Ventilation Tube Connector Overmolding for Sensor Integration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current manufacturing methods for patient ventilation systems are not suitable for mass production, lacking efficiency in integrating electrical components and ensuring precise temperature measurement within a patient ventilation system.

Innovation Solution

A method involving two overmolding steps to create a connector with integrated electrical connections for a patient ventilation system, using a 2D conductor structure to form a 3D conducting connection, and incorporating a temperature sensor for accurate temperature measurement, with options for other parameter measurement, and utilizing ultrasonic welding for electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing methods are used for patient ventilation systems, then individual component assembly is possible, but mass production efficiency and productivity are insufficient

Engineering Contradiction:

Improvemass production efficiencyVSAvoidintegration complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple components (connector housing, electrical contacts, insulation, and sensor elements) into a single integrated assembly that can be produced in one overmolding process. This merging of previously separate manufacturing steps into a single operation enables mass production while maintaining integration complexity at an acceptable level.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The overmolded assembly serves multiple functions simultaneously: it provides structural housing, electrical connection, insulation, and sensor integration. This multi-functionality reduces the number of separate components needed, thereby improving productivity without significantly increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If electrical components are integrated into the connector, then temperature measurement accuracy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidconnector structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor elements and electrical contacts are nested within the overmolded connector housing. This nesting arrangement integrates temperature measurement functionality into the existing connector structure without requiring separate mounting operations, thereby improving measurement precision while limiting the increase in manufacturing complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The electrical contacts and sensor elements are positioned and prepared within the mold cavity before the overmolding process begins. This preliminary action ensures precise alignment and integration, improving temperature measurement accuracy while avoiding complex post-assembly operations.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple overmolding steps are used to integrate electrical connections, then manufacturing precision is improved, but production time increases

Engineering Contradiction:

Improveelectrical connection precisionVSAvoidproduction cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges multiple overmolding steps into a single integrated overmolding operation that forms the connector housing, electrical contacts, and insulation simultaneously. This combining of steps maintains manufacturing precision through proper mold design while significantly reducing production cycle time compared to sequential multi-step overmolding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single overmolding process is segmented into distinct functional zones (housing formation, contact insertion, insulation application) that occur simultaneously within the same mold cavity. This segmentation allows each function to be optimized for precision while the simultaneous execution maintains short cycle times.

Inventive Principle:

Principle #1Segmentation

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

Enables efficient mass production of patient ventilation system assemblies with integrated electrical components and precise temperature measurement, enhancing production throughput and accuracy within a temperature range of -10°C to 80°C with sub-Kelvin accuracy.

Implementation Method 1

utilizing ultrasonic welding for electrical connections

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS20230302242A1Method for the production of an assembly for a patient ventilation system

Publication Date: 2023.09.28 NEW VENTURES GMBH

AI summary

For the production of an assembly for a patient ventilation system, at least one conducting connection is first prepared between contact pins of a component receptacle of a connector for the insertion of at least one electronic component and sheath wires which are guided along a tube sheath of a breathing air tube portion of the assembly. This prepared conducting connection is overmolded to form an inner conduction carrier housing sleeve of the connector. The conducting connection is connected to the sheath wires and the inner conduction carrier housing sleeve is overmolded to form an outer connector housing of the connector in which the component receptacle is implemented. This results in an assembly manufacturing process that is suitable for mass production.