Super wear-resistant fracturing hose assembly and preparation method thereof

Abstract

The invention relates to a super wear-resistant fracturing hose assembly and a preparation method thereof. The super wear-resistant fracturing hose assembly comprises a hose and a joint, the hose comprises a hose body super-wear-resistant layer, an inner rubber layer and a steel wire framework layer. The connector comprises a super-wear-resistant inner core body formed by compounding a metal inner core body and a core body super-wear-resistant layer, a first sleeve arranged on the outer side of the super-wear-resistant inner core body in a sleeving mode, and a second sleeve arranged on the outer side of the first sleeve in a sleeving mode. The inner side of the second sleeve is connected with the outer side of the first sleeve in a buckling and pressing mode, the inner side of the first sleeve is connected with the outer side of the steel wire framework layer in a buckling and pressing mode, and the inner side of the steel wire framework layer is connected with the super-abrasion-resistant inner core body in a buckling and pressing mode on the anti-pulling-off section of the super-abrasion-resistant inner core body and connected with the inner rubber layer in a sealing mode on the sealing section of the super-abrasion-resistant inner core body. The inner rubber layer is in sealing connection with the super-wear-resistant inner core body at the sealing section of the super-wear-resistant inner core body; the core body super-wear-resistant layer and the pipe body super-wear-resistant layer are in high-temperature welding connection through a welding rod; the wear resistance of the hose connector part can be improved.

Description

Technical Field

[0001] The present application relates to the technical field of hoses and hose connections, and in particular to an ultra-wear-resistant fracturing hose assembly and a preparation method thereof. Background Art

[0002] In the field of oil and gas extraction, fracturing operations are a key link in achieving increased oil and gas production. This operation applies a large pressure to enable fracturing sand and other media to be accurately transported to designated locations in the oil and gas layers, thereby breaking the rock formations and achieving the goal of collecting oil and gas to oil wells to increase production. In this process, the fracturing hose is the core component for transporting fracturing media, and its performance and service life are directly related to the efficiency and benefits of the fracturing operation.

[0003] At present, fracturing hoses are generally connected to the outside world using metal joints. However, due to the inherent characteristics of metal materials, their wear resistance is low. In actual use, it is often the case that the hose body is still intact, but the metal joints fail prematurely due to excessive abrasion and have to be scrapped, resulting in a waste of resources.

[0004] With the continuous evolution of fracturing technology, the requirements for fracturing hoses are becoming increasingly stringent, and their development trend shows the characteristics of larger diameters and higher pressures. This has greatly increased the flow rate and flow velocity of the conveying medium, and the erosion effect on the hose joints has become more intense, accelerating the damage rate of the joints; therefore, how to effectively solve the wear resistance of the hose joints is a technical problem that needs to be solved urgently. Summary of the invention

[0005] The present application provides a super wear-resistant fracturing hose assembly and a preparation method thereof, which can improve the wear resistance of the hose joint.

[0006] In the first aspect, the present application provides a super wear-resistant fracturing hose assembly, comprising: a hose and joints arranged at both ends of the hose; wherein the hose comprises, from the inside to the outside, a super wear-resistant layer of a pipe body, an inner rubber layer, and a steel wire skeleton layer; the joint comprises a super wear-resistant inner core body composited by a metal inner core body and a super wear-resistant layer of a core body, a first sleeve sleeved on the outside of the super wear-resistant inner core body, and a second sleeve sleeved on the outside of the first sleeve; the inner side of the second sleeve is press-connected with the outer side of the first sleeve, the inner side of the first sleeve is press-connected with the outer side of the steel wire skeleton layer, the inner side of the steel wire skeleton layer is press-connected with the super wear-resistant inner core body at an anti-pull-out section of the super wear-resistant inner core body, the inner side of the steel wire skeleton layer is seal-connected with the inner rubber layer at a sealing section of the super wear-resistant inner core body, and the inner rubber layer is seal-connected with the super wear-resistant inner core body at a sealing section of the super wear-resistant inner core body; the super wear-resistant layer of the core body and the super wear-resistant layer of the pipe body are high-temperature welded by a welding rod.

[0007] In a possible implementation, the metal inner core in the super wear-resistant inner core is made of metal material, wherein the metal material is alloy steel; the core super wear-resistant layer in the super wear-resistant inner core is made of wear-resistant high-density synthetic material.

[0008] In a possible implementation, the hose further includes an inner fabric layer, an outer fabric layer, and an outer rubber layer; the hose comprises, from inside to outside, the super wear-resistant layer of the tube body, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer, and the outer rubber layer.

[0009] In one possible implementation, the thickness of the super wear-resistant layer of the tube body is 1mm-3mm, and the super wear-resistant layer of the tube body is formed by winding multiple layers of ultra-high molecular weight polyethylene film with a single layer thickness of 0.1mm-0.2mm, and the ultra-high molecular weight polyethylene film corresponding to all winding layers has multiple colors.

[0010] In a possible implementation, the number of steel wire winding layers of the steel wire skeleton layer is not less than 8 layers, the winding angle of each layer of steel wire is set in the range of 54°-55°, and the winding angle of each layer of steel wire is different.

[0011] In one possible implementation, the welding rod includes a front transition chamber, a heating chamber, and a rear transition chamber; wherein, the front transition chamber and the heating chamber are separated by a welding rod front cover, and the heating chamber and the rear transition chamber are separated by a welding rod rear cover, and the welding rod front cover is equipped with an air inlet, an air outlet, a temperature sensor, and a pressure sensor.

[0012] In the second aspect, the present application provides a method for preparing an ultra-wear-resistant fracturing hose assembly as described in any one of the above items, the preparation method comprising: crimping the hose and the joint, wherein there is a connection gap between the ultra-wear-resistant layer of the core in the ultra-wear-resistant inner core of the joint and the ultra-wear-resistant layer of the tube body of the hose; placing the heating chamber in the welding rod below the connection gap, wherein the length of the welding rod is greater than the length of the connection gap; when high-temperature steam is filled into the heating chamber, based on the temperature sensor and the pressure sensor in the welding rod detecting that the preset temperature and preset pressure are met, welding the welding rod, and applying pressure to the connection gap based on the heating chamber after the heating chamber expands due to heat, so that the ultra-wear-resistant layer of the core at the connection gap is seamlessly connected to the ultra-wear-resistant layer of the tube body.

[0013] In a possible implementation, before the hose and the connector are crimped together, the method further includes: stripping the inner rubber layer of the hose to form a partially stripped section and a completely stripped section; when the hose and the connector are crimped together, the completely stripped section corresponds to the position of the anti-pull-off section in the super wear-resistant inner core, and the partially stripped section corresponds to the position of the sealing section in the super wear-resistant inner core.

[0014] In one possible implementation, the preparation process of the super wear-resistant inner core includes: processing and forging a metal material to obtain a metal inner core; sandblasting the inner wall of the inner hole of the metal inner core, and applying an adhesive to the inner wall of the inner hole of the metal inner core after the sandblasting to form a bonding interface; heating a wear-resistant high-density synthetic material by an injection molding machine and injecting it into the inner wall of the inner hole of the metal inner core, so that the wear-resistant high-density synthetic material forms a core super wear-resistant layer at the bonding interface; vulcanizing the metal inner core, the adhesive and the core super wear-resistant layer to obtain a super wear-resistant inner core.

[0015] In a possible implementation, the preparation process of the hose includes: using an ultra-high molecular weight polyethylene film to wrap the fetal membrane tube to obtain an ultra-wear-resistant layer of the tube body; placing the fetal membrane tube wrapped with the ultra-wear-resistant layer of the tube body in an inner rubber extruder, and performing inner rubber coating based on the inner rubber extruder to form an inner rubber layer on the outside of the ultra-wear-resistant layer of the tube body; performing inner fabric winding on the outside of the inner rubber layer to obtain an inner fabric layer; performing steel wire winding based on a preset number of steel wire winding layers and a preset winding angle on the inner fabric layer to obtain a steel wire skeleton layer; performing outer fabric winding on the outside of the steel wire skeleton layer to obtain an outer fabric layer; performing outer rubber coating on the outside of the outer fabric layer to obtain an outer rubber layer; After the vulcanized water cloth is wrapped around the outside of the outer rubber layer, the composite layer including the super wear-resistant layer of the tube body, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer is vulcanized, and after the vulcanization treatment, the vulcanized water cloth and the fetal membrane tube are removed to obtain the hose.

[0016] The embodiment of the present application provides a super wear-resistant fracturing hose assembly and a preparation method thereof, which has the following advantages compared with the prior art: The super wear-resistant fracturing hose assembly includes a hose and joints arranged at both ends of the hose; wherein, the hose includes, from the inside to the outside, a super wear-resistant layer of the hose body, an inner rubber layer, and a steel wire skeleton layer; the joint includes a super wear-resistant inner core body composed of a metal inner core body and a super wear-resistant layer of the core body, a first sleeve sleeved on the outside of the super wear-resistant inner core body, and a second sleeve sleeved on the outside of the first sleeve; by arranging a super wear-resistant layer of the hose body in the hose, and using a super wear-resistant inner core body composed of a metal inner core body and a super wear-resistant layer of the core body in the joint, this double super wear-resistant layer design can effectively resist the erosion of media such as fracturing sand, and can improve the wear resistance of the hose joint.

[0017] The inner side of the second sleeve is press-connected with the outer side of the first sleeve, the inner side of the first sleeve is press-connected with the outer side of the steel wire skeleton layer, the inner side of the steel wire skeleton layer is press-connected with the super wear-resistant inner core at the anti-pull-out section of the super wear-resistant inner core, the inner side of the steel wire skeleton layer is seal-connected with the inner rubber layer at the sealing section of the super wear-resistant inner core, and the inner rubber layer is seal-connected with the super wear-resistant inner core at the sealing section of the super wear-resistant inner core; under the impact of high-pressure and high-flow rate media, this connection method can effectively prevent the joint from loosening or falling off, ensure the structural integrity of the hose assembly under complex working conditions, maintain the sealing of the conveying medium, and improve operation safety.

[0018] The core super-wear-resistant layer and the tube super-wear-resistant layer are connected by high-temperature welding through a welding rod, which further strengthens the connection strength between the joint and the hose and enables the entire structure to achieve a seamless transition at the wear-resistant layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0020] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0021] One or more embodiments are exemplarily described by pictures in the corresponding drawings, and these exemplified descriptions do not constitute limitations on the embodiments. Elements with the same reference numerals in the drawings represent similar elements, and unless otherwise stated, the figures in the drawings do not constitute proportional limitations.

[0022] Figure 1 It is a structural schematic diagram of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 2 This is a schematic diagram of the hose structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 3 It is a schematic diagram of the winding angle of the steel wire skeleton layer of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 4 This is a schematic diagram of the structure of a super wear-resistant inner core of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 5 This is a schematic diagram of welding of a super wear-resistant layer of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 6 This is a schematic diagram of the welding rod structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application; Figure 7 It is a flow chart of an embodiment of a method for preparing a super wear-resistant fracturing hose assembly provided in the present application. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0024] The disclosure below provides many different embodiments or examples to realize the different structures of the present application. In order to simplify the disclosure of the present application, the parts and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present application. In addition, the present application can repeat reference numbers and / or letters in different examples. This repetition is for the purpose of simplification and clarity, and does not itself indicate the relationship between the various embodiments and / or settings discussed.

[0025] It should be understood that when used in this specification, the terms "include" and "comprising" indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or collections thereof.

[0026] It should also be understood that the terms used in this application specification are only for the purpose of describing specific embodiments and are not intended to limit the application. As used in this application specification, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0027] It should be further understood that the term “and / or” used in the specification of the present application refers to any combination and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0028] As used in this specification, the term "if" can be interpreted as "when" or "uponce" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if it is determined" or "if [described condition or event] is detected" can be interpreted as meaning "uponce it is determined" or "in response to determining" or "uponce [described condition or event] is detected" or "in response to detecting [described condition or event]", depending on the context. Example 1, see Figure 1 , Figure 1 : is a structural schematic diagram of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application, such as Figure 1 As shown, the super wear-resistant fracturing hose assembly includes a hose 10 and connectors 20 disposed at both ends of the hose 10, as follows: In one embodiment, the hose 10 includes, from inside to outside, a super wear-resistant tube layer 101 , an inner rubber layer 102 , and a steel wire skeleton layer 103 .

[0029] In one embodiment, the hose further includes an inner fabric layer 104 , an outer fabric layer 105 , and an outer rubber layer 106 .

[0030] In one embodiment, the hose comprises, from inside to outside, the super wear-resistant layer 101 of the hose body, the inner rubber layer 102, the inner fabric layer 104, the steel wire skeleton layer 103, the outer fabric layer 105 and the outer rubber layer 106; Figure 2 As shown, Figure 2 It is a schematic diagram of the hose structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application.

[0031] In one embodiment, the preparation material of the tube body super wear-resistant layer 101 is the same as the preparation material of the core body super wear-resistant layer in the super wear-resistant inner core, both of which are made of wear-resistant high-density synthetic material. Preferably, the wear-resistant high-density synthetic material is a membrane material.

[0032] Preferably, the wear-resistant high-density synthetic material includes but is not limited to ultra-high molecular weight polyethylene (HMPE), polytetrafluoroethylene (PTFE), polyolefin elastomer (POE), etc.

[0033] Specifically, the thickness of the pipe body super wear-resistant layer 101 is 1 mm-3 mm, and the pipe body super wear-resistant layer 101 is formed by winding multiple layers of the ultra-high molecular weight polyethylene film with a single layer thickness of 0.1 mm-0.2 mm. Specifically, the ultra-high molecular weight polyethylene films corresponding to all the winding layers have a plurality of colors; specifically, the color types are no less than 4.

[0034] Preferably, the color of each layer of ultra-high molecular weight polyethylene film is different, or the colors of every two layers of ultra-high molecular weight polyethylene film are different in sequence; by selecting ultra-high molecular weight polyethylene films of different colors, the colors of adjacent layers of ultra-high molecular weight polyethylene film should be clearly distinguished, and the wear amount of the wear-resistant layer of the hose assembly after use can be quickly determined by color.

[0035] Example description: When the super wear-resistant layer 101 of the pipe body is formed by winding 10 layers of the ultra-high molecular weight polyethylene film, the colors of the ultra-high molecular weight polyethylene film are selected to be five colors, with the contact position with the inner rubber layer 102 as the inside, and from the inside to the outside they are black, red, yellow, green, and white, respectively, and two layers of ultra-high molecular weight polyethylene film of each color are wound.

[0036] In one embodiment, the steel wire skeleton layer 103 should be formed by winding multiple layers of steel wires, the number of steel wire winding layers of the steel wire skeleton layer 103 is not less than 8 layers, and the winding angle of each layer of steel wire is set in the range of 54°-55°, and the winding angle of each layer of steel wire is different.

[0037] Specifically, the skeleton material of the steel wire skeleton layer 103 is tin-plated bronze steel wire, the strength of which is in the range of 2000MPa to 3000MPa, and the elongation after fracture should not be less than 5%.

[0038] Specifically, the winding angle of the steel wires of the odd-numbered layers is smaller than the winding angle of the steel wires of the adjacent even-numbered layers; Figure 3 As shown, Figure 3 It is a schematic diagram of the winding angle of the steel wire skeleton layer of an embodiment of an ultra-wear-resistant fracturing hose assembly provided by the present application, as shown in Table 1. Table 1 is a data table of steel wire winding for a 3-inch 15000PSI specification fracturing hose.

[0039] Table 1:

[0040] Specifically, since the cartilage assembly has high pressure bearing capacity requirements for the pipe body and low pulse performance requirements for the pipe during fracturing operations, the winding angle of each layer of steel wire skeleton layer 103 is designed to be between 54°-55°, and the winding angle of each layer of steel wire is different. The winding angle of the steel wire of the odd-numbered layer is smaller than that of the adjacent even-numbered layer to achieve a smaller deformation of the pipe body under pressure. High-strength steel wire is selected with a strength range of 2000MPa~3000MPa to improve the pressure bearing capacity of a single steel wire. By requiring the elongation of the steel wire after break to be no less than 5%, multiple layers of steel wire are coordinated so that each layer of steel wire is subjected to force together, thereby improving the overall pressure bearing capacity of the pipe body.

[0041] In one embodiment, the preparation process of the hose includes: using an ultra-high molecular weight polyethylene film to wrap the fetal membrane tube to obtain an ultra-wear-resistant layer 101 of the tube body; placing the fetal membrane tube wrapped with the ultra-wear-resistant layer 101 of the tube body in an inner rubber extruder, and performing inner rubber coating based on the inner rubber extruder to form an inner rubber layer 102 on the outside of the ultra-wear-resistant layer 101 of the tube body; performing an inner fabric winding process on the outside of the inner rubber layer 102 to obtain an inner fabric layer 104; performing a steel wire winding process on the top of the inner fabric layer 104 based on a preset number of steel wire winding layers and a preset winding angle to obtain to the steel wire skeleton layer 103; perform an outer fabric winding treatment on the outer side of the steel wire skeleton layer 103 to obtain an outer fabric layer 105; perform an outer rubber coating treatment on the outer side of the outer fabric layer 105 to obtain an outer rubber layer 106; after winding a vulcanized water cloth on the outer side of the outer rubber layer 106, perform a vulcanization treatment on the composite layer including the super wear-resistant layer 101 of the tube body, the inner rubber layer 102, the inner fabric layer 104, the steel wire skeleton layer 103, the outer fabric layer 105 and the outer rubber layer 106, and after the vulcanization treatment, remove the vulcanized water cloth and the fetal membrane tube to obtain the hose.

[0042] The preparation process of the hose is described as follows: a. The wear-resistant layer 101 of the pipe body is wound, and the ultra-high molecular weight polyethylene film is wound on the fetal membrane tube for hose production. The thickness of a single layer of film is 0.2mm, and the number of winding layers is 10. The film is wound once to prevent the film layers from loosening due to back and forth transportation; b. The wound ultra-high molecular weight polyethylene film is coated with an inner rubber layer 102 through an inner rubber extruder, and the thickness of the rubber coating is 4 mm; c. Wrap the inner fabric layer 104 on the inner rubber layer 102, with a thickness of 1.5 mm and one layer; d. Wrap a steel wire layer around the inner fabric layer 104. The selected steel wire is tin-plated bronze, with a diameter of 1.8 mm, a steel wire strength of 2450 MPa, and an elongation after fracture of 5%. The number of steel wire winding layers is 8; e. The thickness of the outer fabric layer 105 wound outside the steel wire layer is 1.5 mm, and the number of layers is 1; f. Wrap an outer rubber layer 106 around the outer fabric layer 105, the thickness of the outer rubber layer 106 is 3 mm; g. Wrap the vulcanized water cloth around the outer rubber layer 106, overlapping the water cloth by 1 / 2; h. Enter the vulcanization tank for vulcanization, the vulcanization temperature is 150℃, and the vulcanization time is 150min; j. After vulcanization is completed, remove the vulcanized water cloth, pull out the fetal membrane tube, and obtain the finished hose.

[0043] In one embodiment, the inner rubber layer 102 is prepared from the following raw materials in parts by weight: including: 100 parts of ethylene propylene rubber, 3-5 parts of zinc oxide, 0.5-1.5 parts of stearic acid, 2-4 parts of antioxidant, 0.2-0.8 parts of sulfur, 5-7 parts of cross-linking agent, 60-80 parts of carbon black, 2-10 parts of organic rectorite, 10-15 parts of linear low-density polyethylene, and 5-8 parts of plasticizer; the sealing layer rubber material is obtained by weighing the above raw materials according to weight, mixing them evenly in an internal mixer, and then passing the rubber through an open mixer after debonding to obtain a sealing layer rubber material.

[0044] The preparation process of the inner rubber layer 102 is illustrated as follows: The following raw materials were selected in parts by weight: 100 parts of ethylene propylene rubber, 5 parts of zinc oxide, 1 part of stearic acid, 4 parts of antioxidant, 0.5 parts of sulfur, 6 parts of cross-linking agent, 80 parts of carbon black, 8 parts of organic rectorite, 10 parts of linear low-density polyethylene, and 5 parts of plasticizer.

[0045] Preparation method: weigh the above raw materials according to weight, put EPDM rubber particles, linear low-density polyethylene particles, zinc oxide, stearic acid, and antioxidant into an internal mixer and mix for 2 minutes, then add carbon black, organic rectorite, and plasticizer, mix for 8 minutes, the discharge temperature is 100-120°C, and after discharge, cool it on the lower sheet of the open mixer, stop for 24 hours and then filter, add sulfur and cross-linking agent in two stages after filtration, mix for 30-50 seconds after adding, the discharge temperature is 80-100°C, and after discharge, cut it into strips on the lower sheet of the open mixer and cool it, completing the preparation of the inner rubber of the inner rubber layer 102.

[0046] In one embodiment, the joint 20 includes a super wear-resistant inner core 201 composed of a metal inner core 2011 and a super wear-resistant core layer 2012 , a first sleeve 202 sleeved on the outside of the super wear-resistant inner core 201 , and a second sleeve 203 sleeved on the outside of the first sleeve 202 .

[0047] Preferably, the joint further includes a positioning ring 204 .

[0048] In one embodiment, the metal inner core 2011 in the super wear-resistant inner core 201 is made of metal material, wherein the metal material is alloy steel; Figure 4 As shown, Figure 4 It is a schematic diagram of the structure of a super-wear-resistant inner core of an embodiment of a super-wear-resistant fracturing hose assembly provided in the present application.

[0049] Preferably, the alloy steel includes but is not limited to 42CrMo alloy steel, 35CrMo alloy steel, etc.

[0050] Specifically, the core super wear-resistant layer 2012 in the super wear-resistant inner core 201 is made of wear-resistant high-density synthetic material.

[0051] Preferably, the wear-resistant high-density synthetic material includes but is not limited to ultra-high molecular weight polyethylene (HMPE), polytetrafluoroethylene (PTFE), polyolefin elastomer (POE), etc.

[0052] Specifically, by providing a super-wear-resistant core layer 2012 in the super-wear-resistant inner core 201 of the joint, the wear of the fracturing sand on the joint during the use of the hose assembly is changed from the wear on the metal part to the wear on the wear-resistant high-density synthetic material, which can greatly increase the wear-resistant time of the joint and improve the overall service life of the hose assembly.

[0053] In one embodiment, the preparation process of the super wear-resistant inner core 201 includes: processing and forging a metal material to obtain a metal inner core 2011; sandblasting the inner wall of the inner hole of the metal inner core 2011, and applying an adhesive to the inner wall of the inner hole of the metal inner core 2011 after the sandblasting to form a bonding interface; heating a wear-resistant high-density synthetic material by an injection molding machine and injecting it into the inner wall of the inner hole of the metal inner core 2011, so that the wear-resistant high-density synthetic material forms a core super wear-resistant layer 2012 at the bonding interface; vulcanizing the metal inner core 2011, the adhesive and the core super wear-resistant layer 2012 to obtain a super wear-resistant inner core 201.

[0054] Specifically, the metal inner core 2011 made of metal material and the core super wear-resistant layer 2012 made of non-metallic material are compositely treated based on an adhesive; wherein the adhesive includes but is not limited to CILBOND®12E and CILBOND®80ET. When CILBOND®12E is used as a primer adhesive and CILBOND®80ET is used as a topcoat adhesive, when the primer adhesive and the topcoat adhesive are used to perform primer coating and topcoat on the metal inner core 2011, the coating thickness corresponding to the primer and the topcoat is 0.01mm-0.06mm respectively; preferably, the adhesive can also be an adhesive of different brands with the same raw materials.

[0055] Specifically, the thickness of the core super wear-resistant layer 2012 is 1.0 mm-3.0 mm.

[0056] Specifically, during the vulcanization treatment, the vulcanization temperature is set to 160° C.-180° C., and the vulcanization time is set to 30 min-40 min.

[0057] The preparation process of the super wear-resistant inner core 201 is illustrated as follows: a. The metal material of the metal inner core 2011 is selected as 42CrMo alloy steel, and the 42CrMo alloy steel is integrally forged to obtain the metal inner core 2011; b. Sandblasting the inner wall of the inner hole of the metal inner core 2011; c. Use CILBOND®12E adhesive to prime the metal inner core 2011 after sandblasting, with a coating thickness of 0.03mm; d. Move the primed metal core 2011 to a ventilated place to dry the adhesive in the shade for 24 hours; e. Use CILBOND® 80ET adhesive to topcoat the metal inner core 2011 on the basis of the primer, with a coating thickness of 0.03mm; f. Move the metal inner core 2011 with the surface coating to a ventilated place to dry the adhesive in the shade for 24 hours; g. Install the super wear-resistant layer shaping mold on the metal inner core 2011 coated with adhesive, and keep the gap between the inner wall of the inner hole and the shaping mold at 2mm; h. Install the metal inner core 2011 assembled with the shaping mold into the mold of the injection molding machine, heat the ultra-high molecular weight polyethylene powder of the super wear-resistant layer to 250° C. by injection molding, and inject it into the inner wall of the inner hole of the metal inner core 2011, and the thickness of the super wear-resistant layer is 2 mm; i. After the injection molding is completed, the metal inner core 2011 with the molding mold is quickly transferred to a 160°C high temperature box to maintain a constant temperature for 30 minutes, and the adhesive is vulcanized and bonded with the metal and ultra-high molecular weight polyethylene; j. After the vulcanization, the metal inner core 2011 is transferred to room temperature for cooling. After cooling to room temperature, the molding die is removed to complete the processing and preparation of the core super wear-resistant layer 2012.

[0058] In one embodiment, a super wear-resistant fracturing hose assembly is prepared by crimping the hose and the connector into a whole.

[0059] In one embodiment, the hose and the connector are connected by buckling, and the end of the hose is processed by inner and outer stripping to obtain an installation position for the connector.

[0060] Specifically: the inner rubber layer 102 corresponding to the buckling position is stripped according to the size of the joint to form a partially stripped section and a completely stripped section.

[0061] Specifically, when the hose and the connector are buckled and connected, the completely stripped section corresponds to the position of the anti-pull-out section 201a, and the partially stripped section corresponds to the position of the sealing section 201b.

[0062] Preferably, the length of the completely stripped section is consistent with the length of the anti-pull-out section 201 a of the super wear-resistant inner core 201 , and the length of the partially stripped section is consistent with the length of the sealing section 201 b of the super wear-resistant inner core 201 .

[0063] Preferably, the outer rubber layer 106 corresponding to the buckling position is also stripped according to the size of the joint.

[0064] In one embodiment, when the hose and the connector are crimped together, the inner side of the second sleeve 203 is crimped together with the outer side of the first sleeve 202, the inner side of the first sleeve 202 is crimped together with the outer side of the steel wire skeleton layer 103, the inner side of the steel wire skeleton layer 103 is crimped together with the super wear-resistant inner core 201 at the anti-pull-out section 201a of the super wear-resistant inner core 201, the inner side of the steel wire skeleton layer 103 is sealedly connected to the inner rubber layer 102 at the sealing section 201b of the super wear-resistant inner core 201, and the inner rubber layer 102 is sealedly connected to the super wear-resistant inner core 201 at the sealing section 201b of the super wear-resistant inner core 201; the core super wear-resistant layer 2012 and the tube super wear-resistant layer 101 are connected by high-temperature welding using a welding rod 30.

[0065] Specifically, the second sleeve 203, the first sleeve 202, and the super wear-resistant inner core 201 are installed to the end of the hose after stripping, and the various components in the joint are installed in place relative to the hose through the positioning ring 204. The anti-pull-out section 201a corresponds to the position of the completely stripped section of the inner rubber layer 102 at the end of the hose, and the sealing section 201b corresponds to the position of the partially stripped section of the inner rubber layer 102. At this time, the first sleeve 202 and the second sleeve 203 are buckled separately to achieve the connection of the various components of the super wear-resistant fracturing hose assembly.

[0066] Specifically, when the inner rubber layer 102 is sealed and connected to the super wear-resistant inner core 201 in the sealing section 201b of the super wear-resistant inner core 201, since the EPDM rubber in the inner rubber layer 102 and the ultra-high molecular weight polyethylene in the core super wear-resistant layer 2012 of the super wear-resistant inner core 201 are both non-polar polymers with good compatibility, and the linear low-density ultra-high molecular weight polyethylene has good thermal flowability, the bonding ability between the inner rubber layer 102 and the core super wear-resistant layer 2012 in the sealing layer can be better enhanced.

[0067] In one embodiment, when the hose and the joint are buckled and connected, there is a connection gap between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101; therefore, it is necessary to perform high-temperature welding connection between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101 by a welding rod 30 to achieve seamless connection; Figure 5 As shown, Figure 5 It is a schematic diagram of welding of a super wear-resistant layer of an embodiment of a super wear-resistant fracturing hose assembly provided in the present application.

[0068] In one embodiment, the welding rod 30 includes a front transition chamber 301, a heating chamber 302, and a rear transition chamber 303, wherein the front transition chamber 301 and the heating chamber 302 are separated by a welding rod front cover 304, and the heating chamber 302 and the rear transition chamber 303 are separated by a welding rod rear cover 305, and the welding rod front cover 304 is equipped with an air inlet, an air outlet, a temperature sensor, and a pressure sensor; Figure 6 As shown, Figure 6 It is a schematic diagram of the welding rod structure of an embodiment of a super wear-resistant fracturing hose assembly provided in the present application.

[0069] Specifically, the heating chamber 302 in the welding rod 30 is placed below the connecting gap, wherein the length of the welding rod 30 is greater than the length of the connecting gap; when high-temperature steam is filled into the heating chamber 302, the welding rod 30 is welded when the temperature sensor and the pressure sensor detect that the preset temperature and the preset pressure are met, and the heating chamber 302 applies pressure to the connecting gap after the heating expansion, so that the core super-wear-resistant layer 2012 at the connecting gap is seamlessly connected with the tube super-wear-resistant layer 101.

[0070] Specifically, when performing welding, the welding temperature is set to 150-170° C., and the welding time is set to 15-30 minutes.

[0071] Specifically, since the welding rod 30 is a hollow metal barrel, and the length of the welding rod 30 is greater than the connection gap between the core super wear-resistant layer 2012 and the tube super wear-resistant layer 101; the middle heating chamber 302 is a sealed cavity, which can be filled with high-temperature steam to reach the set welding temperature, and the outer diameter of the welding rod 30 is the same as the inner wall size of the core super wear-resistant layer 2012 and the tube super wear-resistant layer 101, in order to achieve a close fit, the wear-resistant layer is squeezed during the welding process through thermal expansion and contraction to achieve seamless bonding.

[0072] The process of high-temperature welding the connection gap between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101 by the welding rod 30 is described as follows: The crimped joint is installed into the welding rod 30, and the center position of the heating chamber 302 is kept at the connection gap between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101. High-temperature steam is filled into the heating chamber 302 of the welding rod 30 through the air inlet, so that the internal temperature of the heating chamber 302 is 150°C and the pressure is 0.5MPa. After the heating chamber 302 reaches the temperature, the timing starts, and the welding rod 30 is welded for 30 minutes. During the welding, drainage is carried out through the air outlet every 5 minutes to remove the condensed water inside the heating chamber 302. The heating chamber 302 is expanded by heat to provide an extrusion force on the connection gap between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101, so as to achieve seamless welding. After the welding is completed, normal temperature air is introduced into the heating chamber 302 through the air inlet for cooling. After the internal temperature of the heating chamber 302 drops to room temperature, the welding rod 30 can be taken out to achieve seamless connection between the core super-wear-resistant layer 2012 and the tube super-wear-resistant layer 101.

[0073] In one embodiment, a bursting test is performed on the super wear-resistant fracturing hose assembly in the embodiment of the present application, and the bursting pressure thereof can reach above 38,000 psi, which is basically consistent with the calculated value, verifying that the pressure bearing capacity can be greatly improved.

[0074] In addition, a wear resistance test was performed on the super wear-resistant fracturing hose assembly in the embodiment of the present application, and it was compared with the fracturing steel pipe and ordinary fracturing hose of the same specification; when the conveying medium was a 15% sand ratio fracturing fluid, the wear resistance of the super wear-resistant fracturing hose assembly in the embodiment of the present application, the fracturing steel pipe and the ordinary fracturing hose was tested based on the actual working life. The specific wear resistance comparison results are shown in Table 2, which is an example table of wear resistance comparison of different types of fracturing pipelines.

[0075] Table 2:

[0076] It can be seen from Table 2 above that the ultra-wear-resistant fracturing hose assembly prepared in the embodiment of the present application has excellent wear resistance and can greatly improve its service life.

[0077] In one embodiment, the hose made by using a steel wire skeleton layer prepared by different steel wire winding steps as a variable is compared with the ultra-wear-resistant fracturing hose assembly of the steel wire skeleton layer prepared by the above steel wire winding steps in the embodiment of the present application for bursting pressure, and the following control groups are made respectively: Control group 1, using copper-plated steel wire for ordinary hoses, with a steel wire strength of 2000MPa; Control group 2 uses the steel wire mentioned in the embodiment of the present application, but its steel wire winding angle is designed to be matched with the winding angle of an ordinary high-pressure hose.

[0078] Among them, the steel wire winding data of the control group 2 is shown in Table 3, and Table 3 is an example table of steel wire winding data of the control group 2.

[0079] Table 3:

[0080] The hoses made in the above control group 1 and control group 2 and the ultra-wear-resistant fracturing hose assembly made in the embodiment of the present application were subjected to burst tests, and the comparison results are shown in Table 4, which is an example table comparing the burst pressures of fracturing hoses wound with different steel wires.

[0081] Table 4:

[0082] It can be seen from the above Table 4 that the super wear-resistant fracturing hose assembly prepared in the embodiment of the present application has better blasting performance.

[0083] In one embodiment, the super wear-resistant layer of the tube body made of ultra-high molecular weight polyethylene films of multiple colors in the embodiment of the present application is compared with the wear-resistant layer of the tube body in the hose made of only white ultra-high molecular weight polyethylene film, and the super wear-resistant hose assembly made of the two is subjected to a wear resistance test. Based on the test results, it can be seen that the colored ultra-high molecular weight polyethylene film does not affect the adhesion between the layers of the film, nor does it affect the wear resistance of the wear-resistant layer of the tube body, and the super wear-resistant hose assembly made of ultra-high molecular weight polyethylene films of different colors can quickly determine the wear amount of the wear-resistant layer of the super wear-resistant hose assembly after use; the colors of adjacent layers of wear-resistant layer film materials of different colors should be clearly distinguished, and the wear amount of the hose wear-resistant layer can be quickly identified by color.

[0084] In one embodiment, by changing the material of the wear-resistant layer of the pipe body, hoses corresponding to the wear-resistant layer of the pipe body made of polytetrafluoroethylene (PTFE) and polyolefin elastomer (POE) are selected as the control group, and a wear resistance test is carried out with the super wear-resistant fracturing hose assembly made in the embodiment of the present application. Although there are certain differences between the test data and those in Table 2, the wear amount is better than that of the hoses corresponding to control group 1 and control group 2.

[0085] Example 2, see Figure 7 , Figure 7 : is a flow chart of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application, such as Figure 7 As shown, the preparation method includes step S101 and step S103, which are specifically as follows: Step S101: crimping and connecting the hose and the connector, wherein a connection gap exists between the super-wear-resistant layer of the super-wear-resistant inner core of the connector and the super-wear-resistant layer of the tube body of the hose.

[0086] Step S102: placing a heating chamber in a welding rod below the connection gap, wherein the length of the welding rod is greater than the length of the connection gap.

[0087] Step S103: When high-temperature steam is filled into the heating chamber, the welding rod is welded when the temperature sensor and pressure sensor in the welding rod detect that the preset temperature and the preset pressure are met, and pressure is applied to the connection gap based on the heating chamber expanding due to heat, so that the super-wear-resistant layer of the core and the super-wear-resistant layer of the tube body at the connection gap are seamlessly connected.

[0088] In one embodiment, before the hose and the connector are crimped together, the method further includes: stripping the inner rubber layer of the hose to form a partially stripped section and a completely stripped section; when the hose and the connector are crimped together, the completely stripped section corresponds to the position of the anti-pull-off section in the super wear-resistant inner core, and the partially stripped section corresponds to the position of the sealing section in the super wear-resistant inner core.

[0089] In one embodiment, the preparation process of the super wear-resistant inner core includes: processing and forging a metal material to obtain a metal inner core; sandblasting the inner wall of the inner hole of the metal inner core, and applying an adhesive to the inner wall of the inner hole of the metal inner core after the sandblasting to form a bonding interface; heating a wear-resistant high-density synthetic material by an injection molding machine and injecting it into the inner wall of the inner hole of the metal inner core, so that the wear-resistant high-density synthetic material forms a core super wear-resistant layer at the bonding interface; vulcanizing the metal inner core, the adhesive and the core super wear-resistant layer to obtain a super wear-resistant inner core.

[0090] In one embodiment, the preparation process of the hose includes: using an ultra-high molecular weight polyethylene film to wrap the fetal membrane tube to obtain an ultra-wear-resistant layer of the tube body; placing the fetal membrane tube wrapped with the ultra-wear-resistant layer of the tube body in an inner rubber extruder, and performing inner rubber coating based on the inner rubber extruder to form an inner rubber layer on the outside of the ultra-wear-resistant layer of the tube body; performing inner fabric winding on the outside of the inner rubber layer to obtain an inner fabric layer; performing steel wire winding based on a preset number of steel wire winding layers and a preset winding angle above the inner fabric layer to obtain a steel wire skeleton layer; performing outer fabric winding on the outside of the steel wire skeleton layer to obtain an outer fabric layer; performing outer rubber coating on the outside of the outer fabric layer to obtain an outer rubber layer; after winding a vulcanized water cloth on the outside of the outer rubber layer, vulcanizing the composite layer including the ultra-wear-resistant layer of the tube body, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer, and after the vulcanization treatment, removing the vulcanized water cloth and the fetal membrane tube to obtain the hose.

[0091] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0092] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application.

[0093] The above description is only a specific implementation mode of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of various equivalent modifications or substitutions within the technical scope disclosed in the present application, and these modifications or substitutions should be included in the protection scope of the present application.

Claims

1. A super wear-resistant fracturing hose assembly, characterized in that: include: A hose and connectors disposed at both ends of the hose; The hose comprises, from inside to outside, a super wear-resistant layer of the hose body, an inner rubber layer, and a steel wire skeleton layer; The joint comprises a super wear-resistant inner core body composed of a metal inner core body and a super wear-resistant core layer, a first sleeve sleeved on the outer side of the super wear-resistant inner core body, and a second sleeve sleeved on the outer side of the first sleeve; The inner side of the second sleeve is press-connected with the outer side of the first sleeve, the inner side of the first sleeve is press-connected with the outer side of the steel wire skeleton layer, the inner side of the steel wire skeleton layer is press-connected with the super wear-resistant inner core at the anti-pull-out section of the super wear-resistant inner core, the inner side of the steel wire skeleton layer is seal-connected with the inner rubber layer at the sealing section of the super wear-resistant inner core, and the inner rubber layer is seal-connected with the super wear-resistant inner core at the sealing section of the super wear-resistant inner core; the super wear-resistant layer of the core body and the super wear-resistant layer of the tube body are connected by high-temperature welding through a welding rod.

2. The super wear-resistant fracturing hose assembly according to claim 1, characterized in that: The metal inner core in the super wear-resistant inner core is made of metal material, wherein the metal material is alloy steel; The super wear-resistant core layer in the super wear-resistant inner core is made of wear-resistant high-density synthetic material.

3. The super wear-resistant fracturing hose assembly according to claim 1, characterized in that: The hose also includes an inner fabric layer, an outer fabric layer, and an outer rubber layer; The hose comprises, from the inside to the outside, the super wear-resistant layer of the tube body, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer.

4. The super wear-resistant fracturing hose assembly according to claim 1 is characterized in that: The thickness of the super wear-resistant layer of the tube body is 1mm-3mm, and the super wear-resistant layer of the tube body is formed by winding multiple layers of ultra-high molecular weight polyethylene films with a single layer thickness of 0.1mm-0.2mm, and the ultra-high molecular weight polyethylene films corresponding to all the winding layers have multiple colors.

5. The super wear-resistant fracturing hose assembly according to claim 1, characterized in that: The number of steel wire winding layers of the steel wire skeleton layer is not less than 8 layers, the winding angle of each layer of steel wire is set in the range of 54°-55°, and the winding angle of each layer of steel wire is different.

6. The super wear-resistant fracturing hose assembly according to claim 1, characterized in that: The welding rod comprises a front transition chamber, a heating chamber, and a rear transition chamber; Among them, the partition between the front transition chamber and the heating chamber is the welding rod front cover, and the partition between the heating chamber and the rear transition chamber is the welding rod rear cover. The welding rod front cover is equipped with an air inlet, an air outlet, a temperature sensor, and a pressure sensor.

7. A method for preparing the super wear-resistant fracturing hose assembly according to any one of claims 1 to 6, characterized in that: include: The hose and the joint are buckled and connected, wherein there is a connection gap between the super-wear-resistant layer of the super-wear-resistant inner core of the joint and the super-wear-resistant layer of the tube body of the hose; placing a heating chamber in a welding rod below the connection gap, wherein the length of the welding rod is greater than the length of the connection gap; When high-temperature steam is filled into the heating chamber, the welding rod is welded when the temperature sensor and pressure sensor in the welding rod detect that the preset temperature and the preset pressure are met. The heating chamber applies pressure to the connection gap after thermal expansion, so that the super-wear-resistant layer of the core and the super-wear-resistant layer of the tube body at the connection gap are seamlessly connected.

8. The method for preparing the super wear-resistant fracturing hose assembly according to claim 7, characterized in that: Before the hose and the connector are crimped and connected, the method further comprises: The inner rubber layer of the hose is subjected to a rubber stripping process to form a partially rubber stripped section and a completely rubber stripped section; When the hose and the connector are buckled and connected, the completely stripped section corresponds to the position of the anti-pull-out section in the super wear-resistant inner core, and the partially stripped section corresponds to the position of the sealing section in the super wear-resistant inner core.

9. The method for preparing the super wear-resistant fracturing hose assembly according to claim 7, characterized in that: The preparation process of the super wear-resistant inner core comprises: Processing and forging the metal material to obtain a metal inner core; Sandblasting the inner wall of the inner hole of the metal inner core, and applying an adhesive to the inner wall of the inner hole of the metal inner core after the sandblasting to form a bonding interface; Using an injection molding machine, the wear-resistant high-density synthetic material is heated and then injected into the inner wall of the inner hole of the metal inner core, so that the wear-resistant high-density synthetic material forms a super wear-resistant layer of the core at the bonding interface; The metal inner core, the adhesive and the core super wear-resistant layer are vulcanized to obtain a super wear-resistant inner core.

10. The method for preparing the super wear-resistant fracturing hose assembly according to claim 7, characterized in that: The preparation process of the hose includes: The fetal membrane tube is wound with an ultra-high molecular weight polyethylene film to obtain an ultra-wear-resistant layer on the tube body; Placing the fetal membrane tube wrapped with the tube body super wear-resistant layer in an inner rubber extruder, and coating the tube with inner rubber based on the inner rubber extruder to form an inner rubber layer on the outer side of the tube body super wear-resistant layer; Performing an inner fabric winding process on the outer side of the inner rubber layer to obtain an inner fabric layer; Performing a steel wire winding process on the inner fabric layer based on a preset number of steel wire winding layers and a preset winding angle to obtain a steel wire skeleton layer; Performing an outer fabric winding process on the outer side of the steel wire skeleton layer to obtain an outer fabric layer; Performing an outer rubber coating treatment on the outer side of the outer fabric layer to obtain an outer rubber layer; After the vulcanized water cloth is wrapped around the outside of the outer rubber layer, the composite layer including the super wear-resistant layer of the tube body, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer is vulcanized, and after the vulcanization treatment, the vulcanized water cloth and the fetal membrane tube are removed to obtain the hose.

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