Over-molded Heated Hose and Fitting Assembly
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Solution Overview
Problem
Existing methods for producing electrically heated hose and fitting assemblies are time-consuming, unreliable, and costly, particularly in providing consistent heating to fluidic fittings at the ends of hoses used in urea injection systems for diesel engines.
Innovation Solution
An electrically heated, over-molded fluidic hose and fitting assembly is created by embedding heating wires within the hose, wrapping them around the fitting, and encapsulating both in a plastic over-mold, which can optionally include a second over-mold layer for enhanced durability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heater cartridges and manual wrapping methods are used, then heating functionality is provided, but manufacturing time increases and reliability decreases
Solution Approach 1:
The patent combines the hose, fitting, and heating wires into a single integrated assembly that is overmolded as one unit. The heating wires are embedded within the hose material before fitting attachment, eliminating the need for separate heater cartridges and manual wrapping steps. This integration resolves the contradiction by achieving reliable heating through unified construction while reducing manufacturing time by eliminating multiple separate operations.
Solution Approach 2:
The heating wires are pre-embedded within the hose material before the fitting is attached. This preliminary positioning ensures proper wire placement and eliminates the need for time-consuming post-assembly adjustments or corrections, thereby improving both reliability and manufacturing efficiency.
2Ease of manufacture
If multiple separate components (hose, fitting, heater cartridge) are used, then heating functionality is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges the hose, fitting, and heating wires into a single integrated assembly. The heating wires are embedded within the hose material, and the fitting is attached directly to the hose end, creating a unified structure that is then overmolded. This eliminates the need for separate heater cartridges and reduces assembly complexity while maintaining heating functionality.
Solution Approach 2:
The hose material serves multiple functions: it provides fluid containment, embeds the heating wires, and forms part of the final overmolded assembly. This multi-functionality reduces the number of separate components needed, simplifying manufacturing and reducing overall device complexity.
3Object-affected harmful factors
If heating wires are exposed or minimally protected, then manufacturing is simpler, but protection against environmental factors is insufficient
Solution Approach 1:
The patent uses a nested structure where the heating wires are embedded within the hose material, which is then covered by an overmold layer. This nested arrangement provides multiple layers of protection against environmental factors while maintaining a relatively simple manufacturing process through the overmolding operation.
Solution Approach 2:
The final assembly consists of composite structure combining the hose material, heating wires, and overmold layer. This composite construction provides enhanced environmental resistance through the combined properties of different materials while being manufactured in an integrated process.
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
This method provides a reliable, cost-effective, and durable heating solution for hose and fitting assemblies, ensuring consistent heating without the need for separate heater cartridges and enhancing resistance to environmental factors.
Implementation Method 1
The heated hose could contain one or more heating wires that heat up when electrical current is passed through them
Implementation Method 2
The over-mold material bonds to the hose jacket and fitting
Data Source
AI summary
A injection mold machine including a polymer injection assembly, a mold comprising an mold injection half and an mold ejection half, the mold injection half of the mold aligned with the injection assembly for operable mating therewith and the mold injection half adapted for removable, operable mating with the mold ejection half of the mold when aligned therewith, the mold injection half and mold ejection half forming a mold cavity when clamped together adapted to over-mold a portion of an elongated article, a shuttle table supporting the mold ejection half movable between a first position and a second position, where the mold ejection half is aligned with the mold injection half in the first position, and a first basket movable with the shuttle table positioned to contain a portion of the elongated article being over-molded.