Extreme coolant hose assembly with heater system for covering heating

Abstract

A hose assembly includes an inner hose core (12), an insulating layer (16) positioned radially outward with respect to the inner hose core, a resistive element (20) positioned radially outward with respect to the insulating layer, and a cladding layer (24) positioned radially outward with respect to the insulating layer.

Description

Technical Field

[0001] The present application relates generally to heated hoses and, more particularly, to heated hose configurations for use in extreme coolant applications in a manner that prevents condensation on the outer hose covering. Background Art

[0002] Traditional electrically heated hoses are made by wrapping an electrical conductor around an inner hose tube and then enclosing the wrapped tube in a jacket or hose sheath. In many applications employing heated hoses, the inner hose tube is reinforced with a fiber or aramid braid, and the braided inner hose tube is covered with a polyurethane sleeve or hose sheath. To heat the hose, before enclosing it in the hose sheath, the inner hose tube is wrapped with conductive wiring. This wiring is located between the reinforcement layer and the hose sheath and typically consists of flat copper wire, which can be solid ribbon or braided strands. The conductive wiring acts as a resistive heating element, whereby, when electrically connected to an input power source, heat is generated by the current flowing through it. In the low-temperature operating conditions typical of common heated hose applications, a primary concern is preventing the working fluid flowing through the inner hose tube from freezing due to the cold external environment. In such applications, heat conduction from the conductive wiring inwardly into the inner hose tube helps prevent the working fluid from freezing in relatively cold ambient or external conditions.

[0003] In contrast, the present disclosure is applicable to applications of hose assemblies that utilize extreme coolants, which flow through the hose inner tube and have a temperature colder than at least -50°C. In one major application, for example, semiconductor chip manufacturing utilizes extreme heat to maintain the proper flow of process gases. Chillers are used to help regulate the environment required for the production process using the coolant pumped through the hose assembly. The coolant used in such conventional semiconductor chip manufacturing systems is at extremely low temperatures, as low as -50°C to -60°C, and with advances in semiconductor chip manufacturing, even colder coolant temperatures, below -70°C to approximately -90°C, are being used. For applications utilizing extreme coolants operating at such substantially negative temperatures, there is no concern about heating the working fluid, which can occur under more common ambient conditions. Therefore, conductive heater wiring has not been employed for extreme coolant applications because conventional heated hoses are not considered beneficial in such applications.

[0004] To operate in these essentially negative temperature conditions, conventional extreme coolant hose assemblies typically surround the hose inner tube with a suitable insulating layer, such as an aerogel-impregnated insulating material. This insulating layer helps maintain the coolant at the desired extreme low-temperature conditions. However, a problem arises for more modern semiconductor chip manufacturing systems operating at coolant temperatures reaching approximately -70°C or below. Under these lower coolant temperature conditions, the aerogel-impregnated insulating material used in conventional hose assemblies is insufficient to prevent significant cooling of the hose outer covering of the hose assembly. As a result, the external temperature at the hose covering surface can drop below the ambient dew point of the surrounding environment, causing condensation as water or frost to form on the outer surface of the hose covering. This condensation can, in turn, cause water to leak from the hose covering onto the floor or other equipment near the hose assembly, posing a danger to workers and potentially damaging electronic equipment. Condensation can also occur when two or more conventional cold hose assemblies are bundled together, a common occurrence in semiconductor chip manufacturing systems. The bundled hose assemblies exposed to extreme low-temperature conditions cause each other's surfaces to become colder than if each individual hose assembly in the bundle were isolated and exposed only to ambient conditions. Summary of the Invention

[0005] Therefore, there is a need in the art for an extreme low-temperature hose assembly capable of providing coolant flow at a temperature below approximately -70°C without condensation formation as occurs with conventional cryogenic hose assemblies. In an exemplary embodiment, the hose assembly is configured as a multi-layer structure that includes an inner hose core and may also include a reinforcement layer wrapped around or positioned radially outward of the inner hose core. The hose assembly also includes an insulation layer positioned or wrapped radially outward of the inner hose core to provide insulation, thereby helping to maintain the system coolant flowing within the inner hose core at a desired temperature level, which is particularly important when maintaining the temperature of extremely cold coolant fluids. The hose assembly also includes a resistive element positioned or wrapped radially outward of the insulation layer. The hose assembly also includes a covering layer, which is also positioned radially outward of the insulation layer. The resistive element may be positioned between the insulation layer and the covering layer, or radially outward of the covering layer.

[0006] The resistive element provides a low level of heating to the cover, which prevents condensation in the form of water or frost from forming on the radially outer surface of the cover. For example, the resistive element can provide a low level of heat to the cover sufficient to raise the temperature of the outer surface of the cover by approximately 5°C to 17°C, which is sufficient to ensure that the radially outer surface temperature of the cover is above the ambient dew point in typical extreme coolant applications. The resistive element can be configured as a wound spiral or braided wiring. Because the resistive element provides a relatively low level of heating and because the resistive element is positioned or wrapped radially outwardly relative to the insulation layer, the heat generated by the resistive element is blocked by the insulation layer from conducting to the inner hose core, which could otherwise cause undesirable heating of the inner hose core. In this way, in contrast to conventional heated hose assemblies that operate to heat the inner hose core and the working fluid, in the heated hose assembly of the present disclosure, the outer hose cover is heated while heat is prevented from entering the inner hose core and the coolant. Furthermore, the heat provided to the cover by the resistive element allows multiple hose assemblies to be bundled together without causing condensation.

[0007] Thus, one aspect of the present invention is a hose assembly having a heater arrangement configured to heat a hose cover to prevent condensation on a radially outer surface of the hose cover. In an exemplary embodiment, the hose assembly includes: an inner hose core; an insulation layer positioned radially outward relative to the inner hose core; a resistive element positioned radially outward relative to the insulation layer; and a cover layer positioned radially outward relative to the insulation layer.

[0008] In another exemplary embodiment, the hose assembly may further include a thermal barrier layer radially located between the insulation layer and the resistive element. The thermal barrier layer is made of a heat-reflective material that reflects heat to direct radiant heat from the resistive element toward the cover layer while preventing heat from entering the insulation layer, which could otherwise cause undesirable heating of the inner hose core. This results in improved efficiency in heating the cover layer, as substantially all of the heat generated by the resistive element is directed toward heating the cover layer.

[0009] In another exemplary embodiment, the hose assembly may further include a second thermal barrier layer located radially outward of the resistive element and between the resistive element and the cover layer.

[0010] In another exemplary embodiment, the hose assembly may further include a reinforcement layer positioned radially outwardly relative to the inner hose core for improving the pressure bearing capacity of the inner hose core.

[0011] In another exemplary embodiment, the hose assembly may further include an electromagnetic interference (EMI) shield positioned radially outwardly relative to the resistive element. The EMI shield may be used in certain applications where it is necessary to protect the resistive element from EMI sources to prevent interference with the operation of the resistive element.

[0012] In another exemplary embodiment, the thermal barrier layer is a helix wrapped around the insulating layer.

[0013] In another exemplary embodiment, the thermal barrier layer comprises aluminum foil, a metal coating film, or a metallized One or more membranes.

[0014] In another exemplary embodiment, the resistive element is radially located between the insulating layer and the cover layer.

[0015] In another exemplary embodiment, the resistive element is positioned radially outwardly relative to the covering layer.

[0016] In another exemplary embodiment, the resistive element is configured to provide heat to the cover layer to a degree sufficient to raise the temperature of the radially outer surface of the cover layer by 5°C to 17°C.

[0017] In another exemplary embodiment, the resistive element is configured to provide heat to the cover layer to a degree sufficient to raise the temperature of the radially outer surface of the cover layer by an amount sufficient to be above the ambient dew point temperature.

[0018] In another exemplary embodiment, the resistive element is configured as a wound spiral wiring that is spirally wrapped radially outwardly with respect to the insulating layer.

[0019] In another exemplary embodiment, the wound spiral wiring includes at least one pair of wires in 180° opposite spiral orientations.

[0020] In another exemplary embodiment, the resistive element is configured as a braided wiring wrapped radially outwardly relative to the insulating layer.

[0021] In another exemplary embodiment, the resistive element has a nominal resistance of 0.6-15 ohms per meter corresponding to a desired output power of 15-75 watts for operation in a constant voltage, low current input power system.

[0022] In another exemplary embodiment, the resistive element has a nominal resistance of approximately 0.3-1.0 ohms per meter corresponding to a desired output power of 15-75 watts for operation in a constant current low voltage input power system.

[0023] In another exemplary embodiment, the reinforcement layer is wrapped around the inner hose core radially outwardly relative to the insulation layer.

[0024] In another exemplary embodiment, the reinforcement layer includes one or more of a stainless steel braid material or aramid fibers.

[0025] In another exemplary embodiment, the EMI shielding layer is configured as a foil layer wrapped radially outwardly relative to the resistive element.

[0026] In another exemplary embodiment, the EMI shielding layer is applied radially outward relative to the resistive element and radially inward relative to the cover layer.

[0027] In another exemplary embodiment, the inner hose core is a tube comprising one or more of polytetrafluoroethylene (PTFE), corrugated metal, or linear low density polyethylene (LLDPE).

[0028] In another exemplary embodiment, the insulation layer comprises a PTFE-based or silica-based aerogel insulation material infused into a base matrix comprising one or more of glass fibers, a mat, or a fiber matrix.

[0029] In another exemplary embodiment, the insulating layer comprises a strip of insulating material helically wrapped radially outwardly relative to the inner core tube.

[0030] In another exemplary embodiment, the spiral wrap configuration of the insulation layers is applied with a 50% overlap to provide a uniform double layer of insulation along the longitudinal length of the inner hose core.

[0031] In another exemplary embodiment, the cover layer is an elastomer comprising one or more of silicone, thermoplastic polyurethane, or thermoplastic vulcanizate (TPV), having a flexural modulus less than 30,000 psi, and an elongation at break greater than 300%.

[0032] In another exemplary embodiment, the hose assembly may further include a first shield surrounding the first end of the hose assembly; wherein the resistive element includes leads electrically connected to the wiring of the resistive element, the leads extending through a channel formed through an outer wall of the first shield for connection to an external input power source; and a set of first wiring connections positioned internally within the first shield and electrically connecting the leads to the wiring of the resistive element.

[0033] In another exemplary embodiment, the hose assembly may further include a second shroud surrounding a second end of the hose assembly opposite the first end, and a second wiring connection positioned internally within the second shroud and electrically connecting opposite elements of the wiring of the resistive element to each other.

[0034] In another exemplary embodiment, the first shroud is configured as a first clamshell that attaches the hose assembly to a first hose fitting for communicating fluid to or from the hose assembly.

[0035] In another exemplary embodiment, the second shroud is configured as a second clam shell that attaches the hose assembly to a second hose fitting for communicating fluid to or from the hose assembly.

[0036] To achieve the above-mentioned and related ends, the present invention includes the features fully described below and particularly pointed out in the claims. The following description and accompanying drawings set forth in detail certain illustrative embodiments of the present invention. However, these embodiments are merely indicative of some of the various ways in which the principles of the present invention may be employed. Other objects, advantages, and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a first embodiment of the present disclosure.

[0038] Figure 2 is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a second embodiment of the present disclosure.

[0039] Figure 2A is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a variation of the second embodiment of the present disclosure.

[0040] Figure 3 is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a third embodiment of the present disclosure.

[0041] Figure 4 is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a fourth embodiment of the present disclosure.

[0042] Figure 5 is a drawing illustrating a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a fifth embodiment of the present disclosure.

[0043] Figure 6 is a drawing depicting a partially cut-away longitudinal elevation view of an exemplary heated hose assembly showing the various layers of the hose assembly according to a sixth embodiment of the present disclosure.

[0044] Figure 7 is a schematic drawing illustrating a first configuration of wiring for electrically connecting a resistance element to an external power supply line.

[0045] Figure 8 is a schematic drawing showing the internal wiring of the opposite element for the resistor element, Figure 7 The first wiring configuration is opposite to a second wiring configuration for wiring the resistor element on an opposite end of the hose assembly. DETAILED DESCRIPTION

[0046] The embodiments of the present disclosure will now be described with reference to the accompanying drawings, wherein like reference numerals are used to refer to like elements throughout. It will be understood that the drawings are not necessarily to scale.

[0047] Embodiments of the present disclosure provide an enhanced configuration of an extreme low-temperature hose assembly capable of providing coolant flow having a coolant temperature below approximately -70°C, down to -90°C or below, without condensation formation as experienced with conventional low-temperature hose assemblies. To prevent condensation, the hose assembly includes a resistive element positioned or wrapped radially outwardly relative to the insulation layer, such that the resistive element operates to heat the outer covering of the hose assembly without heating the inner hose core. By heating the covering of the hose assembly, the radially outer surface of the covering is maintained at a temperature above the ambient dew point temperature, thereby preventing condensation from forming on such outer surface of the covering. Embodiments of the hose assembly are therefore particularly well-suited for use in advanced semiconductor chip manufacturing systems or in other applications that utilize similar extreme low-temperature coolant flow.

[0048] Figure 1 is a drawing depicting a partially cutaway longitudinal elevation view of an exemplary heated hose assembly 10 showing the various layers of the hose assembly according to a first embodiment of the present disclosure. As used in this disclosure, the terms "inner" and "outer" generally refer to relative radial positions from a central longitudinal axis (indicated by the double-arrowed line) of the hose assembly 10. Figure 1 In the embodiment depicted in FIG, the hose assembly 10 is configured as a multi-layer structure that includes an inner hose core 12 and may also include a reinforcement layer 14 wrapped around the inner hose core 12 or otherwise positioned radially outward relative to the inner hose core 12. The inner hose core 12 is the innermost component of the hose assembly and carries the system working fluid, such as, for example, an extreme coolant material. The reinforcement layer 14 may optionally be employed to reinforce the inner hose core 12 to enhance the pressure-bearing capacity of the inner hose core, as may be encountered in certain applications.

[0049] The hose assembly 10 also includes an insulation layer 16 positioned or wrapped radially outwardly relative to the inner hose core 12 to provide insulation to help maintain the system coolant flowing within the inner hose core at a desired cryogenic temperature, which is particularly important when maintaining extremely cold coolant fluid temperatures. The hose assembly 10 also includes a resistive element 20 positioned or wrapped radially outwardly relative to the insulation layer 16. The hose assembly also includes a covering layer 24, which is also positioned radially outwardly relative to the insulation layer 16. The covering layer 24 protects the reinforcement layer 14 and the inner hose core 12 from environmental conditions and abrasion. Figure 1 In the exemplary configuration, the resistive element 20 is radially located between the insulating layer 16 and the cover layer 24 .

[0050] The resistive element 20 provides a low level of heating to the cover 24, which prevents condensation in the form of water or frost from forming on the radially outer surface of the cover 24. For example, the resistive element may provide a low level of heat to the cover that is sufficient to raise the temperature of the radially outer surface of the cover 24 by approximately 5°C to 17°C, which is sufficient to ensure that the outer surface temperature of the cover is above the ambient dew point temperature in typical extreme coolant applications. Because the radially outer surface temperature of the cover 24 is maintained above the ambient dew point temperature, condensation does not form on such outer surface of the cover. Because the resistive element 20 provides a relatively low level of heating, and because the resistive element 20 is positioned or wrapped radially outwardly relative to the insulation layer 16, the heat generated by the resistive element 20 is blocked by the insulation layer 16 from being conducted to the inner core tube 12, which could otherwise cause undesirable heating of the inner hose core and the coolant. In this manner, in contrast to conventional heated hose assemblies that operate to heat the inner hose core and the working fluid, in the heated hose assembly of the present disclosure, the outer hose covering is heated while heat is prevented from entering the inner hose core and the coolant. Furthermore, the heat provided to the covering 24 by the resistive element 20 allows multiple hose assemblies to be bundled together without causing condensation.

[0051] The inner hose core 12 may be a polytetrafluoroethylene (PTFE) tube having a minimum operating temperature of -70°C or lower, preferably down to at least -90°C or lower. The exact material used may be selected based on the requirements of any particular application and the associated temperature range. Other materials that may be used for the inner hose core 12 used in extreme cold coolant applications include, but are not limited to, one or more of a corrugated metal (e.g., stainless steel) core tube, linear low-density polyethylene (LLDPE), or other cryogenically resistant materials. The reinforcement layer 14 may be a stainless steel braid, however, other suitable reinforcement materials may be used, including aramid fibers, as appropriate for any particular application.

[0052] The insulating layer 16 may be a silica based aerogel insulating material which is typically infused into some base matrix such as, for example, PTFE, fiberglass or otherwise into a mechanically sound fabric, felt or fiber matrix or a polyester / polyethylene fiber matting matrix as is known in the art. Figure 1 As shown in the example depicted in FIG, a strip of insulation material 16 is helically wrapped onto the radially outer surface of the inner member of the hose assembly, which includes the combination of the inner core 12 and the optional reinforcement layer 14 (if present). This helically wrapped configuration can be applied with a 50% overlap to provide a substantially uniform double layer of insulation material along the longitudinal length of the inner hose core 12. Other materials may also be used for the insulation layer 16, as may be appropriate for a particular application, such as, for example, fiberglass insulation.

[0053] exist Figure 1 In the exemplary embodiment, the resistive element 20 is configured as a wound spiral wire radially located between the insulating layer 16 and the covering layer 24. The resistive element 20 can be at least a pair of copper, aluminum, conductive carbon fiber, specialty resistance alloy, or other wires 21, 22 oriented in 180° opposite spirals, each of which can be coated with plastic and helically wound around the insulating layer 16. In the exemplary embodiment, the resistive element 20 is uniformly applied to the hose assembly 10.

[0054] There are two main types of input power systems known in the art for use with heated hose systems: constant voltage systems and constant current systems. In the more common constant voltage system, the voltage input is constant, and the resistive element is configured at the time of manufacture to have a predetermined nominal resistance per length to achieve the desired output power matched to the constant voltage input. In a constant current system, the voltage input is variable, and therefore the output power is not fixed based on the manufactured nominal resistance per length of the electrical heating element. Instead, the voltage level is adjusted based on the resistance per length of the resistive heating element to achieve a constant current corresponding to the desired total output power.

[0055] Accordingly, potential input power systems for the hose assembly 10 include constant current with varying voltage and constant voltage with varying current. As a suitable example for operation in a constant current, low voltage system, the resistive element may have a nominal manufacturing resistance of approximately 0.3-1.0 ohms per meter. For example, if the resistive element is manufactured with a nominal resistance of 0.6 ohms per meter for use in a 5 amp constant current system, a suitable output power of 15-75 watts can be achieved by adjusting the input voltage level. As a suitable example for operation in a constant voltage, low current system, the resistive element may have a nominal manufacturing resistance of approximately 0.6-15 ohms per meter, corresponding to a similar desired output power of 15-75 watts for a given constant input voltage, depending on the voltage level of the constant voltage power supply. The following chart illustrates example parameters of resistive element characteristics that match the electrical operating parameters (voltage and current) and result in a calculated total output power within the range of 15-75 watts. It will be understood that the examples in the following chart are non-limiting, and the various parameters can be adapted to suit any specific application.

[0056] Example 1: Constant 5 amp system with 15 watts per meter of hose heating

[0057]

[0058] Example 2: Constant 15 Volt System with 15 Watts per meter of Hose Heating

[0059]

[0060] The cover layer 24 may be a low-temperature resistant elastomer comprising one or more of silicone, thermoplastic polyurethane, or thermoplastic vulcanizate (TPV), having a flexural modulus of less than 30,000 psi and an elongation at break greater than 300%. Other materials may also be used for the cover layer 24 as may be appropriate for a given application.

[0061] As mentioned above, the level of heat provided by the resistive element 20 is set to a level sufficient to heat the cover 24 sufficiently to prevent condensation, but generally low enough so that the insulation layer 16 prevents heat from entering the inner hose core 12. In some cases, it may be necessary to operate the resistive element at a level where it is desired to provide further thermal protection to the inner hose core in addition to the conventional insulation layer.

[0062] Figure 2 is a drawing depicting a partially cutaway longitudinal elevation view of an exemplary heated hose assembly showing the different layers of the hose assembly according to a second embodiment of the present disclosure that provides additional thermal protection for the inner hose core and enhanced heating of the outer cover to prevent condensation. Figure 2 An example is in Figure 1 The present invention is a variation of the embodiment of the present invention, and therefore similar parts are identified with similar reference numerals. Figure 2 In the example shown, the hose assembly 10 may further include a thermal barrier layer 18 radially located between the insulating layer 16 and the resistive element 20 to provide further thermal protection for the inner hose core 12 .

[0063] The thermal barrier layer 18 is made of a heat reflective material that works to reflect and direct radiant heat from the resistor element toward the covering while preventing the heat from entering the insulation layer, which could otherwise cause undesirable heating of the inner hose core 12 and coolant. The result is an increased efficiency in heating the covering because substantially all of the heat generated by the resistor element is directed toward heating the covering. Additionally, the thermal barrier layer 18 works to better distribute the heater wire energy of the resistor element 20 across the entire inner surface of the covering 24 to prevent additional condensation that might otherwise occur between the resistor element wiring and the hose surface. Thus, with the thermal barrier layer 18, heat is better distributed and condensation is not generated under the cold operating temperature and energy conditions of the resistor element. The thermal barrier layer 18 can be an aluminum foil that is spirally wrapped around the insulation layer 16 or otherwise positioned radially outwardly relative to the insulation layer 16. Other materials can also be used for the thermal barrier layer 18 as would be appropriate for a given application, such as, for example, but not limited to, a metal coating film or a metallized or one or more of other impermeable membranes.

[0064] Figure 2A is a drawing depicting a partially cutaway longitudinal elevation view of an exemplary heated hose assembly showing Figure 2 The different layers of the hose assembly of the second embodiment of the variation. Figure 2A In a variation of , the thermal barrier layer is located radially inwardly and also radially outwardly of the resistor element. Figure 2A A first thermal barrier layer 18a is depicted as being radially inward of the resistive element 20, and a second thermal barrier layer 18b is depicted as being radially outward of the resistive element 20 and between the resistive element and the coating. Sandwiching the resistive element between the two thermal barrier layers enhances the effectiveness of the heat distribution of the heat generated by the resistive element for better heat distribution applied to the coating.

[0065] Figure 3-6 The heated hose assembly 10 is shown in FIG. Figure 1 and Figure 2 For simplicity, not every potential combination of individual features is shown in the figures, but it will be understood that different individual features may be mixed and matched in any combination of one or more such variations as may be appropriate for any particular application.

[0066] As a potential variation, the resistive element may be configured as a braided wiring 20a instead of a wound helical wire 20, as in, for example, Figure 3 The braided wiring 20a is also shown in FIG. Figure 4 18 is shown in combination with the thermal barrier layer 18. In the above example, the resistive element 20 / 20a is specifically positioned radially inwardly relative to the coating 24 and radially outwardly relative to the insulating layer 16. In another exemplary embodiment, the resistive element may be positioned radially outwardly relative to the outer surface of the coating 24 or around the outer surface of the coating. For example, Figure 5 The use of an outer braided resistive element 20a positioned and wrapped radially outwardly relative to the cover 24 is illustrated. As mentioned above, individual features may be mixed and matched as may be appropriate for a given application. For example, in Figure 5 In one embodiment, the outer braided resistive element 20a is used in combination with the thermal barrier layer 18, while in another example, the thermal barrier layer may not be included. In addition, the resistive element configured as a wound wiring can also be applied around the radially outer surface of the cover layer or radially outward relative to the radially outer surface of the cover layer.

[0067] In another exemplary embodiment, the hose assembly may further include an electromagnetic interference (EMI) shielding layer positioned radially outwardly relative to the resistive element. The EMI shielding layer may be used in certain applications where it is necessary to protect the resistive element from EMI sources to prevent interference with the operation of the resistive element and to prevent any EMI generated by the resistive element from interfering with the operation of nearby processing equipment. The EMI shielding layer may be configured as a foil layer that is wrapped around the resistive element or otherwise applied radially outwardly relative to the resistive element. For example, Figure 6 Illustrated is the use of an EMI shielding layer 28 applied radially outward relative to the resistive element 20 and radially inward relative to the cover layer 24. As indicated in relation to other features, the EMI shielding layer may be used or mixed and matched with other variations (such as, for example, with the resistive element 20a constructed in a braided configuration, or with or without the thermal barrier layer 18) or other combinations of features.

[0068] Figure 7FIG2 is a schematic diagram illustrating a first configuration for wiring the resistive element 20 (or 20a) to an external power supply. The hose assembly 10 may also include a first shroud 32 that surrounds the first end 30 of the hose assembly 10. The first shroud 32 may be configured as a clamshell that attaches the hose assembly 10 to a first hose fitting 34 for communicating fluid to or from the hose assembly 10. The resistive element 20 also includes electrical leads 36 and 37 that are electrically connected to an external or remote input power source (not shown), and the electrical leads 36 and 37 are threaded or otherwise extended through a passage formed through the outer wall of the first shroud 32. The electrical leads 36 and 37 from the input power source are electrically connected to the coils 21 and 22 of the resistive element 20, respectively, at a set of first wiring connections 38 and 39 located within the interior of the first shroud 32. It will be understood that while the wiring is illustrated in connection with a coiled wire configuration of the resistive element, a similar wiring configuration may also be employed in connection with a braided wire configuration of the resistive element.

[0069] Figure 8 is a schematic drawing showing the internal wiring of the opposite element for the resistor element relative to Figure 7 The second wiring configuration of the resistor element 20 (or 20a) is connected to the opposite end of the hose assembly from the first wiring configuration. The second wiring configuration corresponds to the internal connection of the spiral wires 21 and 22 of the resistor element 20 at the second end of the hose assembly opposite to the first end of the hose assembly supplying power. Figure 8 As shown in , the hose assembly 10 includes a second shroud 42 that surrounds the second end 40 of the hose assembly 10. The second shroud 42 may also be configured as a clamshell element that attaches the hose assembly 10 to a second hose fitting 44 for communicating fluid to or from the hose assembly 10. In a second wiring configuration, the helical wires 21 and 22 of the resistive element 20 are wired to each other at a second wiring connection 48 located inside the second shroud 42. As shown in Figure 7 In the previous wiring configuration, for Figure 8 It will be appreciated that although the wiring shown is associated with a spiral wire configuration of the resistor element, a similar wiring configuration may be employed in association with a braided wire configuration of the resistor element.

[0070] Although the present invention has been shown and described with respect to one or more specific embodiments, it is apparent that, after reading and understanding this specification and the accompanying drawings, other technical personnel in the art will think of equivalent changes and modifications. In particular, with respect to the various functions implemented by the above-mentioned elements (components, assemblies, devices, compositions, etc.), unless otherwise stated, the terms used to describe such elements (including references to "apparatus") are intended to correspond to any element (i.e., functional equivalents) that implement the specified functions of the elements, even if they are not structurally equivalent to the disclosed structures that implement the functions in one or more exemplary embodiments of the present invention described herein. In addition, although the specific features of the present invention may be described above for only one or more of several illustrative embodiments, such features may also be combined with one or more other features of other embodiments, as would be desirable and advantageous for any given or specific application.

Claims

1. A hose assembly comprising: Inner hose core, an insulating layer positioned radially outwardly relative to the inner hose core; a resistive element positioned radially outwardly relative to the insulating layer; as well as A covering layer positioned radially outwardly relative to the insulating layer.

2. The hose assembly of claim 1 , further comprising a thermal barrier layer located radially between the insulating layer and the resistive element, the thermal barrier layer being made of a heat reflective material that reflects and directs radiant heat from the resistive element toward the cover layer while preventing the heat from entering the insulating layer.

3. The hose assembly according to claim 2, wherein: The thermal barrier layer is helically wrapped around the insulation layer.

4. The hose assembly according to any one of claims 2 to 3, wherein: The thermal barrier layer comprises aluminum foil, metal coating film or metallized One or more membranes.

5. The hose assembly according to any one of claims 2 to 4, further comprising a second thermal barrier layer located radially outward of the resistive element and between the resistive element and the cover layer.

6. The hose assembly according to any one of claims 1 to 5, wherein: The resistive element is radially located between the insulating layer and the covering layer.

7. The hose assembly according to any one of claims 1 to 5, wherein: The resistive element is positioned radially outwardly relative to the coating.

8. The hose assembly according to any one of claims 1 to 7, wherein: The resistive element is configured to provide heat to the covering layer to an extent sufficient to increase the temperature of the radially outer surface of the covering layer by 5°C to 17°C.

9. The hose assembly according to any one of claims 1 to 8, wherein: The resistive element is configured to provide heat to the cover layer to a degree sufficient to raise the temperature of the radially outer surface of the cover layer by an amount sufficient to be above the ambient dew point temperature.

10. The hose assembly according to any one of claims 1 to 9, wherein: The resistance element is configured as a wound spiral wiring spirally wrapped radially outwardly with respect to the insulating layer.

11. The hose assembly according to claim 10, wherein The wound spiral wiring includes at least one pair of wires oriented in 180° opposite spirals.

12. The hose assembly according to any one of claims 1 to 9, wherein: The resistive element is configured as a braided wiring wrapped radially outwardly with respect to the insulating layer.

13. The hose assembly according to any one of claims 1 to 12, wherein: The resistive element has a nominal resistance of 0.6-15 ohms per meter corresponding to a desired output power of 15-75 watts for operation in a constant voltage, low current input power system.

14. The hose assembly according to any one of claims 1 to 12, wherein: The resistive element has a nominal resistance of approximately 0.3-1.0 ohms per meter corresponding to a desired output power of 15-75 watts for operation in a constant current low voltage input power system.

15. The hose assembly of any one of claims 1-14, further comprising a reinforcement layer positioned radially outwardly relative to the inner hose core.

16. The hose assembly of claim 15, wherein: The reinforcement layer is wrapped around the inner hose core at a radially inner portion relative to the insulation layer.

17. The hose assembly according to any one of claims 15-16, wherein: The reinforcement layer includes one or more of stainless steel braided material or polyaramid fiber.

18. The hose assembly of any one of claims 1-17, further comprising an electromagnetic interference (EMI) shielding layer positioned externally relative to the resistive element.

19. The hose assembly of claim 18, wherein: The EMI shielding layer is configured as a foil layer wrapped radially outwardly relative to the resistive element.

20. The hose assembly according to any one of claims 18-19, wherein The EMI shielding layer is applied radially outward relative to the resistive element and radially inward relative to the cover layer.

21. The hose assembly according to any one of claims 1 to 20, wherein: The inner hose core is a tube comprising one or more of polytetrafluoroethylene (PTFE), corrugated metal, or linear low density polyethylene (LLDPE).

22. The hose assembly according to any one of claims 1 to 21, wherein: The insulation layer comprises a PTFE-based or silica-based aerogel insulation material infused into a base matrix comprising one or more of glass fibers, a felt, or a fiber matrix.

23. The hose assembly according to any one of claims 1 to 22, wherein: The insulating layer includes an insulating material strip helically wrapped radially outwardly relative to the inner core tube.

24. The hose assembly of claim 23, wherein: The insulation layers are applied in a spirally wrapped configuration with a 50% overlap to provide a uniform double layer of insulation along the longitudinal length of the inner hose core.

25. The hose assembly according to any one of claims 1 to 24, wherein The cover layer is an elastomer comprising one or more of silicone, thermoplastic polyurethane or thermoplastic vulcanizate (TPV), having a flexural modulus of less than 30,000 psi and an elongation at break greater than 300%.

26. The hose assembly according to any one of claims 1-25, further comprising: a first shroud surrounding the first end of the hose assembly; wherein the resistance element includes a lead wire electrically connected to a wiring of the resistance element, the lead wire extending through a passage formed through an outer wall of the first shield to be connected to an external input power source; and A set of first wiring connections are located inside the first shield and electrically connect the leads to the wiring of the resistance element.

27. The hose assembly of claim 26, further comprising: a second shroud surrounding a second end of the hose assembly opposite the first end; as well as A second wiring connection portion is located inside the second shield and electrically connects opposite elements of the wiring of the resistance element to each other.

28. The hose assembly according to any one of claims 26-27, wherein The first shroud is configured as a first clam shell that attaches the hose assembly to a first hose fitting for communicating fluid to or from the hose assembly.

29. The hose assembly according to any one of claims 27-28, wherein The second shroud is configured as a second clam shell that attaches the hose assembly to a second hose fitting for communicating fluid to or from the hose assembly.

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