Shielded Heating Conductor Connection for Corrosion-Prone Exhaust Heaters
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Solution Overview
Problem
The connection between a heating conductor element of an exhaust gas heater and an electrical connection line in internal combustion engine exhaust gas systems is prone to corrosion, electrical shorts, and mechanical damage due to exposure to media, thermal, and mechanical stresses.
Innovation Solution
A connecting arrangement featuring a shielding sleeve that surrounds the connection region between the heating conductor element and the connection line, providing electrical insulation and mechanical protection while maintaining a conductive connection, using a connecting element that separates conductive and shielding functions, and employing materials like metal and rubber for robustness and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the heating conductor element is directly connected to the connection line, then the electrical connection is simple, but the connection region is exposed to corrosion, thermal loading, and mechanical loading
Solution Approach 1:
The connection system is divided into distinct functional segments: the heating conductor element, the connecting element, the shielding sleeve, and the connection line. This segmentation allows each component to be optimized for its specific function while protecting the connection region from external influences.
Solution Approach 2:
The shielding sleeve acts as an intermediary component between the heating conductor element and the connection line. It provides mechanical protection, electrical insulation, and corrosion resistance, thereby protecting the connection region without interfering with the electrical connection function.
2Ease of manufacture
If the connection region is exposed, then the installation is simple, but media such as salt water, urea solution, and engine oil can cause corrosion and electrical shorts
Solution Approach 1:
The shielding sleeve is pre-installed or pre-positioned to provide protective action before harmful media can reach the connection region. This preliminary protection prevents corrosion and electrical shorts by creating a barrier against salt water, urea solution, engine oil, and other harmful substances.
Solution Approach 2:
The shielding sleeve functions as a protective shell that encloses the connection region. This shell structure provides mechanical protection and electrical insulation while allowing for thermal expansion and contraction, thereby protecting against harmful media without compromising the connection.
3Device complexity
If the connection region is exposed, then the structure is simple, but the region is subject to heavy thermal loading and mechanical loading from shocks and vibrations
Solution Approach 1:
The shielding sleeve provides beforehand cushioning by absorbing and distributing thermal and mechanical stresses before they can reach the vulnerable connection region. This protective layer cushions against shocks, vibrations, and thermal loading, thereby protecting the electrical connection without requiring complex structural reinforcements.
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 effectively shields the connection region from external influences, preventing corrosion and mechanical damage, ensuring reliable electrical conductivity and mechanical robustness, thus enhancing the durability and reliability of the connection.
Implementation Method 1
the shielding sleeve being connected to the heating conductor element in the heating conductor element connecting end region in a first sleeve end portion and being connected to the connection line in the connection line connecting end region in a second sleeve end portion and shielding the exposed end portion of the heating conductor element conductor element, the exposed end portion of the connection line conductor element and the connecting element connecting the exposed end portion of the heating conductor element conductor element to the exposed end portion of the connection line conductor element against external influences
Implementation Method 2
shielding the exposed end portion of the heating conductor element conductor element, the exposed end portion of the connection line conductor element and the connecting element connecting the exposed end portion of the heating conductor element conductor element to the exposed end portion of the connection line conductor element against external influences
Data Source
AI summary
A connecting arrangement electrically connects a heating conductor to an electrical connection line. The heating conductor includes a heating conduction element having an exposed end segment defining a first connecting region and the electrical connection line includes a connection line conductor having an exposed end segment defining a second connecting region. A connector mutually electrically connects the exposed end segments. A shielding sleeve surrounds the first connecting region, the second connecting region and the connector. The shielding sleeve has first and second sleeve end portions and the shielding sleeve is connected to the heating conductor in the first connecting region and is connected to the electrical connection line in the second connecting region and so shields the exposed end segment of the heating conduction element and the exposed end segment of the connection line conductor and the connector against external influences.