Partial-Heated Whip Hose Layout for Flexibility and Wear Reduction
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Solution Overview
Problem
Conventional heated whip hoses are heavier, less durable, and less flexible due to the full-length extension of heating elements, which leads to increased wear and failure, especially near the hand-held sprayer where bending occurs.
Innovation Solution
A multi-layered whip hose design with a partial heating element length and an unheated section to reduce stiffness and weight, eliminating the heating element from high-bending areas and positioning electrical connections near the main hose connection to minimize wear and improve safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a full-length heating element is used in the whip hose, then thermal performance is maintained, but the hose becomes heavier, less flexible, and more prone to failure
Solution Approach 1:
The heating element is segmented into a partial-length configuration rather than extending the full length of the hose. The heated section is positioned only where thermal maintenance is critical (near the fluid source), while the distal portion remains unheated, reducing overall weight and improving flexibility without compromising essential thermal performance.
Solution Approach 2:
The heating function is applied locally only to the section of the hose where it is most needed (proximal section near the fluid source), rather than uniformly across the entire hose length. This localized heating approach maintains temperature where critical while reducing material usage and weight in less critical areas.
2Temperature
If a full-length heating element is used in the whip hose, then thermal performance is maintained, but the hose becomes less flexible
Solution Approach 1:
The hose is divided into heated and unheated sections, with the heating element confined to the proximal portion. The unheated distal section has fewer structural constraints and materials, allowing it to bend and flex more easily during operation without the rigidity imposed by a full-length heating element assembly.
Solution Approach 2:
Flexibility is enhanced locally in the unheated distal section by omitting the heating element and associated insulation layers, allowing this section to provide the necessary flexibility for hand-held sprayer operation while the proximal heated section maintains structural integrity for thermal function.
3Temperature
If a full-length heating element is used in the whip hose, then thermal performance is maintained, but durability decreases due to increased wear and failure
Solution Approach 1:
The heating element is extracted from the high-wear distal section of the hose where it would be most susceptible to failure from bending and mechanical stress. By positioning the heating element only in the more stable proximal section, the design removes the vulnerable combination of heating elements and flexible hose from the high-stress zone, significantly improving durability.
Solution Approach 2:
Instead of placing the heating element where it is most needed for operation (at the distal end near the sprayer), the design inverts the conventional approach by positioning it at the proximal end near the fluid source. This inversion places the heating element in a lower-stress environment while still achieving thermal performance through conductive heating of the fluid.
4Temperature
If electrical connections are positioned at the hand-held sprayer, then heating function is provided, but wear and failure increase due to bending
Solution Approach 1:
Electrical connections are extracted from the high-wear distal end (hand-held sprayer area) and repositioned to the proximal end near the fluid source. This removes the electrical connection points from the zone of maximum bending and mechanical stress, preventing wire fatigue and connection failure while maintaining the heating function through the repositioned heating element.
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
The design enhances durability, flexibility, and safety by reducing heat loss and wear, while maintaining thermal performance and ease of use, offering improved performance over conventional thermoplastic designs.
Implementation Method 1
heating elements configured to heat the fluid or maintain a temperature of a fluid received from the main hose
Implementation Method 2
an outer layer of thermal insulation so that a helically-shaped air passage is formed between adjacent spaced helical turns of the heating tape
Data Source
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AI summary
A heated whip hose (10) includes a hose core (12) configured to deliver a fluid, a heating element (16) disposed around the hose core, a protective layer (20) disposed around the heating element and hose core, an insulating layer (22) disposed around the protective layer, and an abrasion protection layer (26) disposed around insulating layer and forming an outer sheath.