Flexible SCR Tank Heating Cord for Corrosion-Resistant Thawing
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Solution Overview
Problem
Existing heating systems for SCR tanks are complex, difficult to install, and inefficient in heating large volumes, with issues of overheating and short lifespan due to corrosive conditions and inflexible heating wires that cannot be easily positioned in remote sections of the tank.
Innovation Solution
A flexible electrical resistive heating element with metal filaments coated in a polymer layer and a corrosion-resistant metal layer, allowing for efficient heating and easy installation in complex tank designs, featuring a positive temperature coefficient to prevent overheating and durable against cyclic loading and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heating wires are used to heat the precursor liquid, then heating function is provided, but the heating wires become inflexible and cannot be easily positioned in remote sections of the tank
Solution Approach 1:
The patent applies this principle by using a flexible heating element consisting of a serpentine-shaped heating wire enclosed within a flexible tubular sheath. The sheath allows the heating element to be bent and positioned in remote sections of the tank while protecting the heating wire from mechanical damage and corrosion. This resolves the contradiction by providing both flexibility for positioning and structural integrity for the heating wire.
Solution Approach 2:
The flexible tubular sheath acts as an intermediary between the heating wire and the corrosive precursor liquid environment. The sheath protects the heating wire from direct contact with corrosive substances while allowing heat transfer to the liquid, thus maintaining wire flexibility and positioning capability without compromising heating function.
2Productivity
If heating systems are made complex to heat large volumes efficiently, then heating efficiency improves, but installation difficulty and system complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the heating function into multiple heating sections along the length of the tank. Each section has its own heating element that can be independently controlled, allowing efficient heating of large volumes without requiring a single complex heating system. This enables scalable heating capacity while maintaining relative simplicity of individual heating units.
Solution Approach 2:
The heating system incorporates dynamic control capabilities where the power supplied to different heating sections can be adjusted independently based on temperature sensors and control logic. This allows the system to adapt to varying heating requirements throughout the tank, improving overall heating efficiency without requiring excessive complexity in the physical structure.
3Reliability
If heating elements are made durable to withstand corrosive conditions, then lifespan increases, but manufacturing complexity and installation difficulty increase
Solution Approach 1:
The patent applies composite materials by combining the heating wire (for heat generation) with a flexible tubular sheath (for corrosion protection). The sheath is made from corrosion-resistant materials that can withstand the precursor liquid environment while allowing heat transfer. This composite structure provides durability and corrosion resistance without requiring the heating wire itself to be made from complex corrosion-resistant alloys.
Solution Approach 2:
The tubular sheath serves as an intermediary protective layer between the heating wire and the corrosive precursor liquid. This simple protective enclosure provides corrosion resistance and extends lifespan without adding significant manufacturing or installation complexity, as the sheath can be easily fitted over the heating wire in a straightforward assembly process.
4Speed
If heating power is increased to heat large volumes quickly, then heating speed improves, but risk of overheating increases
Solution Approach 1:
The heating system is divided into multiple independent heating sections, each with its own power control. This allows distributed heating throughout the tank volume, increasing overall heating speed while preventing localized overheating. Each section can be controlled independently to maintain safe temperature levels while collectively achieving rapid heating of the entire precursor liquid volume.
Solution Approach 2:
The heating system incorporates temperature sensors and control logic that provide feedback on the temperature conditions within the tank. Based on this feedback, the power supplied to heating elements is automatically adjusted to maintain optimal heating rates while preventing overheating. This closed-loop control enables fast heating while mitigating overheating risks.
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 provides efficient, durable, and easy-to-install heating for large SCR tank volumes, preventing overheating and extending the lifespan of the heating element while maintaining effective heat distribution and resistance to corrosive conditions.
Implementation Method 1
The electrical heating system of the invention comprises one or more heating cords that are immersed in the liquid in the tank
Implementation Method 2
Heating systems immersed in the tank are very efficient in terms of transfer of energy (heat) to the (frozen) precursor liquid
Data Source
AI summary
The invention describes a tank comprising a solution, dispersion or emulsion for selective catalytic reduction in combustion engines. The tank comprises an electrical resistive heating element immersed in the tank. The electrical resistive heating element comprises at least one heating cord. The heating cord comprises metal filaments. The metal filaments ° comprise a copper layer or a layer in a copper alloy, and comprise a surrounding layer in stainless steel, ° or comprise a steel layer, surrounded by a layer in copper or in a copper alloy, surrounded by a nickel, zinc or tin layer or a layer of alloys comprising such metals; ° or comprise a layer of low carbon or high carbon steel, and comprise a surrounding nickel, zinc or tin layer or layer of alloys comprising such metals, and the heating cord comprises a polymer coating layer.