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Publication Number
US-11839719-B2
Publication Date
2023-12-12
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, wherein the first electrical wire is positioned at a first location within a cross-section of the bead that comprises a bonding surface; cooling the bead to cool the plastics material adjacent the first location to prevent migration of the first electrical wire from the first location; re-heating the first bonding surface to cause the plastics material of the bonding surface to become molten; and helically winding the bead onto the hose to put the bonding surface into contact with, and to cause bonding with, the wall of the hose.
Core Innovation
The invention provides a heated respiratory hose assembly for delivering respiratory gases between a medical device and a patient, including an inspiratory hose assembly and an expiratory hose assembly. The hose assembly maintains gas temperature to prevent condensation during delivery of respiratory gases. The hose includes heating wires embedded in a support helix formed in relation to the hose wall.
A support helix is manufactured by extruding plastics material around heating wires and forming a plastics bead that includes a bonding surface. The plastics material adjacent the first location within the cross-section of the bead is cooled sufficiently to prevent migration of the electrical wire away from the first location. The bonding surface is then re-heated so the plastics material of the bonding surface becomes molten, and the bonding surface is put into contact with, and then becomes bonded to, the wall of the hose to become a support helix that incorporates the electrical wire.
The invention further includes provisions for sensor-informed operation and installation error reduction. Flow and temperature sensors are described, along with directional features to reduce installation errors. Heating wire electrical connections are arranged to avoid failure-prone transitions between heating and non-heating wire terminations, including electrical connection schemes using plugs that carry connectors and/or pigtail electrical cable portions of the support helix with sheathing.
Claims Coverage
The partial content identifies one independent claim (clm-00001). The inventive features of that claim include a specific hose-forming sequence using extruding a continuous plastics web, incorporating a helically wound plastics bead around an electrical wire, controlling wire location via cooling, selectively bonding via reheating a bonding surface, and forming a support helix by winding onto a hose wall.
Extruding a continuous web and helically winding to form a hose wall
Extruding a continuous web of plastics material from a hose making apparatus and helically winding the extruded web about a mandrel or rotating rod to form a wall of the hose about a central axis.
Feeding an electrical wire and extruding a bead with a bonding surface
Feeding a first electrical wire into a second extruder and extruding a continuous bead of plastics material around the first electrical wire such that the electrical wire is positioned at a first location within the bead cross-section and the bead cross-section defines an exterior portion comprising a bonding surface covering a portion of the exterior.
Cooling to prevent wire migration
Cooling the first extruded bead sufficiently to cool plastics material adjacent the first location within the bead cross-section to prevent migration of the first electrical wire away from the first location.
Re-heating the bonding surface to bond to the hose wall
Re-heating the first bonding surface of the first extruded bead sufficiently to cause the plastics material of the first bonding surface to become molten.
Helically 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 so that the first bonding surface contacts and becomes bonded to the wall of the hose to become a first support helix that incorporates the first electrical wire.
Across the identified independent claim, the inventive coverage centers on forming the hose wall from a helically wound extruded web, forming a plastics bead around an electrical wire with a defined bonding surface, cooling to prevent wire migration, selectively reheating the bonding surface to become molten, and helically winding the bead so the bonding surface bonds to the hose wall to create a support helix incorporating the wire.
Stated Advantages
Prevents condensation by maintaining gas temperature during delivery of respiratory gases.
Prevents failure-prone transitions between heating and non-heating wire terminations in electrical connection schemes.
Reduces installation errors using flow/temperature sensors with directional features.
Documented Applications
Heated delivery of respiratory gases between a medical device and a patient using an inspiratory hose assembly and an expiratory hose assembly.
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