Air conditioner hose structure with ultrahigh barrier property

Abstract

The invention discloses an ultrahigh-barrier-property air conditioner hose structure and belongs to the technical field of air conditioner hoses. Comprising an air conditioner hose body of a multi-layer structure, the air conditioner hose body is composed of an inner rubber layer 1, an ultrahigh barrier layer A, a middle rubber layer 7, a reinforcing layer 8 and an outer rubber layer 9 from inside to outside, and the ultrahigh barrier layer A is composed of five layers of structures including a PA6 layer, an EVOH layer, a PA6 layer 4, an EVOH layer 5 and a PA6 layer 6 which are sequentially arranged, co-extruded and bonded; the air conditioner hose is of a multi-layer structure, has ultrahigh barrier property and can resist diffusion of refrigerants to the atmosphere like a metal pipe or resist permeation of the refrigerants to the atmosphere, so that contribution is made to GWP; due to the fact that the main body material is the ultra-high-barrier-property air conditioner hose made of rubber, the ultra-high-barrier-property air conditioner hose has the soft and bendable characteristics regardless of the diameter of the hose, and therefore the ultra-high-barrier-property air conditioner hose is easy to install and can be suitable for extremely wide occasions, and particularly the problem can be solved by replacing the ultra-high-barrier-property air conditioner hose in the occasions where metal pipes are difficult to install.

Description

Technical Field

[0001] The invention belongs to the technical field of air-conditioning hoses, and in particular relates to an air-conditioning hose structure with ultra-high barrier properties. Background Art

[0002] The existing air conditioning hose is also the common automobile air conditioning hose. From the three-layer structure hose of the last century, that is, the hose with inner rubber layer + yarn reinforcement layer + outer rubber layer structure, R11, R12 refrigerants and petroleum-based refrigeration oil flow in the tube. Gradually developed to the current five-layer structure hose with inner rubber layer + nylon 6 barrier layer + middle rubber layer + yarn reinforcement layer + outer rubber layer or four-layer structure hose without inner rubber layer, R134a or R1234yf refrigerant and synthetic refrigeration oil flow in the tube. This air conditioning hose can only be used in automobiles, not in household air conditioners. The reason is very simple, that is, the requirement of extremely low permeability or leakage of household air conditioners limits the use of the above air conditioning hose in household air conditioners.

[0003] To this end, the applicant has conducted useful explorations and attempts and found solutions to the above problems. The technical solutions to be introduced below were produced in this context. Summary of the invention

[0004] The present invention mainly aims at the technical problem that the existing air conditioning hose cannot meet the requirement of extremely low refrigerant permeation of household air conditioners, and provides an air conditioning hose structure with ultra-high barrier properties. The principle of its ultra-high barrier property is to give full play to the extremely excellent gas barrier property, that is, barrier property, of EV0H, which is well bonded with nylon 6, namely PA6, under the process conditions of co-extrusion to form a composite barrier layer with ultra-high barrier properties.

[0005] An ultra-high barrier air conditioning hose structure, comprising an air conditioning hose with a multi-layer structure, wherein the air conditioning hose is composed of an inner rubber layer 1, an ultra-high barrier layer A, a middle rubber layer 7, a reinforcement layer 8 and an outer rubber layer 9 from inside to outside;

[0006] The ultra-high barrier layer A is composed of a five-layer structure of PA6 layer 2+EVOH layer 3+PA6 layer 4+EVOH layer 5+PA6 layer 6, which are arranged in the above order and co-extruded and bonded. The ultra-high barrier layer A described below is all of this five-layer structure.

[0007] Preferably, the air conditioning hose may also be composed of an ultra-high barrier layer A, a middle rubber layer 7, a reinforcement layer 8 and an outer rubber layer 9 from the inside to the outside;

[0008] The ultra-high barrier layer A has the same five-layer structure as the ultra-high composite barrier layer A mentioned above.

[0009] Preferably, the air conditioning hose may also be composed of an ultra-high barrier layer A, a middle rubber layer 7 and a reinforcement layer 8 from the inside to the outside;

[0010] The ultra-high barrier layer A has the same five-layer structure as the ultra-high composite barrier layer A mentioned above.

[0011] Preferably, the material of the reinforcing layer is selected from one of polyester yarn, nylon yarn, rayon yarn, vinylon yarn, glass fiber yarn, and rust-resistant metal wire. When used in a hose containing three rubber layers, inner, middle, and outer, or when used in a hose containing two rubber layers, middle and outer, the hose reinforcement layer is allowed to be manufactured by a weaving process or a winding process.

[0012] Preferably, the reinforcing layer is made of one of polyester yarn, nylon yarn, rayon yarn, vinylon yarn, glass fiber yarn and metal wire. When used in a hose containing only a middle rubber layer, the reinforcing layer is only allowed to be manufactured using a weaving process.

[0013] Preferably, the inner rubber layer 1, the middle rubber layer 7 and the outer rubber layer 9 all contain a meta-methyl methacrylate adhesive or a maleic anhydride adhesive.

[0014] Preferably, the inner rubber layer 1, the middle rubber layer 7 and the outer rubber layer 9 of the ultra-high barrier air-conditioning hose are bonded together with the PA6 layer and the reinforcement layer thereof during the vulcanization process.

[0015] Preferably, the air conditioning hose has ultra-high anti-permeability to R290, R600a, R32, R134a, R1234yf or other refrigerants with zero ODP flowing in the hose.

[0016] Preferably, the air conditioning hose is compatible with petroleum-based refrigeration oil or synthetic refrigeration oil flowing in the hose.

[0017] The present invention has the beneficial effects:

[0018] 1. The present invention is an air conditioning hose with a multi-layer structure, which has ultra-high barrier properties and can resist refrigerants like a metal tube

[0019] Emission to the atmosphere, or resistance to refrigerant penetration into the atmosphere, contributes to GWP.

[0020] Second, since the main material is made of rubber, the air conditioning hose with ultra-high barrier properties is soft and durable regardless of the hose diameter.

[0021] Due to its bending properties, it is easy to install and can be adapted to a wide range of occasions, especially in situations where metal pipes are difficult to install, using it instead can solve the problem.

[0022] 3. It can measure the actual distance between indoor and outdoor units on site, and cut ultra-high barrier materials without length restrictions according to needs.

[0023] Air conditioning hose, convenient and quick installation of indoor and outdoor unit connecting pipes on site, completely eliminating the various troublesome problems caused by factory-produced fixed-length indoor and outdoor metal connecting pipes.

[0024] 4. As the era of large-scale promotion and application of new energy is coming, the price of copper tubes will remain high for a long time, and the household air conditioner industry

[0025] Faced with the huge pressure of rising costs, this ultra-high barrier air conditioning hose has extremely obvious cost advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a schematic structural diagram of Embodiment 1 of the present invention;

[0027] Figure 2 is a schematic diagram of the structure of Embodiment 2 of the present invention;

[0028] Figure 3 is a schematic diagram of the structure of Embodiment 3 of the present invention;

[0029] In the figure: 1, inner rubber layer; 2, PA6 layer; 3, EVOH layer; 4, PA6 layer; 5, EVOH layer; 6, PA6 layer; 7, middle rubber layer; 8, reinforcement layer; 9, outer rubber layer.

[0030] Below through embodiment, with attached Figure 1-Figure 3 , the technical solution of the present invention is further specifically described.

[0031] Embodiment 1:

[0032] An ultra-high barrier air conditioning hose structure, comprising an air conditioning hose with a multi-layer structure, wherein the air conditioning hose is composed of an inner rubber layer 1, an ultra-high barrier composite barrier layer A, a middle rubber layer 7, a reinforcement layer 8 and an outer rubber layer 9 from the inside to the outside; wherein the ultra-high barrier composite barrier layer A is composed of a PA6 layer 2 + an EVOH layer 3 + a PA6 layer 4 + an EVOH layer 5 + a PA6 layer 6 and is arranged in the above order and co-extruded and bonded. The following ultra-high barrier composite barrier layers A are all like this. In this embodiment, the inner rubber layer 1 is the first layer in the tube, and it is in direct contact with the refrigerant and the refrigeration oil. Therefore, the design of the inner rubber layer formula must ensure that the inner rubber layer 1 does not produce physical and chemical reactions with the refrigerant and the refrigeration oil.

[0033] The inner rubber layer 1, the middle rubber layer 7, and the outer rubber layer 9 are added with a meta-methyl methacrylate adhesive or a maleic anhydride adhesive during rubber refining, and will be bonded with the corresponding PA6 layer and the reinforcing layer during vulcanization to form an ultra-high barrier air conditioning hose.

[0034] Embodiment 2:

[0035] This embodiment further develops an air conditioning hose without an inner rubber layer 1 based on the embodiment 1, that is, it is composed of an ultra-high barrier composite barrier layer A, a middle rubber layer 7, a reinforcement layer 8 and an outer rubber layer 9 from the inside to the outside;

[0036] The middle rubber layer 7 and the outer rubber layer 9 are added with a methylene blue adhesive or a maleic anhydride adhesive during rubber refining, and will be bonded with the corresponding PA6 layer and the reinforcing layer during vulcanization to form an ultra-high barrier air conditioning hose.

[0037] Embodiment 3:

[0038] This embodiment further develops the structure of the air conditioning hose from the inside to the outside, which is composed of an ultra-high barrier layer A, a middle rubber layer 7 and a reinforcement layer 8 on the basis of embodiment 1;

[0039] In this embodiment, there is neither the extruded rubber layer 1 nor the outer rubber layer 9 covering the extrusion, but the other parts are the same as those in the embodiment 1, and the same ultra-high barrier property to the refrigerant is provided. The other parts will not be described in detail.

[0040] The ultra-high barrier rubber air-conditioning hoses manufactured in the above embodiments can flow R290, R600a, R32, R1234yf, R134a or other refrigerants with zero ODP, and are compatible with petroleum-based refrigeration oil or synthetic refrigeration oil.

[0041] The manufacturing process of the present invention:

[0042] Preparation:

[0043] 1. Prepare the inner layer rubber, middle layer rubber and outer layer rubber for use;

[0044] 2. Clean the surface of the rubber core of specified diameter first, then apply the release agent, evenly arrange the wires and wrap them around the wire reel, which is then placed on the wire-releasing machine for standby use.

[0045] 3. Load PA6 and EVOH into the drying cylinders of the plastic extruder and dry them for later use.

[0046] 4. Keep the vulcanizing tank in a warm state for standby use.

[0047] 5. Wind the yarn that meets the process requirements onto the spindle and install it on the knitting machine for use.

[0048] The steps for implementing the production process of the structural hose shown in Figure 1 are as follows:

[0049] Step 1: The traction machine sends the rubber soft core on the wire drum to the T-shaped head of the rubber extruder at the specified linear speed. After the inner rubber layer is extruded, the diameter is detected and controlled by the diameter gauge. After being cooled by water, it is blown dry to maintain a constant linear speed.

[0050] Step 2: After the semi-finished hose coated with the inner rubber layer passes through the multi-layer co-extrusion heads of multiple plastic extruders at a constant linear speed, the hose is coated with the high barrier A layer. It also needs to be measured to control the diameter size, blown dry with cold water, and continue to move forward at a constant linear speed.

[0051] Step three, the semi-finished hose coated with layer A enters the T-shaped head of the rubber extruder, and the middle rubber layer is extruded and coated on the outer diameter surface of layer A of the hose. It also needs to measure the diameter to control the diameter size, then water cool, blow dry, apply the isolation agent, maintain a constant line speed, and wind the wire reel full through the winding machine, and then transfer it to the weaving process.

[0052] Step 4: Connect the hose coated with the middle rubber layer to the braiding machine for braiding, and maintain the required braiding tension and required braiding angle. The hose coated with the braided layer is wound at a constant line speed. When the reel is full of the hose coated with the braided layer, it is replaced and transferred to the outer rubber coating production line.

[0053] Step 5: Use a traction machine to feed the braided hose semi-finished product on the reel into the T-shaped head of the outer rubber extruder at a constant linear speed to extrude and coat the outer rubber layer. It is also necessary to measure the diameter and control the required outer diameter. Move forward at a constant linear speed, cool with water, blow dry, and then coat with TPX plastic. Cool and blow dry, still at a constant linear speed, and transfer the reel to the vulcanization process after it is fully wound.

[0054] Step 6: Fill the accumulated multiple wire reels into the horizontal vulcanizing tank for vulcanization. It is necessary to maintain the steam pressure, temperature and time specified in the process stably before venting and opening the tank to remove the wire reels and transfer them to the stripping machine to remove the TPX plastic layer, and then use high-pressure water to remove the rubber soft core to obtain the ultra-high barrier air conditioning hose. The subsequent other process will not be repeated.

[0055] 1. By changing the winding equipment process, vertical vulcanization tanks can also be used for vulcanization, and its process requirements are the same as those of horizontal tank vulcanization.

[0056] 2. If the reinforcing layer 8 is produced by a winding process, online production can be achieved without the problem of intermittent production as in the weaving process.

[0057] 3. This hose can also be cured by bare vulcanization, water-wrapped cloth vulcanization and other rubber curing processes.

[0058] 4. If necessary, flame retardant can also be added to the outer rubber.

[0059] The above is Figure 1 Introduction to the production steps of structural ultra-high barrier air conditioning hose

[0060] Figure 2 shows the process implementation steps of the structure:

[0061] In the process implementation steps of the structure shown in FIG1 , except that the step of extruding the inner rubber layer 1 is omitted, the other manufacturing steps are the same as those described in the manufacturing process 1 above;

[0062] It can also be vulcanized by plastic coating, bare vulcanization, and water-reel vulcanization;

[0063] If required, flame retardants can also be added to the outer rubber layer.

[0064] Figure 3 shows the process implementation steps of the structure:

[0065] Based on the process implementation steps of the structure shown in Figure 1.

[0066] 1. Omit the step of extruding the inner rubber layer 1;

[0067] 2. Omit the step of extruding the outer rubber layer 9;

[0068] 3. However, the reinforcement layer must be made by weaving technology, there is no second choice;

[0069] 4. After the weaving process is completed, it must be covered with TPX before it can be sent for vulcanization.

[0070] 5. The subsequent process implementation steps are the same as those of the structure shown in Figure 1.

[0071] Finally, it should be pointed out that the above embodiments are only representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments, and there are many variations. Any simple modification, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention should be considered to belong to the protection scope of the present invention.

Claims

1. An ultra-high barrier air conditioning hose structure, comprising an air conditioning hose with a multi-layer structure, characterized in that The air conditioning hose is composed of an inner rubber layer (1), an ultra-high barrier layer A, a middle rubber layer (7), a reinforcement layer (8) and an outer rubber layer (9) from the inside to the outside; The ultra-high barrier layer A is composed of a five-layer structure of PA6 layer (2) + EVOH layer (3) + PA6 layer (4) + EVOH layer (5) + PA6 layer (6) and is arranged in the above order and co-extruded and bonded.

2. The ultra-high barrier air conditioning hose structure according to claim 1, characterized in that The air conditioning hose is composed of an ultra-high barrier layer A, a middle rubber layer (7), a reinforcement layer (8) and an outer rubber layer (9) from the inside to the outside.

3. The ultra-high barrier air conditioning hose structure according to claim 1 is characterized in that The air conditioning hose is composed of an ultra-high barrier layer A, a middle rubber layer (7) and a reinforcement layer (8) from the inside to the outside.

4. The ultra-high barrier air conditioning hose structure according to claim 1 or 2, characterized in that The material of the reinforcing layer (8) is selected from one of polyester yarn, nylon yarn, rayon yarn, vinylon yarn, glass fiber yarn, and metal wire, and the reinforcing layer (8) can be manufactured by a weaving process or a winding process.

5. The ultra-high barrier air conditioning hose structure according to claim 3 is characterized in that The material of the reinforcing layer (8) is selected from one of polyester yarn, nylon yarn, rayon yarn, vinylon yarn, glass fiber yarn and metal wire, and the reinforcing layer (8) is only allowed to be manufactured by weaving technology.

6. The ultra-high barrier air conditioning hose structure according to claim 1, 2 or 3, characterized in that The inner rubber layer (1), the middle rubber layer (7) and the outer rubber layer (9) all contain a methylene blue system adhesive or a maleic anhydride adhesive.

7. The ultra-high barrier air conditioning hose structure according to claim 1, characterized in that The PA6 layer and the reinforcing layer (8) corresponding to the inner rubber layer (1), the middle rubber layer (7) and the outer rubber layer (9) are bonded together into a tubular shape after vulcanization.

8. The ultra-high barrier air conditioning hose structure according to any one of claims 1 to 3, characterized in that This air conditioning hose has super high permeation resistance when R290, R600a, R32, R134a, R1234yf or refrigerant with zero ODP flows through the hose.

9. The ultra-high barrier air conditioning hose structure according to any one of claims 1 to 3, characterized in that The air conditioning hose is compatible with petroleum-based refrigeration oil or synthetic refrigeration oil flowing in the hose.

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