Rigid Substrate Heating Device for Urea Tank Thawing

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Solution Overview

Problem

Existing heating devices for motor vehicle tanks storing aqueous urea solution face inefficiencies in heat transfer due to flexible designs, which are prone to mechanical stress and result in varying heat transmission behaviors, leading to prolonged thawing times and increased pollutant emissions during low external temperatures.

Innovation Solution

A heating device with a resistance heating trace directly connected to a rigid substrate without intermediate films, where the trace is protected by a flexible film and optionally embedded in a thermally hardenable intermediate layer, ensuring consistent heat transfer and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible heating device with resistance heating trace between two films is used, then the heating device can be introduced in different receiving volumes due to flexibility, but the resistance heating trace is subject to varying mechanical load from vibration and shocks, and heat transmission behavior varies between identical receiving volumes

Engineering Contradiction:

Improveadaptability to different receiving volumesVSAvoidmechanical stability of resistance heating trace

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The heating device uses a flexible film as the outer shell that can adapt to different receiving volumes while the resistance heating trace is mounted on a rigid substrate inside, combining the adaptability of flexible films with the stability of rigid mounting

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The resistance heating trace is mounted on a rigid substrate (adding structural dimension) rather than being directly embedded in flexible material, creating a layered structure that separates the flexible outer shell from the rigid heating element mounting

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the resistance heating trace is disposed between two flexible films, then the heating device can assume different positions and orientations in identical receiving volumes, but different heat transmission behaviors occur in serially produced tanks

Engineering Contradiction:

Improveposition and orientation flexibilityVSAvoidconsistency of heat transmission behavior

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The resistance heating trace is pre-mounted on a rigid substrate in a fixed position before the heating device is installed in the tank, ensuring consistent heat transmission behavior across all serially produced tanks while still allowing flexibility in installation orientation

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the resistance heating trace is connected to the rigid substrate without intermediate film arrangement, then the resistance heating trace is fixed in a definite position for consistent heat transmission, but the resistance heating trace is more exposed to environmental influences

Engineering Contradiction:

Improveconsistency of heat transmission behaviorVSAvoidexposure to chemically aggressive operating fluid

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A flexible film serves as a protective shell covering the resistance heating trace that is mounted on the rigid substrate, allowing direct connection for consistent heat transmission while the film provides chemical protection from the operating fluid

Inventive Principle:

Principle #30Flexible shells and thin films

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 configuration ensures rapid and consistent heat transfer to the operating fluid, reducing mechanical stress on the heating trace and minimizing exposure to aggressive fluids, thereby shortening thawing times and reducing pollutant emissions.

Implementation Method 1

an electrical resistance heating trace with a heating side on which in intended use heat is emitted to a fluid to be heated

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heat can be quickly transferred from the heating device to the operating fluid

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10352221B2Heating device and tank with heating device

Publication Date: 2019.07.16 ROECHLING AUTOMOTIVE SE & CO KG

AI summary

Heating device (10), in particular for heating an operating fluid tank of a motor vehicle, preferably a tank for storage of aqueous urea solution, the heating device (10) comprising an electrical resistance heating trace (14) with a heating side (14b), on which, in intended operation, heat is emitted to a fluid to be heated, and the heating side (14b) opposing a carrier side (14a), on which the resistance heating trace (14) faces a mounting supporting it, wherein the resistance heating trace (14) is disposed between a flexible film (16) on its heating side (14b) and a substrate (12), rigid in comparison with the flexible film (16), as the supporting mounting on the carrier side (14a), which is characterized in that the resistance heating trace (14a) is connected to the rigid substrate (12) on the carrier side (14a) without intermediate arrangement of a further film.