Method for manufacturing flat hose
By using a production line with a combination of permeation extrusion and winding technology in flat hose manufacturing, the winding layer is set and the adhesive layer is strengthened, which solves the problem that traditional methods cannot produce large-diameter high-pressure hoses, and achieves high pressure and compressive resistance. promote.
Patent Information
- Application Number
- CN202111298062.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2021-11-04
- Publication Date
- 2024-12-20
- Estimated Expiration
- 2041-11-04
AI Technical Summary
Traditional flat hose manufacturing technology cannot produce large diameter and high pressure hose products, and the production of ultra-large diameter products is very difficult. Traditional methods have problems such as hammer dissolution and insufficient compressive resistance.
The flat hose manufacturing method is adopted, including a media conveying layer, an axial tensile layer, annular compressive layer and an outer protective layer from the inside to the outside, and the combined production line of the permeation extruder, winding machine and negative pressure coated extruder is adopted. An circumferential compressive layer of at least two winding layers is provided with opposite winding directions to improve compressive strength, and an adhesive layer is provided between the winding layers to enhance bonding.
The high pressure design of large-diameter hoses is realized, the pressure strength of the annular compressive layer is improved, the use needs in ultra-high pressure environments is met, and the occurrence of dissolution hammer phenomenon is avoided.
Smart Images
Figure CN113977899B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of high-pressure hoses, and in particular to a method for manufacturing a flat hose. Background Art
[0002] Traditional flat hoses are generally used in temporary transportation, firefighting, agriculture and other fields with small diameters and low transportation pressures. The manufacturing method of traditional flat hoses cannot produce large diameter and high pressure hose products. And with traditional production and manufacturing technology, the larger the diameter, the lower the working pressure. Traditional manufacturing technology is generally braided composite or one-time extrusion. The former requires steam bonding through penetration, which requires a fixed length production line and a short hose length. The latter requires the plastic rubber to be infiltrated and extruded into the inner layer. The braided fibers need to reserve gaps, and high pressure cannot be achieved. In addition, for ultra-large diameters, penetration and extrusion will have a more serious melt hammer phenomenon, making normal production very difficult. Summary of the invention
[0003] The object of the present invention is to provide a method for manufacturing a flat hose to solve the above technical problems.
[0004] To achieve the above object, the present invention adopts the following technical solution:
[0005] A method for manufacturing a flat hose,
[0006] The flat hose comprises at least a medium transport layer, an axial tensile layer, a first adhesive layer, an annular pressure-resistant layer and an outer protective layer from the inside to the outside, the annular pressure-resistant layer comprises at least two winding layers in an even number, the winding layers comprise at least one first winding layer and at least one second winding layer, the winding directions of the first winding layer and the second winding layer are opposite, and the number of the first winding layer and the second winding layer is the same;
[0007] The flat hose is produced by a production line, which includes an infiltration extruder, a winding machine, and a negative pressure coating extruder arranged in sequence upstream and downstream, the winding machine includes a first circumferential winding machine and a second circumferential winding machine, the infiltration extruder is used to form a tube blank at one time, the first circumferential winding machine is used to circumferentially wind a first winding layer on the outer periphery of the tube blank, the second circumferential winding machine is used to circumferentially wind a second winding layer on the outer periphery of the tube blank, the winding directions of the first winding layer and the second winding layer are opposite, and the number of the first winding layer and the second winding layer is the same;
[0008] The manufacturing method comprises the following steps:
[0009] S1: weaving the polyester yarn into a cylindrical shape in the direction of the warp and weft to form an axial tensile layer, and passing the axial tensile layer into an infiltration extruder to form a tube blank through infiltration extrusion;
[0010] S2: Winding at least one first winding layer and at least one second winding layer from inside to outside on the outer circumference of the tube blank by a winding machine, wherein the winding directions of the first winding layer and the second winding layer are opposite, and the number of the first winding layer and the second winding layer is the same;
[0011] S3: Using a negative pressure coating extruder to coat the outer circumference of the tube blank wrapped with the first winding layer and the second winding layer, and heating and molding to form the flat hose.
[0012] As a further improvement of the technical solution of the present invention, step S11 is also included after step S1 and before step S2: supporting the inside of the tube blank by an inner mold, correcting the roundness of the tube blank by a roundness correction traction machine on the outside of the tube blank, and then tightening the tube blank by a main traction machine to maintain a certain roundness.
[0013] As a further improvement of the third technical solution of the present invention, the step S2 further includes: winding an adhesive tape around the outer periphery of the first winding layer or the outer periphery of the second winding layer to form an adhesive layer.
[0014] As a further improvement of the technical solution of the present invention, the angle between the first winding layer and the axis of the flat hose is 80°~90°, and the angle between the second winding layer and the axis of the flat hose is 80°~90°.
[0015] As a further improvement of the technical solution of the present invention, a second adhesive layer is provided between the first winding layer and the second winding layer to bond the first winding layer to the second winding layer.
[0016] As a further improvement of the technical solution of the present invention, the first winding layer and the second winding layer are bonded in staggered layers in sequence.
[0017] As a further improvement of the technical solution of the present invention, at least two of the first winding layers are bonded in sequence, at least two of the second winding layers are bonded in sequence, and at least two of the first winding layers are bonded to the outside of at least two of the second winding layers.
[0018] As a further improvement of the technical solution of the present invention, the winding machine also includes an adhesive tape winding machine for winding an adhesive tape around the periphery of each first winding layer or each second winding layer.
[0019] Compared with the prior art, the beneficial effects of the present invention are: the flat hose manufactured by the above-mentioned manufacturing method, the annular pressure-resistant layer of the flat hose is provided with at least one first winding layer and at least one second winding layer, the total number of winding layers is an even number, the first winding layer and the second winding layer are wound in opposite directions, the first winding layer and the second winding layer can be bonded, the annular pressure-resistant layer can be increased according to different pressure designs, thereby improving the pressure strength of the annular pressure-resistant layer. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Figure 1 It is a schematic diagram of the structure of the flat hose of the present invention;
[0021] Figure 2 is an exploded schematic diagram of a flat hose manufacturing apparatus of the present invention;
[0022] Figure 3 It is a partial front view of the winding machine of the present invention;
[0023] Figure 4 is a side view of the winding machine of the present invention;
[0024] Figure 5 is a side view of the osmotic extruder of the present invention;
[0025] Figure 6 It is a side view of the negative pressure coating extruder of the present invention;
[0026] Figure 7 It is a flow chart of the flat hose manufacturing method of the present invention. DETAILED DESCRIPTION
[0027] The exemplary embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings. If there are several embodiments, the features of these embodiments can be combined with each other without conflict. When the description refers to the drawings, unless otherwise specified, the same numbers in different drawings represent the same or similar elements. The contents described in the following exemplary embodiments do not represent all embodiments consistent with the present invention; on the contrary, they are only examples of devices, products and / or methods consistent with some aspects of the present invention as recorded in the claims of the present invention.
[0028] The terms used in the present invention are only for the purpose of describing specific embodiments, and are not intended to limit the scope of protection of the present invention. The singular forms "a", "said" or "the" used in the specification and claims of the present invention are also intended to include plural forms, unless the context clearly indicates other meanings.
[0029] It should be understood that the words used in the specification and claims of the present invention, such as "first", "second" and similar words, do not indicate any order, quantity or importance, but are only used to distinguish the names of features. Similarly, words such as "one" or "an" do not indicate a quantitative limitation, but indicate the existence of at least one. Unless otherwise specified, words such as "front", "rear", "upper", "lower" and similar words appearing in the present invention are only for the convenience of explanation and are not limited to a specific position or a spatial orientation. Words such as "include" or "comprise" are an open-ended expression, meaning that the elements appearing before "include" or "comprise" include the elements appearing after "include" or "comprise" and their equivalents, which does not exclude that the elements appearing before "include" or "comprise" may also include other elements. If "several" appears in the present invention, it means two or more.
[0030] Please refer to Figure 1 The present invention discloses a flat hose, which is a hose with a maximum diameter of more than 600 mm, used for transporting liquid media. The flat hose is cylindrical, and from the inside to the outside, the flat hose includes at least a medium transport layer 1, an axial tensile layer 2, a first bonding layer 3, an annular pressure-resistant layer 4, and an outer protective layer 5. The medium transport layer 1 and the outer protective layer 5 are made of plastic or rubber. The medium transport layer 1 is in contact with the liquid medium. The axial tensile layer 2 is fixed into a grid cylindrical structure through an axial tensile fiber structure woven by a few annular fibers. The strength of the axial tensile structure is much higher than that of the annular fixed structure. The axial fibers mainly provide axial extension force along the pipeline direction and drag force for construction. The first bonding layer 3 is made of an adhesive material that is heated and fused to bond the axial tensile layer 2 to the annular pressure-resistant layer 4.
[0031] Please refer to Figures 1 to 6 The annular pressure-resistant layer 4 includes at least two winding layers of an even number, and the at least two winding layers include at least one first winding layer 41 and at least one second winding layer 42 .
[0032] The angle between the first winding layer 41 and the axis of the hose is 80°~90°, and the angle between the second winding layer 42 and the axis of the hose is 80°~90°, so as to provide circumferential compressive strength. The winding directions of the first winding layer 41 and the second winding layer 42 are opposite, and the number of the first winding layer 41 and the second winding layer 42 is the same to balance the torque. A second adhesive layer is provided between the first winding layer 41 and the second winding layer 42 to bond the first winding layer 41 and the second winding layer 42. This arrangement is used to provide the pressure strength of the circumferential pressure-resistant layer 4. In order to enable the circumferential pressure-resistant layer 4 to provide the pressure-bearing capacity of the hose, the circumferential pressure-resistant layer 4 can be increased according to different pressure designs. In the first embodiment, the first winding layer 41 and the second winding layer 42 are both 1 layer, and the first winding layer 41 is bonded to the second winding layer 42. A second adhesive layer is provided between the first winding layer 41 and the second winding layer 42 to bond the first winding layer 41 and the second winding layer 42.
[0033] In the second embodiment, the first winding layer 41 and the second winding layer 42 are both more than two layers, and the first winding layer 41 and the second winding layer 42 are sequentially staggered and bonded. A second adhesive layer is provided between two adjacent winding layers to bond the two adjacent winding layers.
[0034] In the third embodiment, the first winding layer 41 and the second winding layer 42 are both at least two layers, all the first winding layers 41 are bonded in sequence, all the second winding layers 42 are bonded in sequence, and all the first winding layers 41 are bonded to the outside of at least two second winding layers 42. A second adhesive layer is provided between two adjacent winding layers for bonding the two adjacent winding layers.
[0035] In the above embodiment, the first winding layer 41 and the second winding layer 42 are wound in opposite directions, the first winding layer 41 and the second winding layer 42 have the same number of layers, and the first winding layer 41 and the second winding layer 42 are wound in opposite directions to ensure torque balance. The first winding layer 41 is bonded to the second winding layer 42 by the second adhesive layer, so that the compressive strength of the hose can be improved to meet the use in ultra-high pressure environments.
[0036] The flat hose in this patent application meets the requirements of a maximum outer diameter of more than 600 mm and a working pressure greater than 0.4 MPa. The flat hose itself needs to be folded and stored by winding.
[0037] Please refer to Figures 2 to 5The present invention also discloses a production line for producing the flat hose as described above. The production line includes an infiltration extruder 101, a wrapping machine 102, and a negative pressure coating extruder 103 arranged in sequence upstream and downstream. The wrapping machine 102 includes a first circumferential wrapping machine 1021 and a second circumferential wrapping machine 1022. The infiltration extruder 101 is used to form a tube blank at one time. The first circumferential wrapping machine 1021 is used to circumferentially wrap a first wrapping layer 41 around the outer periphery of the tube blank. The second circumferential wrapping machine 1022 is used to circumferentially wrap a second wrapping layer 42 around the outer periphery of the tube blank. The winding directions of the first wrapping layer 41 and the second wrapping layer 42 are opposite, and the number of the first wrapping layer 41 and the second wrapping layer 42 is the same. The wrapping machine 102 also includes an adhesive tape wrapping machine 107, which is used to wrap an adhesive tape around the outer periphery of each of the first wrapping layers 41 or each of the second wrapping layers 42. A positioning frame 108 is provided between the infiltration extruder 101, the wrapping machine 1021, the adhesive tape wrapping machine 107, and the negative pressure coating extruder 103 to center the tube blank to prevent the tube blank from deforming and ensure that the tube blank always maintains a cylindrical shape in the production line.
[0038] Please refer to Figure 6 The present invention also provides a manufacturing method for producing the flat hose as described above, comprising the following steps:
[0039] S1: Weave the polyester yarn into a cylindrical shape in the direction of the warp and weft to form an axial tensile layer 2, and insert the axial tensile layer 2 into the penetration extruder 101 to form a tube blank by the penetration extrusion process. Specifically, in this embodiment, 30000 denier polyester yarn is selected as the warp of the circular loom 106, and 3000 denier polyester yarn is selected as the weft of the circular loom 106 for weaving. The weft weaving density is designed to be 10 / 10 cm, the number of warp threads is designed to be 3800, and the caliber of the braided belt blank is 1130 mm. After weaving, it is transported to the belt storage and feeding machine for storage. The braided cylindrical object is inserted into the penetration extruder 101 and the mold for penetration extrusion. The outer size of the extrusion core mold is 1130 mm, the inner size of the extrusion die is 1140 mm, the extrusion material is PE, the extrusion temperature is 150℃-200℃, the screw speed is 30 rpm, and the extrusion speed is 1.5 m / min.
[0040] S2: At least one first winding layer 41 and at least one second winding layer 42 are sequentially wound from the inside to the outside on the outer circumference of the tube blank by the winding machine 102. The winding directions of the first winding layer 41 and the second winding layer 42 are opposite, and the number of the first winding layer 41 and the second winding layer 42 is the same. Specifically, the tube blank enters the winding process, and is wound in positive and negative spirals by the first hoop spiral winding machine 1021 and the second hoop spiral winding machine 1022. 48000 denier polyester yarn is selected as the winding material. The first hoop spiral winding machine 1021 sets the winding angle to 88.9°, and the number of winding roots is designed to be 870; the second hoop spiral winding machine 1022 sets the winding angle to 88.8°, and the number of winding roots is designed to be 870. The first hoop spiral winding machine 1021 winds the first winding layer 41. The second hoop spiral winding machine 1022 winds the second winding layer 42. After the winding process is completed, the tube blank is wound with an adhesive tape, and heated and cured to form an adhesive layer. The winding adhesive tape is an acrylic adhesive tape.
[0041] After step S1 and before step S2, step S11 is also included: the inner mold is used to support the inside of the tube blank, the roundness is corrected by the roundness correction traction machine 104 on the outside of the tube blank, and the tube blank is tightened by the main traction machine 105 to maintain a certain roundness.
[0042] After step S11 and before step S2, the method further includes step S12: winding an adhesive tape around the outer circumference of the tube blank to form an adhesive layer.
[0043] S3: The outer periphery of the tube blank wrapped with the first winding layer 41 and the second winding layer 42 is coated by a negative pressure coating extruder 103. The outer protective layer material is PE, the extrusion temperature is 150℃-200℃, the screw speed is 35 rpm, the extrusion speed is 1.5 m / min, and after heating and molding, a flat hose is formed.
[0044] As a further improvement of the present invention, the method further includes step S2: winding an adhesive tape between the first winding layer and the second winding layer to form an adhesive layer.
[0045] To sum up: the annular pressure-resistant layer 4 of the flat hose is provided with at least one first winding layer 41 and at least one second winding layer 42, the total number of winding layers is an even number, the first winding layer 41 and the second winding layer 42 are wound in opposite directions, the first winding layer 41 and the second winding layer 42 can be bonded, and the annular pressure-resistant layer 4 can be increased according to different pressure designs, thereby improving the pressure strength of the annular pressure-resistant layer 4.
[0046] The above embodiments are only used to illustrate the present invention but not to limit the technical solutions described in the present invention. The understanding of this specification should be based on the technical personnel in the relevant technical field. For example, the directional descriptions such as "front", "back", "left", "right", "up", and "down" are described in detail in this specification with reference to the above embodiments. However, ordinary technicians in this field should understand that technicians in the relevant technical field can still modify or replace the present invention with equivalents, and all technical solutions and improvements that do not depart from the spirit and scope of the present invention should be covered within the scope of the claims of the present invention.
Claims
1. A method for manufacturing a flat hose, characterized in that: The flat hose comprises, from the inside to the outside, at least a medium transport layer (1), an axial tensile layer (2), a first adhesive layer (3), an annular pressure-resistant layer (4) and an outer protective layer (5); the annular pressure-resistant layer (4) comprises at least two winding layers of an even number; the winding layers comprise at least one first winding layer (41) and at least one second winding layer (42); the winding directions of the first winding layer (41) and the second winding layer (42) are opposite; and the number of the first winding layer (41) and the second winding layer (42) is the same; The flat hose is produced by a production line, the production line comprising an infiltration extruder (101), a winding machine (102), and a negative pressure coating extruder (103) arranged in sequence upstream and downstream, the winding machine (102) comprising a first circumferential winding machine and a second circumferential winding machine, the infiltration extruder (101) is used for forming a tube blank at one time, the first circumferential winding machine is used for circumferentially winding a first winding layer (41) on the outer circumference of the tube blank, the second circumferential winding machine is used for circumferentially winding a second winding layer (42) on the outer circumference of the tube blank, the winding directions of the first winding layer (41) and the second winding layer (42) are opposite, and the number of the first winding layer (41) and the second winding layer (42) is the same; The manufacturing method comprises the following steps: S1: weaving polyester yarns into a cylindrical shape in the direction of warp and weft to form an axial tensile layer (2), inserting the axial tensile layer (2) into a permeation extruder (101), and permeation extruding to form a tube blank; S2: using a winding machine (102), sequentially winding at least one first winding layer (41) and at least one second winding layer (42) on the outer circumference of the tube blank from the inside to the outside, wherein the winding directions of the first winding layer (41) and the second winding layer (42) are opposite, and the number of the first winding layer (41) and the number of the second winding layer (42) are the same; S3: Using a negative pressure coating extruder (103) to coat the outer circumference of the tube blank wrapped with the first winding layer (41) and the second winding layer (42), and heating and molding to form the flat hose.
2. The manufacturing method according to claim 1, characterized in that: The method further comprises step S11 after step S1 and before step S2: supporting the tube blank by an inner mold, correcting the roundness of the tube blank by a roundness correction traction machine (104) on the outside of the tube blank, and then tightening the tube blank by a main traction machine (105) to maintain a certain roundness.
3. The manufacturing method according to claim 2, characterized in that: The step S2 further comprises: winding an adhesive tape around the outer periphery of the first winding layer (41) or the outer periphery of the second winding layer (42) to form an adhesive layer.
4. The manufacturing method according to claim 1, characterized in that: The included angle between the first winding layer (41) and the axis of the flat hose is 80° to 90°, and the included angle between the second winding layer (42) and the axis of the flat hose is 80° to 90°.
5. The manufacturing method according to claim 4, characterized in that: A second adhesive layer is provided between the first winding layer (41) and the second winding layer (42), for bonding the first winding layer (41) and the second winding layer (42).
6. The manufacturing method according to any one of claims 1 to 5, characterized in that: The first winding layer (41) and the second winding layer (42) are bonded in staggered layers in sequence.
7. The manufacturing method according to any one of claims 1 to 5, characterized in that: At least two of the first winding layers (41) are bonded in sequence, and at least two of the second winding layers (42) are bonded in sequence, and at least two of the first winding layers (41) are bonded to the outside of at least two of the second winding layers (42).
8. The manufacturing method according to claim 1, characterized in that: The winding machine (102) further comprises an adhesive tape winding machine, which is used to wind an adhesive tape around the periphery of each first winding layer (41) or each second winding layer (42).