Injection-Molded Peristaltic Pump Hose with Tight Tolerance
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Solution Overview
Problem
Existing dispensing cartridges for peristaltic pumps require individual adjustment of hose tension forces due to manufacturing method-induced diameter variations, leading to inefficient production and flow rate inconsistencies between hoses.
Innovation Solution
A hose manufactured using an injection molding process with controlled internal cross-sectional area tolerances, allowing for consistent flow rates without individual tension adjustments, and capable of complete closure over a rotor without a hose bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hoses are manufactured by extrusion, then production is simple and cost-effective, but the diameter tolerance is large leading to flow rate inconsistencies
Solution Approach 1:
The patent changes the manufacturing parameter from extrusion to injection molding. This process parameter change enables precise control of the internal cross-sectional area within ±0.5 mm² tolerance, directly resolving the diameter inconsistency problem while maintaining manufacturing efficiency through automated injection molding processes.
Solution Approach 2:
The patent replaces the mechanical extrusion process with an injection molding process. This substitution fundamentally changes how the hose is formed, allowing for precise dimensional control of the internal cross-sectional area without the tolerance issues inherent in extrusion, while still enabling mass production.
2Reliability
If individual tension adjustment is provided for each hose, then flow rate consistency is achieved, but production time and complexity increase
Solution Approach 1:
The injection molded hoses self-regulate flow rate consistency through their precisely controlled internal cross-sectional area. The manufacturing process inherently produces uniform dimensions without requiring post-production tension adjustment, making the system self-sufficient and eliminating the need for individual adjustment mechanisms.
Solution Approach 2:
The patent removes the tension adjustment mechanism entirely from the system. By achieving flow rate consistency through precise manufacturing control rather than mechanical adjustment, the complex adjustment devices are extracted from the design, simplifying the overall system and improving productivity.
3Reliability
If multiple cartridges are attached step-by-step, then proper installation is ensured, but installation time and complexity increase
Solution Approach 1:
The patent merges multiple separate cartridges into a single integrated cartridge assembly. The precisely manufactured hoses enable this integration by ensuring proper fit and function without requiring sequential adjustment of each component, thereby reducing installation steps while maintaining installation correctness.
4Productivity
If hose diameter varies due to manufacturing speed, then production flexibility is maintained, but flow rate uniformity is compromised
Solution Approach 1:
The patent changes the critical manufacturing parameter from diameter (controlled in extrusion) to internal cross-sectional area (controlled in injection molding). This parameter change allows for tighter tolerance control (±0.5 mm²) while maintaining production flexibility through adjustable injection molding parameters such as injection pressure, temperature, and cycle time.
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
Facilitates efficient production and consistent flow rates across hoses, reducing production time and enabling easy replacement, with improved service life and handling due to precise dimensions and material properties.
Implementation Method 1
The hose is produced by an injection molding process and has a suitable tolerance in its internal cross-sectional area
Implementation Method 2
The medium within the hoses is transported by means of peristalsis. This means that due to the deformation of the hose, the medium inside the hose is conveyed specifically in one direction
Implementation Method 3
The hose is suitable to closing completely when stretched over the rotor with a tension force of 1 to 10 N
Data Source
AI summary
Disclosed and described is a hose for attachment to a dispensing cartridge for placement in a peristaltic pump, for stretching over a rotor of the peristaltic pump, and for conveying a medium by external mechanical deformation of the hose. The hose has a length of preferably 20 mm to 200 mm, an internal cross-sectional area of 0.07 to 7.07 mm2, and a wall thickness of 0.3 mm to 2.2 mm. Thickenings are formed at both ends of the hose and the distance between the thickenings is 40 mm to 100 mm. According to the invention, it is provided that the hose is manufactured by an injection molding process, the inner cross-sectional area has a tolerance of at most±33%, and the hose is suitable for closing completely when stretched over the rotor with a tension force of 1 to 10 N.