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Publication Number
US-11813403-B2
Publication Date
2023-11-14
Expiration Date
Abstract
A method of forming a hose includes: extruding a web of plastics material from a first extruder; helically winding the extruded web about a mandrel or at least one rotating rod to form a wall of the hose; feeding an electrical wire into a second extruder; extruding a bead of plastics material around the electrical wire from the second extruder such that the extruded bead includes the electrical wire at a location within a cross-section of the extruded bead; cooling the extruded bead to cool the plastics material adjacent the location to prevent migration of the electrical wire away from the location; re-heating the extruded bead to cause outer surface portions of the plastics material of the extruded bead to become molten; and helically winding the extruded bead onto and about an external surface of the wall to provide the wall a support helix that incorporates the electrical wire.
Core Innovation
A heated respiratory hose assembly and hose-making process are described for ventilator and CPAP use. Heating electrical wires are incorporated into a hose wall by helically winding an extruded plastics web about a mandrel or rotating rod to form the hose wall about a central axis.
A bead of plastics material is extruded around the electrical wire and then wound onto the exterior of the hose wall so the bead forms a support helix that incorporates the wire. The process includes cooling the extruded bead sufficiently to cool plastics material adjacent a first location within the cross-section of the bead to prevent migration of the electrical wire away from that location.
After cooling, the bead is re-heated sufficiently to cause outer surface portions of the plastics material to become molten. The re-heated bead is helically wound onto and about an external surface of the wall of the hose so the support helix incorporates the electrical wire while bonding the bead to the hose exterior without melting adjacent interior material at the wire location.
Claims Coverage
The independent claim presents five inventive features: forming a hose wall from a helically wound extruded plastics web, embedding an electrical wire in an extruded bead at a specified cross-sectional location, cooling to prevent wire migration, re-heating to soften molten outer surface portions, and winding the bead onto an external surface to form a support helix incorporating the wire.
Forming a hose by extruding and helically winding a plastics web
Extruding a continuous web of plastics material of substantially uniform width and helically winding the extruded web about a mandrel or at least one rotating rod to form a wall of the hose about a central axis.
Embedding an electrical wire in an extruded plastics bead
Feeding a first electrical wire into a second extruder and extruding a first continuous bead of plastics material around the first electrical wire such that the first extruded bead comprises the first electrical wire at a first location within a cross-section of the first extruded bead.
Cooling the bead to prevent wire migration
Cooling the first extruded bead sufficiently to cool the plastics material adjacent the first location within the cross-section of the first extruded bead to prevent migration of the first electrical wire away from the first location.
Re-heating the bead so outer surface portions become molten
Re-heating the first extruded bead sufficiently to cause outer surface portions of the plastics material of the first extruded bead to become molten.
Winding the bead to form a support helix incorporating the wire
Helically winding the first extruded bead onto and about an external surface of the wall of the hose formed from the helical winding of the extruded web to provide the wall a first support helix that incorporates the first electrical wire.
The claim coverage centers on forming a hose wall from a helically wound extruded plastics web and incorporating embedded electrical wires by extruding and cooling a plastics bead around a wire at a defined cross-sectional location, re-heating to make only outer surface portions molten, and then helically winding the bead onto an external surface to form a support helix that incorporates the wire.
Stated Advantages
Prevents migration of the electrical wire away from a first location within the cross-section of the extruded bead.
Causes bonding of outer surface portions of the plastics material by re-heating so outer surface portions become molten.
Avoids melting adjacent interior material at the embedded wire location by cooling and controlled re-heating that targets outer surface portions.
Documented Applications
Heated respiratory hose assemblies for ventilator and CPAP use.
Inspiratory hose assemblies and expiratory hose assemblies with heating loop control for different temperatures.
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