An ultra-wear-resistant fracturing hose assembly and a preparation method thereof

Abstract

The application 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 pipe body super-wear-resistant layer, an inner rubber layer and a steel wire framework layer. The joint comprises a super-wear-resistant inner core body which is composed of a metal inner core body and a core body super-wear-resistant layer, a first sleeve which is sleeved on the outer side of the super-wear-resistant inner core body, and a second sleeve which is sleeved on the outer side of the first sleeve. The inner side of the second sleeve is connected with the outer side of the first sleeve through buckling and pressing, the inner side of the first sleeve is connected with the outer side of the steel wire framework layer through buckling and pressing, the inner side of the steel wire framework layer is connected with the super-wear-resistant inner core body through buckling and pressing at the anti-pulling-off section of the super-wear-resistant inner core body, the inner side of the steel wire framework layer is sealingly connected with the inner rubber layer at the sealing section of the super-wear-resistant inner core body, and the inner rubber layer is sealingly connected 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 connected through high-temperature welding with a welding rod. The application can improve the wear resistance of the joint part of the hose.

Description

TECHNICAL FIELD

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

[0002] In the field of oil and gas exploration, fracturing operation is a key link to achieve oil and gas yield increase; through exerting a large pressure, the operation promotes the accurate delivery of fracturing medium such as fracturing sand to the designated position of the oil and gas layer, and then breaks the rock layer to achieve the purpose of oil and gas gathering to the oil well to improve the yield. In this process, the fracturing hose as the core component for delivering the fracturing medium, its performance and service life are directly related to the efficiency and benefit of the fracturing operation.

[0003] At present, the fracturing hose and the external connection are generally connected in the form of a metal joint. However, due to the inherent characteristics of the metal material, its wear resistance is low. In actual use, often the hose body is still intact, but the metal joint is prematurely failed due to excessive abrasion, and has to be forced to be scrapped, causing waste of resources.

[0004] With the continuous evolution of fracturing technology, the requirements for fracturing hoses are increasingly stringent, and the development trend presents the characteristics of larger diameter and higher pressure. This greatly increases the flow and flow rate of the delivered medium, and the erosion effect on the hose joint is increasingly strong, accelerating the damage speed of the joint. Therefore, how to effectively solve the wear resistance of the hose joint part is a technical problem that needs to be solved at present. SUMMARY

[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 part.

[0006] In a first aspect, the present application provides a super-wear-resistant fracturing hose assembly, comprising: a hose and a joint arranged at both ends of the hose; wherein the hose comprises, from inside to outside, a pipe body super-wear-resistant layer, 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 core body super-wear-resistant 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 connected with the outer side of the first sleeve by crimping, the inner side of the first sleeve is connected with the outer side of the steel wire skeleton layer by crimping, the inner side of the steel wire skeleton layer is connected with the super-wear-resistant inner core body by crimping at the anti-pulling-off section of the super-wear-resistant inner core body, the inner side of the steel wire skeleton layer is sealingly connected with the inner rubber layer at the sealing section of the super-wear-resistant inner core body, and the inner rubber layer is sealingly connected 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 connected by high-temperature welding with 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 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.

[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 the 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 steel wire winding angle of each layer is set within the range of 54°-55°, and the steel wire winding angle of each layer 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 partition between the front transition chamber and the heating chamber is a welding rod front cover, and the partition between the heating chamber and the rear transition chamber is 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 preparation method of 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 core ultra-wear-resistant layer in the ultra-wear-resistant inner core of the joint and the tube ultra-wear-resistant layer 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, the welding rod is welded when the temperature sensor and pressure sensor in the welding rod detect that the preset temperature and preset pressure are met, and pressure is applied to the connection gap based on the heating chamber after the heating chamber expands due to heat, so that the core ultra-wear-resistant layer and the tube ultra-wear-resistant layer at the connection gap are seamlessly connected.

[0013] In a possible implementation, before the hose and the joint are connected by crimping, 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 joint are connected by crimping, the completely stripped section corresponds to the position of the anti-pulling-off section in the super wear-resistant inner core body, and the partially stripped section corresponds to the position of the sealing section in the super wear-resistant inner core body.

[0014] In a possible implementation, the preparation process of the super wear-resistant inner core body includes: processing and forging a metal material to obtain a metal inner core body; performing sand blasting treatment on the inner hole inner wall of the metal inner core body, and performing smearing treatment on the inner hole inner wall of the metal inner core body after the sand blasting treatment by using an adhesive to form a bonding interface; injecting a wear-resistant high polymer synthetic material into the inner hole inner wall of the metal inner core body after heating the wear-resistant high polymer synthetic material based on an injection molding machine, so that the wear-resistant high polymer synthetic material forms a core super wear-resistant layer at the bonding interface; and performing vulcanization treatment on the metal inner core body, the adhesive and the core super wear-resistant layer to obtain a super wear-resistant inner core body.

[0015] In a possible implementation, the preparation process of the hose includes: performing winding treatment on a tire membrane tube by using a super high molecular weight polyethylene film to obtain a tube super wear-resistant layer; placing the tire membrane tube with the tube super wear-resistant layer wound thereon in an inner rubber extruder, and performing inner rubber coating based on the inner rubber extruder, so that an inner rubber layer is formed outside the tube super wear-resistant layer; performing inner fabric winding treatment outside the inner rubber layer to obtain an inner fabric layer; performing steel wire winding treatment 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 treatment outside the steel wire skeleton layer to obtain an outer fabric layer; and performing outer rubber coating treatment outside the outer fabric layer to obtain an outer rubber layer.

[0016] After winding a vulcanization cloth outside the outer rubber layer, a composite layer including the tube super wear-resistant layer, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer is subjected to vulcanization treatment, and after the vulcanization treatment, the vulcanization cloth and the tire membrane tube are removed to obtain the hose.

[0017] The embodiments of the present application provide a super wear-resistant fracturing hose assembly and a preparation method thereof, which have the following advantages compared with the prior art.

[0018] The super wear-resistant fracturing hose assembly comprises a hose and a joint arranged at both ends of the hose; wherein the hose comprises, from inside to outside, a pipe body super wear-resistant layer, an inner rubber layer and a steel wire framework layer; the joint comprises a super wear-resistant inner core body composed of a metal inner core body and a core body super wear-resistant layer, a first sleeve sleeved outside the super wear-resistant inner core body and a second sleeve sleeved outside the first sleeve; by arranging the pipe body super wear-resistant layer in the hose and adopting the super wear-resistant inner core body composed of the metal inner core body and the core body super wear-resistant layer in the joint, the double super wear-resistant layer design can effectively resist the erosion of fracturing sand and other media and improve the wear resistance of the hose joint part.

[0019] The inner side of the second sleeve is connected with the outer side of the first sleeve by pressing, the inner side of the first sleeve is connected with the outer side of the steel wire framework layer by pressing, the inner side of the steel wire framework layer is connected with the super wear-resistant inner core body by pressing at the anti-pulling-off section of the super wear-resistant inner core body, the inner side of the steel wire framework layer is sealingly connected with the inner rubber layer at the sealing section of the super wear-resistant inner core body, and the inner rubber layer is sealingly connected with the super wear-resistant inner core body at the sealing section of the super wear-resistant inner core body; under the impact of high-pressure and high-flow-rate medium, this connection mode 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 property of the conveying medium and improve the operation safety.

[0020] The core body super wear-resistant layer and the pipe body super wear-resistant layer are connected by high-temperature welding with a welding rod, which further strengthens the connection strength of the joint and the hose, and makes the whole structure realize seamless transition at the wear-resistant layer. BRIEF DESCRIPTION OF DRAWINGS

[0021] The drawings incorporated into the specification and forming a part thereof show embodiments consistent with the present application and, together with the specification, serve to explain the principles of the application.

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced below, and obviously, other drawings can also be obtained by those skilled in the art without creative labor under the premise of not paying creative labor.

[0023] One or more embodiments are exemplarily illustrated by the pictures in the corresponding drawings, and these exemplary illustrations do not constitute a limitation on the embodiments, and the elements with the same reference numerals in the drawings represent similar elements, unless otherwise specified, and the drawings do not constitute a proportional limitation.

[0024] Figure 1 is a structural schematic view of one embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0025] Figure 2 Figure 1 is a schematic diagram of a hose structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0026] Figure 3 Figure 2 is a schematic diagram of a steel wire framework layer winding angle of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0027] Figure 4 Figure 3 is a schematic diagram of a super wear-resistant inner core structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0028] Figure 5 Figure 4 is a schematic diagram of a super wear-resistant layer welding of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0029] Figure 6 Figure 5 is a schematic diagram of a welding rod structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application;

[0030] Figure 7 Figure 6 is a schematic diagram of a flow of an embodiment of a preparation method of a super wear-resistant fracturing hose assembly provided by the present application. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme of the embodiments of the present application will be described clearly and completely below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0032] The following disclosure provides many different embodiments, or examples, for implementing different structures of the present application. For the purpose of simplification, the components and arrangements of specific examples are described in the following. Of course, they are merely examples, and the purpose is not to limit the present application. In addition, reference numerals and / or letters can be repeated in different examples. Such repetition is for the purpose of simplification and clarity, and does not itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0033] It should be understood that when used in the specification, the terms "comprise" and "comprising" indicate the presence of the 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 groups thereof.

[0034] It should also be understood that the terms used herein are for the purpose of describing particular embodiments and are not intended to limit the application. As used in this specification, "an", "a", or "the" as used herein means "one or more" unless the context clearly dictates otherwise.

[0035] It should also be further understood that the term "and / or" used in the specification means any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.

[0036] As used in this specification, the terms "if", "when" or "responsive to" can be interpreted to mean "upon determination" or "in response to a determination" or "upon detection" or "in response to a detection", depending on the context. Similarly, the phrases "if determined" or "if detected [the described condition or event]" can be interpreted to mean "upon determination" or "in response to a determination" or "upon detection" or "in response to a detection" of [the described condition or event], depending on the context.

[0037] Embodiment 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, as Figure 1 shown, the super-wear-resistant fracturing hose assembly includes a hose 10 and a connector 20 arranged at both ends of the hose 10, specifically as follows:

[0038] In an embodiment, the hose 10 includes, from inside to outside, a pipe body super-wear-resistant layer 101, an inner rubber layer 102, and a steel wire skeleton layer 103.

[0039] In an embodiment, the hose further includes an inner fabric layer 104, an outer fabric layer 105, and an outer rubber layer 106.

[0040] In an embodiment, the hose includes, from inside to outside, the pipe body super-wear-resistant layer 101, 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; as Figure 2 shown, Figure 2 is a structural schematic diagram of a hose of an embodiment of a super-wear-resistant fracturing hose assembly provided by the present application.

[0041] In an embodiment, the pipe body super-wear-resistant layer 101 is made of the same material as the core body super-wear-resistant layer in the super-wear-resistant inner core body, both of which are made of a wear-resistant high polymer synthetic material, preferably a film material.

[0042] Preferably, the wear-resistant high molecular synthetic material includes, but is not limited to, ultra-high molecular weight polyethylene (HMPE), polytetrafluoroethylene (PTFE), polyolefin elastomer (POE), etc.

[0043] Specifically, the thickness of the pipe body super wear-resistant layer 101 is 1mm-3mm, 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 0.1mm-0.2mm.

[0044] Specifically, the color types of the ultra-high molecular weight polyethylene film corresponding to all the winding layers are multiple; specifically, the color types are not less than 4.

[0045] Preferably, the color of each layer of ultra-high molecular weight polyethylene film is different, or the color of every two layers of ultra-high molecular weight polyethylene film is different; by selecting ultra-high molecular weight polyethylene films of different colors, the color of the ultra-high molecular weight polyethylene film between adjacent layers should be obviously distinguished, and the wear amount of the wear-resistant layer after use of the hose assembly can be quickly determined by color.

[0046] Example: when the pipe body super wear-resistant layer 101 is formed by winding 10 layers of the ultra-high molecular weight polyethylene film, the color of the selected ultra-high molecular weight polyethylene film is five colors, and the contact position with the inner rubber layer 102 is inside, from inside to outside, black, red, yellow, green, and white, and two layers of ultra-high molecular weight polyethylene film of each color are wound.

[0047] In an embodiment, the steel wire framework layer 103 should be formed by winding multiple layers of steel wire, the number of layers of steel wire winding of the steel wire framework layer 103 is not less than 8, 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.

[0048] Specifically, the framework material of the steel wire framework layer 103 adopts tin-plated bronze steel wire, the strength range is 2000MPa~3000MPa, and the elongation after break should be not less than 5%.

[0049] Specifically, the winding angle of the steel wire of the odd layer is smaller than the winding angle of the steel wire of the adjacent even layer; as Figure 3 shown, Figure 3 is a winding angle diagram of the steel wire framework layer of an embodiment of the super wear-resistant fracturing hose assembly provided by the present application, as shown in Table 1, Table 1 is a steel wire winding data table of a 3-inch 15000PSI specification fracturing hose.

[0050] Table 1:

[0051]

[0052] Specifically, since the cartilage assembly has a higher requirement for the pressure-bearing capacity of the pipe body and a smaller requirement for the pulse performance of the pipe during the fracturing operation, the steel wire winding angle of each layer of the steel wire framework layer 103 is designed to be between 54° and 55°, and the steel wire winding angle of each layer is different, and the steel wire winding angle of the odd layer is smaller than that of the adjacent even layer to realize smaller deformation of the pipe body under pressure. High-strength steel wires with a strength range of 2000 MPa to 3000 MPa are selected to improve the pressure-bearing capacity of a single steel wire, and the steel wire breakage elongation is required to be not less than 5% to coordinate the multiple layers of steel wires, so that each layer of steel wire bears force together, thereby improving the overall pressure-bearing capacity of the pipe body.

[0053] In an embodiment, the preparation process of the hose includes: performing a winding treatment on a tire membrane tube with an ultra-high molecular weight polyethylene film to obtain a pipe body ultra-wear-resistant layer 101; placing the tire membrane tube wound with the pipe body ultra-wear-resistant layer 101 in an inner rubber extruder, and performing inner rubber coating based on the inner rubber extruder to form an inner rubber layer 102 outside the pipe body ultra-wear-resistant layer 101; performing inner fabric winding treatment outside the inner rubber layer 102 to obtain an inner fabric layer 104; performing steel wire winding treatment on the inner fabric layer 104 based on a preset number of steel wire winding layers and a preset winding angle to obtain a steel wire framework layer 103; performing outer fabric winding treatment outside the steel wire framework layer 103 to obtain an outer fabric layer 105; performing outer rubber coating treatment outside the outer fabric layer 105 to obtain an outer rubber layer 106; winding a vulcanized water cloth outside the outer rubber layer 106, and then performing vulcanization treatment on the composite layer including the pipe body ultra-wear-resistant layer 101, the inner rubber layer 102, the inner fabric layer 104, the steel wire framework layer 103, the outer fabric layer 105, and the outer rubber layer 106, and after the vulcanization treatment, removing the vulcanized water cloth and the tire membrane tube to obtain the hose.

[0054] The preparation process of the hose is illustrated as follows:

[0055] a. Pipe body wear-resistant layer 101 winding: The ultra-high molecular weight polyethylene film is wound on the tire membrane tube for hose production, the single-layer film thickness is 0.2 mm, the number of winding layers is 10, and once winding is formed to keep the film layers from loosening due to back-and-forth transportation;

[0056] b. The wound ultra-high molecular weight polyethylene film is coated with an inner rubber layer 102 by an inner rubber extruder, and the rubber coating thickness is 4 mm;

[0057] c. The inner fabric layer 104 is wound on the inner rubber layer 102, the thickness is 1.5 mm, and the number of layers is 1;

[0058] d. winding a steel wire layer outside 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 at break of 5%; the number of layers of the steel wire winding is 8;

[0059] e. winding an outer fabric layer 105 outside the steel wire layer, the thickness of the outer fabric layer 105 is 1.5 mm, and the number of layers is 1;

[0060] f. winding an outer rubber layer 106 outside the outer fabric layer 105, the thickness of the outer rubber layer 106 is 3 mm;

[0061] g. winding a vulcanized cloth outside the outer rubber layer 106, the cloth is overlapped by 1 / 2;

[0062] h. entering a vulcanization tank for vulcanization, the vulcanization temperature is 150°C, and the vulcanization time is 150 min;

[0063] j. after the vulcanization is completed, the vulcanized cloth is removed, the tire membrane tube is extracted, and a finished product hose is obtained.

[0064] In an embodiment, the inner rubber layer 102 is prepared from the following raw materials by weight: 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 crosslinking agent, 60-80 parts of carbon black, 2-10 parts of organically modified hectorite, 10-15 parts of linear low-density polyethylene, and 5-8 parts of plasticizer; the above raw materials are weighed according to the weight, uniformly mixed based on a Banbury mixer, and then sheeted after discharging to obtain a sealing layer rubber material through an open mill.

[0065] The preparation process of the inner rubber layer 102 is exemplarily illustrated as follows:

[0066] The following raw materials are selected 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 crosslinking agent, 80 parts of carbon black, 8 parts of organically modified hectorite, 10 parts of linear low-density polyethylene, and 5 parts of plasticizer.

[0067] Preparation method: the above raw materials are weighed according to the weight, the ethylene-propylene rubber particles, linear low-density polyethylene particles, zinc oxide, stearic acid, and antioxidant are put into a Banbury mixer and mixed for 2 min, then the carbon black, organically modified hectorite, and plasticizer are added and mixed for 8 min, the discharging temperature is 100-120°C, the sheeting is performed after discharging, and then the sheet is cooled, stored for 24 h, filtered, and then the sulfur and crosslinking agent are added in the second stage, mixed for 30-50 s after being added, the discharging temperature is 80-100°C, the sheeting is performed after discharging, and then the sheet is cut and cooled, thereby the preparation of the inner rubber of the inner rubber layer 102 is completed.

[0068] In an embodiment, the joint 20 comprises a super wear-resistant inner core 201 composed of a metal inner core 2011 and a core super wear-resistant layer 2012, a first sleeve 202 sleeved outside the super wear-resistant inner core 201, and a second sleeve 203 sleeved outside the first sleeve 202.

[0069] Preferably, the joint further comprises a positioning ring 204.

[0070] In an embodiment, the metal inner core 2011 in the super wear-resistant inner core 201 is made of a metal material, wherein the metal material is alloy steel; for example, Figure 4 Figure 4 is a schematic diagram of a super wear-resistant inner core structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application.

[0071] Preferably, the alloy steel includes but is not limited to 42CrMo alloy steel, 35CrMo alloy steel, etc.

[0072] Specifically, the core super wear-resistant layer 2012 in the super wear-resistant inner core 201 is made of a wear-resistant high polymer synthetic material.

[0073] Preferably, the wear-resistant high polymer synthetic material includes but is not limited to ultra-high molecular weight polyethylene (HMPE), polytetrafluoroethylene (PTFE), and polyolefin elastomer (POE).

[0074] Specifically, by arranging the core super wear-resistant layer 2012 in the super wear-resistant inner core 201 of the joint, the wear of the joint by fracturing sand during the use of the hose assembly is changed from wear of the metal part to wear of the wear-resistant high polymer synthetic material, which can greatly prolong the wear resistance of the joint and improve the overall service life of the hose assembly.

[0075] In an embodiment, the preparation process of the super wear-resistant inner core 201 comprises: processing and forging a metal material to obtain a metal inner core 2011; performing sand blasting treatment on the inner wall of the inner hole of the metal inner core 2011, and performing smearing treatment on the inner wall of the inner hole of the metal inner core 2011 after the sand blasting treatment by using an adhesive to form a bonding interface; based on an injection molding machine, injecting a wear-resistant high polymer synthetic material into the inner wall of the inner hole of the metal inner core 2011 after heating the wear-resistant high polymer synthetic material, so that the wear-resistant high polymer synthetic material forms a core super wear-resistant layer 2012 at the bonding interface; and performing vulcanization treatment on the metal inner core 2011, the adhesive, and the core super wear-resistant layer 2012 to obtain a super wear-resistant inner core 201.

[0076] ​Specifically, the metal inner core body 2011 of metal material and the core super wear-resistant layer 2012 of non-metal material are subjected to composite treatment based on an adhesive. 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, the primer adhesive and the topcoat adhesive are used for primer coating and topcoat coating of the metal inner core body 2011, and the coating thickness of the primer coating and the topcoat coating is 0.01 mm-0.06 mm respectively. Preferably, the adhesive can also be an adhesive of the same raw material but different brands.

[0077] Specifically, the thickness of the core super wear-resistant layer 2012 is 1.0 mm-3.0 mm.

[0078] Specifically, when the vulcanization treatment is performed, the vulcanization temperature is set to 160°C-180°C, and the vulcanization time is 30 min-40 min.

[0079] The preparation process of the super wear-resistant inner core body 201 is exemplarily illustrated as follows:

[0080] a. The metal material of the metal inner core body 2011 is 42CrMo alloy steel, and the metal inner core body 2011 is obtained by overall forging processing of the 42CrMo alloy steel.

[0081] b. The inner hole inner wall of the metal inner core body 2011 is subjected to sand blasting treatment.

[0082] c. The adhesive of CILBOND® 12E is used for primer coating of the metal inner core body 2011 after the sand blasting treatment, and the coating thickness is 0.03 mm.

[0083] d. The metal inner core body 2011 after the primer coating is transferred to a ventilated place for air drying of the adhesive, and the drying time is 24 h.

[0084] e. The adhesive of CILBOND® 80ET is used for topcoat coating of the metal inner core body 2011 on the basis of the primer coating, and the coating thickness is 0.03 mm.

[0085] f. The metal inner core body 2011 after the topcoat coating is transferred to a ventilated place for air drying of the adhesive, and the drying time is 24 h.

[0086] g. The metal inner core body 2011 after the adhesive brushing is installed in a super wear-resistant layer shaping mold, and the gap between the inner hole inner wall and the shaping mold is 2 mm.

[0087] h. The metal inner core body 2011 with the shaping mold is installed into the injection molding machine mold, the super wear-resistant layer of the super high molecular weight polyethylene powder is heated to 250℃ by injection molding, and is injected onto the inner hole inner wall of the metal inner core body 2011, and the thickness of the super wear-resistant layer is 2mm;

[0088] i. After the injection molding is completed, the metal inner core body 2011 with the shaping mold is quickly transferred into a high-temperature box at 160℃ for constant temperature keeping, the keeping time is 30min, and vulcanization bonding of the adhesive and the metal and the super high molecular weight polyethylene is performed;

[0089] j. After the vulcanization is completed, the metal inner core body 2011 is transferred to the room temperature adjustment for cooling, the shaping mold is removed after the cooling to the room temperature, and the processing and preparation of the core super wear-resistant layer 2012 are completed.

[0090] In an embodiment, the preparation of the super wear-resistant fracturing hose assembly is to connect the soft body and the joint by crimping to form a whole.

[0091] In an embodiment, when the hose and the joint are crimped and connected, the end of the hose is processed by inner stripping and outer stripping to form the installation position of the joint.

[0092] Specifically, the inner rubber layer 102 corresponding to the crimping position is stripped according to the size of the joint to form a partial stripping section and a complete stripping section.

[0093] Specifically, when the hose and the joint are crimped and connected, the complete stripping section corresponds to the position of the anti-pull-out section 201a, and the partial stripping section corresponds to the position of the sealing section 201b.

[0094] Preferably, the length of the complete stripping section is consistent with the length of the anti-pull-out section 201a of the super wear-resistant inner core body 201, and the length of the partial stripping section is consistent with the length of the sealing section 201b of the super wear-resistant inner core body 201.

[0095] Preferably, the outer rubber layer 106 corresponding to the crimping position is also stripped according to the size of the joint.

[0096] In an embodiment, when the hose and the joint are crimped and connected, the inner side of the second sleeve 203 is crimped and connected with the outer side of the first sleeve 202, the inner side of the first sleeve 202 is crimped and connected with the outer side of the steel wire framework layer 103, the inner side of the steel wire framework layer 103 is crimped and connected with the anti-pulling-off section 201a of the super wear-resistant inner core body 201 and the super wear-resistant inner core body 201, the inner side of the steel wire framework layer 103 is sealingly connected with the inner rubber layer 102 at the sealing section 201b of the super wear-resistant inner core body 201, and the inner rubber layer 102 is sealingly connected with the super wear-resistant inner core body 201 at the sealing section 201b of the super wear-resistant inner core body 201; the super wear-resistant layer 2012 of the core body and the super wear-resistant layer 101 of the pipe body are connected by high-temperature welding with a welding rod 30.

[0097] Specifically, the second sleeve 203, the first sleeve 202, and the super wear-resistant inner core body 201 are installed to the end of the hose after stripping, the components in the joint are positioned and installed in place relative to the hose by the positioning ring 204, the anti-pulling-off section 201a corresponds to the position of the completely stripped section of the inner rubber layer 102 of the hose end, 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 crimped and connected respectively, and the components of the super wear-resistant crimped hose assembly are connected.

[0098] Specifically, when the inner rubber layer 102 is sealingly connected with the super wear-resistant inner core body 201 at the sealing section 201b of the super wear-resistant inner core body 201, the ethylene-propylene rubber in the inner rubber layer 102 and the ultra-high molecular weight polyethylene in the super wear-resistant layer 2012 of the core body are both non-polar polymers, have good compatibility, and the linear low-density ultra-high molecular weight polyethylene flows well under heat, so that the adhesion between the inner rubber layer 102 and the super wear-resistant layer 2012 of the core body in the sealing layer can be better enhanced.

[0099] In an embodiment, when the hose and the joint are crimped and connected, a connection gap exists between the super wear-resistant layer 2012 of the core body and the super wear-resistant layer 101 of the pipe body; therefore, the connection gap between the super wear-resistant layer 2012 of the core body and the super wear-resistant layer 101 of the pipe body needs to be connected by high-temperature welding with a welding rod 30 to realize seamless connection. Figure 5 Figure 5 is a super wear-resistant layer welding schematic diagram of an embodiment of the super wear-resistant crimped hose assembly provided in the present application.

[0100] ​In an embodiment, the welding rod 30 comprises a front excess cavity 301, a heating cavity 302, and a rear excess cavity 303, wherein a partition between the front excess cavity 301 and the heating cavity 302 is a welding rod front cover 304, a partition between the heating cavity 302 and the rear excess cavity 303 is a welding rod rear cover 305, the welding rod front cover 304 is provided with an air inlet, an air outlet, a temperature sensor, and a pressure sensor; as shown in Figure 6 Figure 6 is a schematic diagram of a welding rod structure of an embodiment of a super wear-resistant fracturing hose assembly provided by the present application.

[0101] Specifically, the heating cavity 302 in the welding rod 30 is placed below the connection gap, wherein the length of the welding rod 30 is greater than the length of the connection gap; when high-temperature steam is filled into the heating cavity 302, the welding rod 30 is welded based on the temperature sensor and the pressure sensor detecting that the preset temperature and the preset pressure are met, and the connection gap is pressed by the heating cavity 302 after thermal expansion, so that the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101 at the connection gap are seamlessly connected.

[0102] Specifically, when welding, the welding temperature is set to 150-170°C, and the welding time is set to 15-30 minutes.

[0103] 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 pipe body super wear-resistant layer 101; the heating cavity 302 therebetween is a sealed cavity, which can be filled with high-temperature steam to reach the set welding temperature, and the outer diameter size of the welding rod 30 is the same as the inner wall size of the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101, which is a close fit. Through thermal expansion and cold shrinkage, the wear-resistant layer is extruded during the welding process to achieve seamless combination.

[0104] The process of high-temperature welding connection of the connection gap between the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101 by the welding rod 30 is exemplarily illustrated as follows:

[0105] ​The joint after crimping is loaded into the welding rod 30, the center position of the heating cavity 302 is kept at the connection gap between the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101, high-temperature steam is filled into the heating cavity 302 of the welding rod 30 through the gas inlet, the internal temperature of the heating cavity 302 is 150 DEG C, the pressure is 0.5 MPa, after the heating cavity 302 reaches the temperature, the timing starts, the welding rod 30 is welded for 30 min, during the welding, the drainage treatment is carried out once every 5 min through the gas outlet, the condensed water in the heating cavity 302 is removed, the extrusion force of the connection gap between the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101 is provided through the thermal expansion of the heating cavity 302, seamless welding is realized, after the welding is completed, normal temperature air is introduced into the heating cavity 302 through the gas inlet for cooling, the welding rod 30 can be taken out after the internal temperature of the heating cavity 302 is reduced to room temperature, the seamless connection of the core super wear-resistant layer 2012 and the pipe body super wear-resistant layer 101 is realized.

[0106] In an embodiment, the super wear-resistant fracturing hose assembly in the embodiment of the application is subjected to a blasting test, and the blasting pressure can reach 38000 psi or more, which is basically consistent with the calculated value, verifying that the pressure-bearing capacity can be greatly improved.

[0107] Moreover, the super wear-resistant fracturing hose assembly in the embodiment of the application is subjected to a wear resistance test, and is compared with a fracturing steel pipe and a common fracturing rubber hose of the same specification; the wear resistance of the super wear-resistant fracturing hose assembly in the embodiment of the application, the fracturing steel pipe and the common fracturing rubber hose is detected based on the actual service life, and the specific wear resistance comparison results are shown in Table 2, which is a wear resistance comparison example table of different types of fracturing pipelines.

[0108] Table 2:

[0109]

[0110] It can be seen from Table 2 that the wear resistance of the super wear-resistant fracturing hose assembly prepared in the embodiment of the application is better, and the service life can be greatly improved.

[0111] In an embodiment, the steel wire skeleton layer prepared by different steel wire winding steps is used as a variable to make a hose, and the super wear-resistant fracturing hose assembly in the embodiment of the application is subjected to a blasting pressure comparison, and the following control groups are made respectively:

[0112] Control group 1: ordinary rubber hose is selected, and the copper-plated steel wire has a strength of 2000 MPa;

[0113] Control group 2: the steel wire mentioned in the embodiment of the application is used, but the steel wire winding angle is designed according to the winding angle of an ordinary high-pressure rubber hose.

[0114] The steel wire winding data of the control group 2 is shown in Table 3, which is an example table of the steel wire winding data of the control group 2.

[0115] Table 3:

[0116]

[0117] The blast test is performed on the hoses made of the control group 1 and the control group 2 and the ultra-wear-resistant fracturing hose assembly made in the embodiment of the application, and the comparison results are shown in Table 4, which is an example table of the blast pressure comparison of the fracturing hoses with different steel wire winding.

[0118] Table 4:

[0119]

[0120] It can be seen from Table 4 that the blast performance of the ultra-wear-resistant fracturing hose assembly prepared in the embodiment of the application is better.

[0121] In an embodiment, the wear-resistant layer of the pipe body made of the ultra-high molecular weight polyethylene film with multiple colors in the embodiment of the application is compared with the wear-resistant layer of the pipe body made of the ultra-high molecular weight polyethylene film with only white color, and the ultra-wear-resistant hose assemblies made of the two are subjected to wear resistance test. Based on the test results, it is known that the colored ultra-high molecular weight polyethylene film does not affect the adhesion between the films of each layer, nor does it affect the wear resistance performance of the wear-resistant layer of the pipe body. The ultra-wear-resistant hose assembly made of the ultra-high molecular weight polyethylene film with different colors can quickly determine the wear amount of the wear-resistant layer of the ultra-wear-resistant hose assembly after use. The colors of the wear-resistant layer film materials of adjacent layers should be obviously distinguished, and the wear amount of the wear-resistant layer of the hose can be quickly identified by color.

[0122] In an embodiment, the wear-resistant layer of the pipe body made of polytetrafluoroethylene (PTFE) and polyolefin elastomer (POE) is prepared by changing the variable of the wear-resistant layer material of the pipe body, and the corresponding hose is the control group. The wear resistance test is performed on the ultra-wear-resistant fracturing hose assembly made in the embodiment of the application, and although there is a certain difference in the test data compared with Table 2, the wear amount is better than that of the corresponding hose of the control group 1 and the control group 2.

[0123] Embodiment 2, see Figure 7 , Figure 7 is a flowchart of an embodiment of the ultra-wear-resistant fracturing hose assembly provided by the application, as shown in Figure 7 , the preparation method comprises steps S101 and S103, and the details are as follows:

[0124] Step S101: the hose and the connector are connected by pressing, wherein there is a connection gap between the core wear-resistant layer in the ultra-wear-resistant inner core body of the connector and the pipe body wear-resistant layer of the hose.

[0125] Step S102: placing a heating cavity in the welding rod below the connecting gap, wherein the length of the welding rod is greater than the length of the connecting gap.

[0126] Step S103: when the heating cavity is filled with high-temperature steam, the welding rod is welded based on the preset temperature and pressure detected by the temperature sensor and the pressure sensor in the welding rod, and the connecting gap is pressed by the heating cavity after thermal expansion to make the core body ultra-wear-resistant layer and the pipe body ultra-wear-resistant layer seamlessly connected at the connecting gap.

[0127] In an embodiment, before the hose and the joint are connected by crimping, the method further comprises: stripping the inner rubber layer of the hose to form a partially stripped section and a completely stripped section; when the hose and the joint are connected by crimping, the completely stripped section corresponds to the position of the anti-pull-out section in the ultra-wear-resistant inner core body, and the partially stripped section corresponds to the position of the sealing section in the ultra-wear-resistant inner core body.

[0128] In an embodiment, the preparation process of the ultra-wear-resistant inner core body comprises: processing and forging a metal material to obtain a metal inner core body; sandblasting the inner hole inner wall of the metal inner core body and applying adhesive to the sandblasted inner hole inner wall of the metal inner core body to form a bonding interface; heating and injecting wear-resistant high polymer synthetic material into the inner hole inner wall of the metal inner core body based on an injection molding machine, so that the wear-resistant high polymer synthetic material forms a core body ultra-wear-resistant layer at the bonding interface; and vulcanizing the metal inner core body, the adhesive and the core body ultra-wear-resistant layer to obtain an ultra-wear-resistant inner core body.

[0129] In an embodiment, the preparation process of the hose comprises: winding a tire membrane tube with an ultra-high molecular weight polyethylene film to obtain a pipe body ultra-wear-resistant layer; placing the tire membrane tube wound with the pipe body ultra-wear-resistant layer in an inner rubber extruder, and coating the inner rubber based on the inner rubber extruder to form an inner rubber layer outside the pipe body ultra-wear-resistant layer; winding an inner fabric layer outside the inner rubber layer; winding a steel wire skeleton layer above the inner fabric layer based on a preset number of steel wire winding layers and a preset winding angle; winding an outer fabric layer outside the steel wire skeleton layer; coating an outer rubber layer outside the outer fabric layer; winding a vulcanization cloth outside the outer rubber layer; and vulcanizing the composite layer comprising the pipe body ultra-wear-resistant layer, the inner rubber layer, the inner fabric layer, the steel wire skeleton layer, the outer fabric layer and the outer rubber layer after the vulcanization cloth and the tire membrane tube are removed to obtain the hose.

[0130] In the above embodiments, the description of each embodiment has its own focus, and the parts not described in detail in a certain embodiment can be referred to the relevant description of other embodiments.

[0131] Obviously, various modifications and changes can be made to the application without departing from the spirit and scope of the application.

[0132] The above description is merely illustrative of the application and not restrictive thereof. Any modifications made by those skilled in the art without departing from the technical scope disclosed in the application should be encompassed within the scope of the application.

Claims

1. A super wear-resistant fracturing hose assembly, characterized in that: include: A hose and connectors provided at both ends of the hose; The hose comprises, from the inside to the outside, a super wear-resistant layer of the tube body, an inner rubber layer, and a steel wire skeleton layer; The joint comprises a super wear-resistant inner core composed of a metal inner core and a super wear-resistant core layer, a first sleeve sleeved on the outside of the super wear-resistant inner core, 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 at the anti-pullout 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 high-temperature welded by a welding rod; The welding rod comprises a front transition chamber, a heating chamber, and a rear transition chamber; 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, the welding rod front cover is equipped with an air inlet, an air outlet, a temperature sensor, and a pressure sensor, and the welding rod is a hollow metal barrel; The length of the welding rod is greater than the connection gap between the core super-wear-resistant layer and the tube super-wear-resistant layer, the heating chamber in the welding rod is placed below the connection gap, and the outer diameter of the welding rod is the same as the inner wall size of the core super-wear-resistant layer and the tube super-wear-resistant layer; The preparation process of the super wear-resistant inner core comprises: 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 and injecting it into the inner wall of the inner hole of the metal inner core using an injection molding machine, 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; The inner rubber layer is prepared from the following raw materials in parts by weight: 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 crosslinking 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 preparation method of the inner rubber layer comprises the following steps: weighing the above raw materials according to parts by weight, adding ethylene propylene rubber particles, linear low-density polyethylene particles, zinc oxide, stearic acid, and an antioxidant into an internal mixer and mixing for 2 minutes, then adding carbon black, organic rectorite, and a plasticizer, mixing for 8 minutes, and setting the binder removal temperature at 100-120° C., cooling the sheet on an open mill after the binder removal, standing for 24 hours, and then filtering, adding sulfur and a cross-linking agent in two stages after filtration, mixing for 30-50 seconds after the addition, and setting the binder removal temperature at 80-100° C., cutting the sheet on an open mill after the binder removal, and cooling the sheet, thereby completing the preparation of the inner rubber layer; In which, the hose and the connector are connected by buckling, and before the hose and the connector are buckled, the inner rubber layer corresponding to the buckling position is stripped according to the size of the connector to form a partially stripped section and a completely stripped section; when the hose and the connector are buckled, 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.

2. The super wear-resistant fracturing hose assembly according to claim 1, characterized in that: The metal inner core of 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 tube body super wear-resistant layer, 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, characterized in that: The thickness of the super wear-resistant layer of the pipe body is 1mm-3mm, and the super wear-resistant layer of the pipe 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.

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 within the range of 54°-55°, and the winding angle of each layer of steel wire is different.

6. A method for preparing the super-wear-resistant fracturing hose assembly according to any one of claims 1 to 5, characterized in that: include: The hose and the connector are buckled and connected, 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; 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 core super-wear-resistant layer and the tube super-wear-resistant layer are welded based on the temperature sensor and pressure sensor in the welding rod detecting that the preset temperature and preset pressure are met. Based on the heating chamber applying pressure to the connection gap after thermal expansion, the core super-wear-resistant layer and the tube super-wear-resistant layer at the connection gap are seamlessly connected.

7. The method for preparing the super wear-resistant fracturing hose assembly according to claim 6, characterized in that: Before the hose and the connector are crimped together, the method further comprises: The inner rubber layer of the hose is subjected to a stripping process to form a partially stripped section and a completely 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.

8. The method for preparing the super wear-resistant fracturing hose assembly according to claim 6, wherein: The preparation process of the hose includes: The fetal membrane tube is wrapped with 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 performing inner rubber coating 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 wrapping the vulcanized water cloth around the outside of the outer rubber layer, the composite layer comprising 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. After the vulcanization treatment, the vulcanized water cloth and the fetal membrane tube are removed to obtain the hose.

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