Integrated Flexible Heater for Urea Tank Freeze Protection
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Solution Overview
Problem
Existing urea tanks face challenges in efficiently heating urea solutions to prevent freezing, especially in cold conditions, due to the rigidity and inflexibility of traditional heating elements, which complicates their integration into the tank and accessories, leading to ineffective heating and flexibility issues.
Innovation Solution
A urea tank with an integrated flexible heating element, comprising a resistive heater with flexible parts that can be easily adapted to the tank's geometry, including tentacles and a base plate that incorporates active components like sensors and a pump, ensuring uniform heating and effective operation in freezing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid heating elements are used in urea tanks, then heating function is provided, but integration into tank and accessories becomes complex and flexibility is compromised
Solution Approach 1:
The patent employs flexible heating elements constructed from thin film structures that can conform to various tank geometries and accessory surfaces. These flexible heaters replace rigid heating elements, enabling easy integration into curved surfaces, corners, and complex shapes of urea tanks while maintaining effective heating functionality.
2Power
If heating tubes with minimum diameter of several mm are inserted into the tank, then heating capability is achieved, but insertion into certain parts becomes difficult
Solution Approach 1:
The invention replaces bulky heating tubes with thin film flexible heaters that can be easily inserted and conform to any surface. These thin film elements eliminate the minimum diameter constraint of rigid tubes, allowing placement in tight spaces, curved surfaces, and complex geometries without insertion difficulties.
3Area of stationary object
If cartridge (rod) heaters are used at various locations in the tank, then heating coverage is improved, but flexibility and mobility are compromised
Solution Approach 1:
The patent utilizes flexible thin film heaters that can be cut and shaped to cover various locations and surfaces within the tank. These flexible elements can be arranged in multiple configurations and positions, providing comprehensive heating coverage while maintaining the flexibility to adapt to different tank designs and requirements.
4Temperature
If external heating tubes are used for connections, then heating of connections is attempted, but effectiveness is reduced due to ice plug formation
Solution Approach 1:
The invention integrates heating elements directly within connection components, nesting the heating function inside the connection structure itself. This internal integration ensures direct contact between the heating element and the urea solution flowing through the connection, preventing ice plug formation by heating from within rather than attempting to heat externally.
Solution Approach 2:
The patent employs heating filaments or thin film heaters as intermediaries that are directly embedded in connection passages. These intermediary heating elements transfer thermal energy directly to the urea solution at the critical connection points, ensuring effective heating and preventing ice formation where external heating tubes fail.
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 flexible heating element ensures rapid and uniform heating of the urea solution, even in extreme cold, allowing for easy integration into various tank geometries and accessories, preventing ice formation and ensuring continuous operation of the SCR process.
Implementation Method 1
said heating element comprises at least one flexible heating part (that is to say, equipped with a device enabling it to heat up, such as a resistive element for example)
Data Source
AI summary
Urea tank and base plate with an integrated heating element in which the heating element comprising at least one resistive track affixed to one flexible film and/or placed between two flexible films.