floating characteristics - the heating element floats horizontally to accommodate thermal expansion while being vertically constrained by gravity and container geometry. This selective fixation maintains attachment strength where needed while allowing movement to prevent fatigue damage from repeated thermal cycling.
Solution Approach 2:
The system exploits changes in physical parameters - specifically thermal expansion and contraction - by allowing the heating element to move freely in horizontal directions while maintaining vertical positioning. This parameter-based adaptation enables the system to withstand temperature fluctuations without creating damaging stresses.
3Stability of the object's composition
If metal retaining clips are used to support the heating element, then positioning is secure, but liquid seepage occurs between the clips and plastic wall
Solution Approach 1:
The container, heating element, and mounting structure are all made from the same plastic material to ensure homogeneous thermal expansion characteristics. This material uniformity prevents differential expansion that would create gaps and seepage paths, while maintaining secure positioning through the floating mounting system.
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 ensures a permanently sealed container that withstands temperature fluctuations and vibrations, reducing the risk of leaks and extending the service life while maintaining efficient heat distribution and energy savings through effective thermal management.
Implementation Method 1
a heating element that is arranged essentially in the internal cavity of the container... to heat the liquid in the container
Implementation Method 2
The heating coil is also supported in the base area... an area of the inner wall of the tank serves as a bracing element
Implementation Method 3
it is impossible to prevent thermal expansion of the material as a result of the heat experienced during subsequent operation. This particularly affects the heating element, which is susceptible to expansion when warming up
Implementation Method 4
at least part of which is encased in the plastic material by sintering... creating a homogeneous, leak-proof bond through sintering
Data Source
AI summary
A heatable liquid container made from plastic material, particularly for holding water/urea mixtures and having an internal cavity and a heating element arranged essentially in the internal cavity of the container, and with at least one connection end, the heating element is braced by a bracing element in at least one bearing area in the internal cavity of the liquid container. The heating element is supported in a horizontally floating manner by the bracing element. The bracing element is an insert part that is at least partially encased in the plastic material by sintering and is made from the same material as the inner wall of the liquid container.