Self-Piercing Connector for SCR Urea Heating
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Solution Overview
Problem
Selective Catalytic Reduction (SCR) vehicles face inefficiencies in maintaining the liquid state of automotive urea solution due to freezing issues, requiring inefficient heating wire solutions that necessitate redesigns and are inflexible, and existing connectors lack a self-piercing mechanism for electrical connections in fluid conduits.
Innovation Solution
A self-piercing connector with semi-circular cutting members that extend tangentially from each end, ensuring electrical isolation and allowing for efficient electrical connections within a fluid conduit, which includes conductors for resistance heating to prevent freezing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating wires are molded into or wrapped around the AUS hose to prevent freezing, then the urea solution can be maintained in liquid state, but the solution requires complete redesign of the fluid line and multiple production runs to change heating properties
Solution Approach 1:
The heating system is segmented into discrete connector components rather than requiring complete fluid line redesign. The cutting members with integrated heating elements can be independently manufactured and assembled, allowing modular replacement and adjustment without redesigning the entire hose assembly.
Solution Approach 2:
The heating characteristics can be adjusted by changing parameters of the cutting members (such as wire pitch, wire size, or number of wires) during production, allowing flexibility in heating properties without requiring complete fluid line redesign. This enables parameter optimization while maintaining the same basic connector design.
2Reliability
If traditional insulation piercing connectors with metal piercing blades and teeth are used to make electrical connections, then electrical continuity can be achieved, but the connector cannot pierce through the insulating layer of fluid conduits independently
Solution Approach 1:
The piercing function and electrical connection function are merged into a single cutting member component. The cutting member integrates both the piercing edges for penetrating the insulating layer and the electrical contact surfaces for establishing electrical continuity, eliminating the need for separate piercing blades and teeth assemblies.
Solution Approach 2:
The cutting member is designed to perform the piercing action itself without requiring external piercing tools or separate blade assemblies. The cutting member's own structure includes sharp edges that enable it to cut through the insulating layer and establish electrical contact independently, making the connector self-sufficient for both piercing and connection functions.
3Ease of manufacture
If heating wires are wrapped around the AUS hose to provide heating, then the wiring can be easily installed, but changing the heating characteristics requires another production run of the hose with modified wire assembly
Solution Approach 1:
The heating characteristics can be modified by changing parameters of the cutting members (wire pitch, wire size, number of wires) during connector production. This allows flexible adjustment of heating properties without requiring complete fluid line redesign or new hose production runs, as the cutting members can be independently manufactured with different specifications.
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 self-piercing connector effectively maintains the urea solution in a liquid state by providing efficient electrical connections and resistance heating, eliminating the need for frequent redesigns and inflexible heating wire solutions.
Implementation Method 1
conductors disposed therein... providing efficient electrical connections and resistance heating
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A self-piercing connector comprising, a first body, a second body, the first body comprising a first cutting member for piercing a fluid conduit insulating layer to engage a fluid conduit first conductor, the second body comprising a second cutting member for piercing the fluid conduit insulating layer to engage a fluid conduit second conductor, the first cutting member having a semi-circular form and comprising portions that extend tangentially from each end of the first cutting member, the second cutting member having a semi-circular form and comprising portions that extend tangentially from each end of the second cutting member, the first cutting member and the second cutting member electrically isolated from each other, the first body comprising a first connection member for engaging a cooperating second connection member on the second body, a first body receiver for receiving an electrical conductor connectible to the first cutting member, and a second body receiver for receiving an electrical conductor connectible to the second cutting member.