Segmented Protective Corrugated Tube for SCR Systems

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Solution Overview

Problem

Existing corrugated protective tubes for temperature-controlled media lines, such as those used in SCR systems, are not sufficiently resistant to tensile and torsional forces, leading to potential impairment or damage and disrupting the supply of urea solutions used for nitrogen oxide reduction in vehicle exhaust gases.

Innovation Solution

A protective tube design featuring a central corrugated section with wave crests and troughs, end-side corrugated sections with specific crest configurations, and cylindrical sections with varying wall thicknesses, providing enhanced structural integrity while maintaining thermal insulation and mechanical protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the protective tube is designed as a corrugated tube over the entire length, then thermal insulation and mechanical protection are improved, but resistance to tensile forces and torsional forces deteriorates

Engineering Contradiction:

Improvemechanical protection and thermal insulationVSAvoidresistance to tensile forces and torsional forces

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The protective tube is divided into different sections: a central corrugated section for thermal insulation and mechanical protection, and end sections with cylindrical portions that provide enhanced resistance to tensile and torsional forces. This segmentation allows each section to optimize its function without compromising the overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the protective tube have different structural qualities. The central section has corrugations for insulation, while the end sections have cylindrical portions with increased wall thickness for strength. This local differentiation resolves the contradiction by providing the right quality in the right location.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If the protective tube uses uniform wall thickness, then manufacturing is simplified, but structural integrity under tensile and torsional forces deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The wall thickness varies locally along the protective tube. The end sections have increased wall thickness to resist tensile and torsional forces, while the central section has standard thickness for insulation. This local quality variation maintains structural integrity without significantly complicating manufacturing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protective tube is segmented into regions with different wall thicknesses. The end sections are manufactured with greater thickness for strength, while the central section uses standard thickness. This segmentation allows optimized structural performance with manageable manufacturing complexity.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If the end-side corrugated tube section has only full-circumference crests, then manufacturing is easier, but resistance to tensile and torsional forces is insufficient

Engineering Contradiction:

Improvecrest formation simplicityVSAvoidresistance to tensile and torsional forces

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The end-side corrugated sections incorporate both full-circumference crests and partial-circumference crests. The full-circumference crests provide basic structural support, while the additional partial crests enhance resistance to tensile and torsional forces. This local quality enhancement improves strength without significantly increasing manufacturing difficulty.

Inventive Principle:

Principle #3Local quality

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 proposed design significantly reduces the risk of damage from tensile and torsional forces, ensuring a stable and reliable supply of temperature-controlled media lines, particularly for urea solutions, while maintaining thermal insulation and mechanical protection.

Implementation Method 1

The protective tube generally surrounds the heatable media line at a certain distance, and air or an air layer is arranged in the space between the protective tube and the media line. The protective tube serves on the one hand to protect against external mechanical influences and on the other hand also for thermal insulation.

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP2662606B1Protective corrugated tubes for a pipe with a medium to be tempered, pipe module thereof

Publication Date: 2015.09.23 TI AUTOMOTIVE FULDABRUCK

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Figure 3~4
Figure 5~6

AI summary

Protective tube (1) for a media line (2) to be temperature controlled, wherein the protective tube (1) is partially designed as a corrugated tube. At least one central corrugated tube section (3) is provided with central corrugation crests (4) and corrugation troughs (5), wherein at least one end-end corrugated tube section (6) with end-end corrugation crests (7) and corrugation troughs (8) is arranged at at least one end of the protective tube (1). At least one cylindrical tube section (9) is arranged between the central corrugated tube section (3) and an end-end corrugated tube section (6).