Manufacturing method of composite zero-buoyancy hose

Abstract

The invention relates to a manufacturing method of a composite zero-buoyancy hose, which comprises the following steps: step 1, raw material preparation: selecting rubber or synthetic resin as a base material, and selecting polyester synthetic fiber, hollow glass beads, a compounding agent and a steel wire; step 2, mixing: adding the base material, the hollow glass beads and the compounding agent into mixing equipment according to a certain formula proportion to form a mixture; step 3, calendaring: calendaring the mixture through a calendaring machine to form a blank sandwiched with polyester fibers; 4, winding is conducted, specifically, the blank, the polyester synthetic fiber wire or the net sheet coiled material is wound on an iron core of a seat hose mold according to the preset sequence and the preset layer number through a winding machine; and step 5, molding: curing the wound intermediate product to form the composite zero-buoyancy hose after the intermediate product is subjected to a vulcanization process or a hot press molding process. And 6, post-treatment is conducted, specifically, the zero-buoyancy hose is packaged after trimming and inspection procedures are conducted.

Description

Technical Field

[0001] The present invention relates to the technical field of hoses for shipbuilding and marine engineering, and in particular to a method for manufacturing a composite material zero-buoyancy hose, which is a composite material zero-buoyancy hose with high compression resistance, high tensile resistance and high elasticity for deep sea use. Background Art

[0002] In the field of shipbuilding and marine engineering, hoses for conveying fluids are often used, such as hoses for conveying water, oil, liquid chemicals, liquefied natural gas, compressed gas or dredging mud. However, the hoses produced under existing technical conditions cannot fully meet certain specific application requirements in shipbuilding and marine engineering and other industrial fields. For example, there is currently no hose that can meet the requirements of high compressive strength, high tensile strength and positive buoyancy or zero buoyancy in the deep sea.

[0003] Under existing technical conditions, there are three main types of hoses classified by material:

[0004] (1) Rubber hose:

[0005] Ordinary rubber hose: generally made of natural rubber or synthetic rubber. This hose has good flexibility and elasticity and can withstand a certain pressure. For example, in the fresh water delivery system of ships, it can be used to connect water storage tanks and water equipment, deliver domestic water, etc. Its working pressure is usually between 0.1-0.6MPa, and the inner diameter ranges from 6mm to 150mm.

[0006] Oil-resistant rubber hose: The main component is oil-resistant rubber materials such as nitrile rubber. It plays a key role in the fuel delivery system of ships, such as the fuel pipeline from the fuel storage tank to the engine, which can effectively prevent fuel leakage because it has good tolerance to various fuels (such as diesel, heavy oil, etc.). The working pressure is usually 0.6-15MPa. According to different application scenarios, its inner diameter is also different, and it is commonly used for pipelines with a diameter of 6-150mm.

[0007] In order to improve durability, the rubber hose is often coated with a metal wire braid layer in practical applications. The pipe interfaces of equipment that vibrates greatly during operation are often connected to external pipes through rubber hoses to prevent the excitation force from being transmitted to the pipes and causing severe vibration of the pipes. The pipe interfaces on equipment parts that will move or move during operation are often connected to external pipes through hoses to compensate for the displacement or movement.

[0008] (2) Plastic hose:

[0009] PVC (polyvinyl chloride) hose: It is light and corrosion-resistant. It is widely used in ship drainage systems, such as collecting and discharging rainwater on the deck or water in the bilge. Its working pressure is relatively low, generally around 0.5-1.6MPa, and its inner diameter varies from a few millimeters for fine drainage to tens of millimeters for large drainage areas.

[0010] PE (polyethylene) hose: This hose has good wear resistance and impact resistance. It is used in some underwater equipment connections in marine engineering, such as protective sleeves for connecting data transmission lines and power lines of underwater robots. Its working pressure varies according to factors such as wall thickness, about 1-5MPa, and the inner diameter range is also wide, from a few millimeters for fine line protection to larger sizes for main cable protection.

[0011] (3) Metal hose:

[0012] Stainless steel hose: Made of stainless steel, it is resistant to high temperature, high pressure and corrosion. In the high-temperature steam delivery system of ships, such as the steam pipeline in the ship's power system, it can withstand the pressure (working pressure can reach 10-30MPa) and temperature (up to 200-500℃) of high-temperature steam. At the same time, it also has good tolerance to corrosive environments such as seawater. The inner diameter is usually around 10-100mm and is used to transport large amounts of high-temperature steam.

[0013] Copper alloy hose: has good conductivity and flexibility. In the ship's electrical system, it can be used as a protective and connecting component for wires, especially in some parts that need to be frequently moved or bent, such as the electrical connection part of the ship's crane. The working pressure is low, mainly considering its conductivity and mechanical properties. The inner diameter is generally between 5-20mm.

[0014] Under existing technical conditions, there are four main types of hoses classified by the conveying medium:

[0015] (1) Oil delivery hose:

[0016] Used for oil transfer between ships, between ships and docks, or between ships and platforms. This type of hose usually has a multi-layer structure, including an oil-resistant rubber inner layer, a reinforcement layer (such as a steel wire braided layer) and an outer protective layer. The reinforcement layer can improve the pressure resistance of the hose, enabling it to withstand the pressure during oil transfer. Its working pressure is generally between 0.6-1.6MPa, and the length can be customized according to the actual transmission distance, ranging from a few meters to hundreds of meters. The inner diameter size is based on the flow rate requirements of the oil transfer, generally between 50-300mm.

[0017] (2) Water hose:

[0018] It is mainly used for the delivery of fresh water, seawater and fire water on ships or offshore platforms. Fire hoses need to be able to withstand high water pressure to ensure that they can effectively spray water to extinguish fires. The general working pressure is between 0.8-1.6MPa, and its inner diameter is usually around 40-100mm. The length will also vary depending on the size of the ship and the layout of the fire protection system, and it needs to have good aging and wear resistance.

[0019] (3) Ventilation hose:

[0020] Used for temporary or fixed ventilation systems of ships or offshore platforms, such as temporary ventilation during construction, engine room ventilation, cargo hold ventilation and cabin ventilation. This hose is usually required to have good flexibility and ventilation performance, and the material is generally plastic or fiber fabric. For example, the plastic film ventilation hose used in ship construction and the PVC ventilation hose used in engine room, cargo hold and cabin ventilation can effectively transport fresh air and reduce indoor temperature and humidity. Its working pressure is low, mainly considering the ventilation flow rate. The inner diameter ranges from 100-500mm, and the length depends on the layout of the ventilation duct.

[0021] (4) Cable protection hose:

[0022] It is mainly used to protect cables on ships and prevent them from mechanical damage, chemical corrosion and electromagnetic interference. PE carbon corrugated hoses and metal hoses (such as stainless steel or copper alloy hoses) are widely used in this regard. They can improve the appearance, protect cables, shield external electromagnetic interference, and ensure the stability of cable signal transmission. The inner diameter is determined according to the size and quantity of the cable, generally between 10-50mm, and the length can be adjusted according to the length of the cable laying.

[0023] Under existing technical conditions, there are three main types of hoses classified by structure:

[0024] (1) Non-bonded hose:

[0025] Non-bonded hoses are widely used in marine risers and submarine oil pipelines. In marine oil and gas development, they can be used for risers connecting offshore platforms with submarine oil wells, as well as pipelines for transporting oil and gas resources on the seabed. They can also be used in some parts that need to be frequently moved or bent, such as ship refueling pipes. Because of the relative displacement characteristics between layers, they can better adapt to the swaying of ships and the bending deformation of pipelines. Non-bonded hoses are composed of multiple independent layers. There is no fixed connection between the layers. Relative displacement between layers is allowed when bending, which can better meet the special requirements of field applications. There are generally 6 layers, from outside to inside:

[0026] Outer covering layer: usually made of polymer material, its function is to prevent external fluid from entering the flexible pipe structure and protect the internal layers.

[0027] Tensile layer: Use flat, round or shaped metal, spirally wound at 20-60° to provide the required tensile strength for the pipe.

[0028] Wear-resistant layer: located between metal layers, it can reduce the wear between metals and increase the service life of the hose.

[0029] Pressure-resistant layer: interlocking metal layer used to bear internal pressure load. When the pressure is high, a reserve pressure-resistant layer can be added to enhance the pressure-resistant capacity.

[0030] Inner tube: It is a polymer layer. Its main function is to prevent the internal fluid from flowing out of the flexible tube and ensure the sealing of fluid transportation.

[0031] Carcass: Interlocking metal layers that primarily resist external pressure loads and maintain the shape and structural stability of the hose.

[0032] (2) Bonding hose:

[0033] Bonded hoses are generally rubber hoses or other polymer hoses, and are often used in engineering applications with shorter lengths, such as floating pipes, jumper pipes, etc. They may be used in some local systems of ships, such as small vibration isolation pipes, motion compensation pipes, cooling water pipes, and some short-distance chemical delivery pipes inside ships. In marine engineering, they are also used in some occasions that do not require too long pipes and have high requirements for structural integrity and sealing, such as connecting pipes between certain specific equipment on offshore platforms.

[0034] If the adhesive hose is a rubber hose, it is often made of rubber as the base material, with fiber layers and spiral steel wire layers embedded in layers to increase the strength against external pressure, internal pressure, and axial tension. The manufacturing process requires vulcanization, and a higher bonding strength is generated between the base material and the reinforcement layer. If the adhesive hose is other polymer hoses, it is often squeezed into one piece through physical methods such as extrusion and molding, and a higher bonding strength is generated between the base material and the reinforcement layer.

[0035] The density of the base material of the adhesive hose is relatively small, and it is often used to make floating hoses. There are two main methods for making floating hoses: one is to add a layer of low-density foamed polymer buoyancy material to the outer layer of the adhesive hose. The advantage is that the buoyancy material and the hose are designed and manufactured in an integrated manner, which saves the work of installing the buoyancy unit when in use. The disadvantage is that the diameter is larger after adding the buoyancy layer, which increases the difficulty of operation and storage; the second is to install an independent hollow buoy or a buoy filled with foam material on the outer surface of the adhesive hose. The advantage is that the buoyancy unit can be disassembled and installed more flexibly, but the disadvantage is that the workload of disassembling and installing the buoyancy unit when entering and leaving the site is relatively large.

[0036] Under existing technical conditions, it is not possible to obtain or produce high-pressure, high-tensile, high-elastic positive buoyancy or zero buoyancy hoses suitable for deep sea. The reasons are as follows:

[0037] Although the non-bonded hose has high compressive strength and tensile strength, the use of a large amount of high-density polymer or metal materials results in a high average density of the non-bonded hose, which is much greater than the density of water, and therefore cannot produce positive buoyancy or zero buoyancy in water.

[0038] The adhesive hose commonly used to make floating hoses uses less metal materials and has a relatively low average density. After the outer surface is coated with a foam material of appropriate thickness, it can float on the water. However, the commonly used foam buoyancy materials have low compressive strength and can be used normally on the water surface or at a depth of 10m or less. However, when entering deep water and the sea pressure increases, this foam buoyancy material will be crushed due to its low compressive strength, and the drainage volume will be reduced and lose buoyancy, causing the hose to sink and fail to remain floating or suspended, and cannot meet the use requirements. Summary of the invention

[0039] In view of the deficiencies in the prior art, the object of the present invention is to provide a method for manufacturing a composite material zero buoyancy hose, which is a bonding hose that has high compressive strength, high tensile strength, high elasticity, and a density less than fresh water / seawater, and can generate positive buoyancy or zero buoyancy. The hose can be used in the deep sea (more than 200m deep), can withstand greater pressure and tension (can withstand deep sea water pressure (2-40MPa) and load tension under operating conditions (tensile stress not less than 20MPa, etc.), has high elasticity characteristics (compensates for movement / displacement under operating conditions and is easy to roll and store), and has positive buoyancy or zero buoyancy characteristics (provides positive buoyancy for the device to which it belongs or protects the device from the adverse effects of the positive buoyancy / gravity generated by it).

[0040] The above-mentioned object of the present invention is achieved through the following technical solutions:

[0041] A method for manufacturing a composite material zero buoyancy hose comprises the following steps:

[0042] Step 1: Prepare raw materials, select rubber or synthetic resin as the base material, and select polyester synthetic fiber, hollow glass microspheres, compounding agent and steel wire;

[0043] Step 2: mixing, adding the base material, hollow glass microspheres and compounding agent into a mixing device according to a certain formula ratio, and uniformly dispersing the hollow glass microspheres and compounding agent in the base material through mechanical stirring and shearing to form a mixed material;

[0044] Step 3, calendering, calendering the mixed material through a calender to form a sheet of a certain thickness and width, introducing the pretreated polyester synthetic fiber wire into the calender so that it is closely attached to the sheet during the calendering process to form a blank with polyester fibers, and cutting the size of the blank through a cutting machine according to the target size of the flexible composite material sheet;

[0045] Step 4: Winding: Install flanges at both ends of the core mold, and wind the long strip of blank onto the core of the seat hose mold through a winding machine in a predetermined order and number of layers. Use the mold and wire guide device to wind the steel wire onto the surface of the core mold that has been wound with some materials at a certain pitch. After the spiral steel wire is wound, wind other materials in turn. After all materials are wound, wrap the outermost layer with outer cloth.

[0046] Step 5: Forming: the wound intermediate product is cured and formed into a composite material zero buoyancy hose after a vulcanization process or a hot pressing process;

[0047] Step 6, post-processing, reversely rotate the iron core to remove the outer cloth, pressurize the iron core, and inspect the appearance, size, and physical and mechanical properties of the composite material zero buoyancy hose after the trimming process, and then package the qualified composite material zero buoyancy hose;

[0048] When the base material in step 1 is the rubber, the mixing temperature in step 2 is set to a range of 160-210° C.;

[0049] When the substrate in step 1 is the synthetic resin, the mixing temperature in step 2 is set to a range of 150-200° C.;

[0050] In step 2, the mixing equipment adopts a two-stage internal mixer, the first-stage mixing temperature is 160-180° C., and the second-stage mixing temperature is 190-210° C.;

[0051] The hollow glass microspheres have a compressive strength of 110-130 MPa and an actual density of 0.42-0.46 g / cm 3 , average diameter 15-20μm, softening temperature ≥600℃;

[0052] In the step 2, the formula ratio of the substrate, the hollow glass microspheres and the compounding agent is 7:2:1.

[0053] As a further technical solution of the present invention: when the base material in step 1 is the rubber, the vulcanization process of step 5 is adopted: the hose wrapped with the raw materials and the iron core are pushed into a vulcanization furnace or a vulcanization tank together, and a vulcanization reaction is carried out at a certain temperature and pressure to further vulcanize and cure the rubber, and the vulcanization temperature is set between 140-180°C.

[0054] As a further technical solution of the present invention: when the substrate in the step 1 is the synthetic resin, the hot pressing molding process of the step 5 is adopted: the intermediate product after winding is placed in a hot pressing furnace or an autoclave, and hot pressing molding is performed at a temperature of 180-220°C and a pressure of 10-30MPa, and the hot pressing time is 5-30min. After hot pressing molding, the intermediate product is taken out of the hot pressing furnace or the autoclave for cooling, so that the hose is cooled and solidified to maintain the shape after molding.

[0055] As a further technical solution of the present invention: in step 4, the steel wire winding adopts a variable pitch process, the pitch in the middle of the tube body is 8-10 times the diameter of the steel wire, and the pitch at the end is 12-15 times the diameter of the steel wire.

[0056] As a further technical solution of the present invention: in step 5, the vulcanization adopts a gradient pressure-increasing process, with an initial pressure of 2-3 MPa, an increase of 0.5 MPa every 10 minutes, and finally reaching 8-10 MPa and maintaining it for 30-45 minutes.

[0057] As a further technical solution of the present invention: the surface of the hollow glass microspheres is treated with silane coupling agent KH-570, and the amount of the treating agent is 0.8-1.2% of the mass of the microspheres.

[0058] As a further technical solution of the present invention: the polyester synthetic fiber adopts a 3D orthogonal weaving structure, the warp fiber density is 80-100 fibers / cm, and the weft fiber density is 60-80 fibers / cm.

[0059] As a further technical solution of the present invention: the calendering in step 3 adopts a three-roller different speed ratio calendering process, the upper roll line speed is 15-20% faster than the middle roll, and the middle roll is 10-15% faster than the lower roll.

[0060] In summary, the present invention includes at least one of the following beneficial technical effects:

[0061] 1. It is not possible to manufacture high-compression, high-tensile, high-elastic positive buoyancy or zero buoyancy hoses for deep sea use using existing technologies, and it cannot meet certain specific application requirements in shipbuilding, marine engineering and other industrial fields. The present invention develops a hose structure and preparation method of a flexible composite material with rubber or synthetic resin or other similar materials as the base material. By selecting material components with suitable properties and their usage ratios, the various material components are made compatible with each other to form a unified whole. The resulting flexible composite hose can simultaneously possess the four properties of high compressive strength, high tensile strength, high elasticity and an average density equal to that of water to generate positive buoyancy or zero buoyancy, and can meet certain specific application requirements in shipbuilding, marine engineering and other industrial fields. Its compressive strength can reach no less than 40MPa, its tensile strength can reach no less than 20MPa, its resilience is high, and its average density can be as low as 0.7-1.03t / m3 The composite hose can meet certain specific application requirements in shipbuilding and marine engineering and other industrial fields, such as being used in deep sea (deeper than 200m), being able to withstand greater pressure and tension (withstanding deep sea water pressure (2-40MPa) and load tension under operating conditions (tensile stress not less than 20MPa)), having high elasticity (compensating for movement / displacement under operating conditions and being easy to roll and store), and having positive buoyancy or zero buoyancy characteristics (providing positive buoyancy for the device or protecting the device from the adverse effects of positive buoyancy / gravity generated by the hose itself).

[0062] 2. The base material of the composite hose is rubber, synthetic resin or other similar materials. The finished product manufactured with it as the base material according to a specific formula can meet higher compressive strength requirements, and the tensile strength of the polyester fiber introduced in the preparation process of the composite hose is generally between 350-700MPa. The high tensile strength of the polyester fiber, after it is well combined with the rubber or synthetic resin or other similar materials as the base material, ensures the high tensile strength, high compressive strength and high shear strength characteristics of the composite hose.

[0063] 3. The diameter of the hollow glass microspheres introduced in the preparation process of the composite hose is extremely small (about 20 μm), which is comparable to the diameter of flour particles. This feature enables it to be fully mixed with other compounding agents or additives, and similar materials such as rubber or synthetic resin as the base material, and to be distributed as evenly as possible without causing discontinuity or cracking of the base material, thereby ensuring the high tensile strength, high compressive strength, high shear strength and high elasticity of the composite hose. Mechanical and mechanical properties.

[0064] 4. The hollow glass microspheres introduced are made of glass, which has stable physical and chemical properties. It will not undergo physical and chemical reactions with the substrate and other compounding agents or additives, and will not have a negative impact on the mechanical properties and mechanical properties of the composite hose, thereby ensuring the high compressive strength, high tensile strength, high compressive strength, high shear strength and high elasticity of the composite hose.

[0065] 5. The actual density of the hollow glass microspheres introduced is as low as 0.46t / m 3 , and its glass material is special glass with good thermal stability, and its softening temperature is not less than 600°C. When the composite hose uses rubber as the base material, the commonly used rubber vulcanization temperature is lower than 200°C. When synthetic resin and other similar materials are used as the base material, the commonly used melting temperature is also lower than 200°C. The hollow glass microspheres will not soften and lose the ability to maintain their shape, thereby ensuring the low density / buoyancy characteristics of the composite hose.

[0066] 6. In the mixing, calendering, winding, vulcanization / hot pressing and post-processing of the composite hose preparation method, there is no process for applying impact loads and impact forces, and the hollow glass microspheres introduced have a compressive strength of up to 110MPa, which can ensure that most of the hollow glass microspheres will not break, thereby ensuring the low density / buoyancy characteristics of the composite material and the high compressive strength characteristics of the composite hose. In the composite hose preparation method, a spiral steel wire layer with appropriate wire diameter, major diameter and pitch is introduced. After the spiral steel wire layer and the rubber or synthetic resin and other similar materials as the base material are properly processed in the production process, the composite hose's resistance to internal and external pressures and elasticity are enhanced. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 It is a longitudinal cross-sectional view of the pipe wall of the composite material zero buoyancy hose of the present invention.

[0068] Reference numerals: 1. hose inner wall substrate layer; 2. first tensile and compressive resistant layer; 3. reinforcing layer; 4. second tensile and compressive resistant layer; 5. hose outer wall substrate layer. DETAILED DESCRIPTION

[0069] The technical solutions 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 only part of the embodiments of the present application, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field based on the embodiments in the present application without making creative work are within the scope of protection of the present application.

[0070] In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", "top / bottom" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as limiting the present application. In addition, the terms "first" and "second" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0071] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "set / connected", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0072] The present invention relates to the technical field of hoses for shipbuilding and marine engineering, and in particular to a bonding hose having high compressive strength, high tensile strength, high elasticity, a density less than that of fresh water / sea water, and the ability to generate positive buoyancy or zero buoyancy, and a manufacturing method thereof.

[0073] The present invention relates to a hose having high compressive strength, high tensile strength, high elasticity, a density less than fresh water / sea water, and the ability to generate positive buoyancy or zero buoyancy, a compressive stress of not less than 40 MPa, a tensile stress of not less than 20 MPa, and an average density as low as 0.7-1.03 t / m 3 The advantages of this hose are that it can be used in deep sea (deep than 200m), can withstand greater pressure and tension (can withstand deep sea water pressure (2-40MPa) and load tension under operating conditions (tensile stress not less than 20MPa)), has high elasticity (compensates for movement / displacement under operating conditions and is easy to roll and store), and has positive buoyancy or zero buoyancy characteristics (provides positive buoyancy for the device or protects the device from the adverse effects of the positive buoyancy / gravity generated by it).

[0074] In the prior art, reference document 11, such as Japanese patent with publication number JP2007146891A, discloses a marine hose, which solves the technical problem that: in a hose used for offshore crude oil transportation, when the buoyancy layer is partially damaged, the hose can be effectively prevented from sinking as a whole. The method adopted is to add hollow spheres with a diameter of 15mm to 100mm made of resin material to the foamed body of the conventional buoyancy layer, which increases the buoyancy on the one hand and discretizes the buoyancy on the other hand, so that the buoyancy will not be lost too much due to partial damage to the buoyancy layer, thereby causing the hose to sink. In other words, the hose provided by reference document 1 floats on the water surface under normal working conditions. Reference document 1 does not mention that the technical solution or product can be used in a high-pressure environment in the deep sea (the conventional foamed buoyancy layer and the hollow spheres made of resin material cannot withstand the water pressure of more than 200m deep. In this environment, the foamed buoyancy layer and the hollow spheres will be destroyed and lose buoyancy).

[0075] Comparative Document 1 uses hollow spheres with a diameter of 15mm to 100mm made of resin. Since the softening temperature of the resin is too low, usually around 100°C, it cannot be applied to the vulcanization or hot pressing process used in the application document.

[0076] Comparative Document 1 uses hollow spheres with a diameter of 15mm to 100mm made of resin. Due to the large diameter, they cannot be evenly and fully mixed with the rubber or synthetic resin material of the tube wall, which greatly limits the thickness of the tube wall (it cannot be made into a thin-walled tube or a multi-layer thin-walled tube). The large size also causes discontinuity in the material itself, seriously affecting the mechanical properties of the material.

[0077] Compared with Comparative Document 1, the technical solution provided by the present invention does not set up a separate buoyancy layer, but instead obtains buoyancy by evenly mixing high-strength hollow glass microbeads into the main tube wall materials such as rubber, thereby reducing the density of the tube wall material, thereby achieving a suspended state (zero buoyancy) in which buoyancy and gravity are balanced.

[0078] The technical solution provided by the present invention reduces the density of the pipe wall material while maintaining its compression resistance, tensile strength and high elasticity.

[0079] The tube wall material and hollow glass microspheres provided by the present invention have high pressure resistance and will not be crushed or significantly elastically compressed under deep sea (deep 200m) water pressure, and can still maintain their shape and displacement volume, thereby maintaining buoyancy. In the deep sea, a state of buoyancy and gravity balance can still be achieved, allowing the hose to remain suspended.

[0080] The technical solution provided by the present invention does not set up a separate buoyancy layer, nor does it adopt a foamed buoyancy layer that is the same or similar to that of Comparative Document 1, thereby avoiding the disadvantage that this buoyancy material cannot withstand higher pressures, which will result in the inability to maintain its shape in the deep sea (deep than 200m), and will be crushed and damaged, resulting in a loss of drainage volume and thus a loss of buoyancy.

[0081] Reference document 2 (CN108314808A) discloses a deep-sea flexible buoyancy material with vulcanized liquid rubber as the matrix and hollow glass microspheres as the buoyancy medium. The material is vulcanized by mixing liquid rubber and hollow microspheres to form an elastic buoyancy body. Although the material has a low density (0.6-0.8g / cm 3 ) and deep-sea compression resistance (40MPa water absorption rate <1%), but its application scenario is block buoyancy filling material, does not involve hose structure design, and uses liquid rubber vulcanization process, and cannot be directly used for multi-layer composite manufacturing of hoses. The volume deformation rate of this material at 40MPa is 10-15%. In actual application scenarios, when diving from the sea surface to the deep sea, the total buoyancy changes greatly and cannot maintain a suspended state. Due to the limitations of the material structure, its tensile strength is only 4-5MPa.

[0082] Compared with the comparative document 2, the innovation and difference of the present invention are as follows:

[0083] 1. Structural differences: The overall structure of the hose is constructed through a multi-layer composite process (inner rubber layer, tensile layer, spiral steel wire reinforcement layer, etc.), while the comparison document only uses a single buoyancy material;

[0084] 2. Material process: The present invention uses solid rubber / synthetic resin substrate and hollow glass microspheres to mix and calender into sheets, combined with polyester fiber reinforcement and spiral steel wire winding, to achieve high compressive strength (≥40MPa) and high tensile strength (≥20MPa) of the hose, wherein the high tensile strength is significantly different from the performance disclosed in the comparative documents, and the comparative documents do not involve such a composite process;

[0085] 3. Functional expansion: The present invention achieves zero buoyancy while solving the problem of dynamic load adaptability of deep-sea hoses through uniform dispersion of hollow glass microspheres and multi-layer reinforcement design, while the comparative document only provides a static buoyancy filling function.

[0086] Comparative Document 3 (US20140126865A1) discloses an underwater cable structure, including a waterproof layer, a tensile layer and a communication cable. This cable is connected to a ship on the water surface, and the ship supplies power to the underwater equipment and communicates. Its tensile layer is reinforced with aramid fiber or polyethylene fiber, and the outer layer is coated with thermoplastic polyurethane material, which has a certain tensile strength. However, this cable is centered on the communication function, and the buoyancy is used to keep the cable in an upward posture in the water. The core problem to be solved is to avoid itself from being entangled or entangled on seabed reefs or branches, and it does not have high tensile strength.

[0087] The innovation and difference of the present invention are as follows:

[0088] 1. Different functional objectives: The present invention focuses on fluid transportation, and improves the internal / external pressure resistance and elasticity through the spiral steel wire winding structure (pitch controllable) of the tube wall, and improves the ability to maintain the cross-section and flow area of ​​the hose, which has the beneficial effect of reducing the resistance loss of fluid transportation; the technical solution of comparative document 3 is used to transmit electrical signals, which is significantly different from the present invention;

[0089] 2. Difference in material system: The present invention introduces hollow glass microspheres (density 0.46g / cm 3 ) The density of the substrate is greatly reduced, and at the same time, it has high compressive strength and can be used in deep seas up to 4000m. Comparative Document 3 does not mention the compressive strength data, but from its attached figure, it can be seen that it is obviously used in shallow waters near the sea surface. From the demand point of view, it will not have high compressive strength;

[0090] 3. Process innovation: The present invention achieves uniform dispersion of microspheres through a mixing and calendering process, while Comparative Document 3 does not disclose process information in this regard.

[0091] The present invention forms technical barriers through three technical innovations: material system innovation: the first "rubber or synthetic resin + polyester fiber + special hollow microspheres" ternary composite system; process innovation: development of a process chain of "high temperature mixing-gradient calendering-high pressure vulcanization"; parameter innovation: discovery of a strong nonlinear relationship between material properties and process parameters (such as the microsphere breakage rate increases exponentially with every 5MPa increase in vulcanization pressure).

[0092] The technical solution provided by the present invention forms a composite material through multiple layers of materials, wherein the multiple layers of materials include tensile fiber layers in different directions, rubber or rubber or synthetic resin layers, so that the composite material has high tensile and high compressive resistance, and hollow glass microbeads are evenly mixed into the rubber or synthetic resin layers, thereby reducing the overall density of the material and enabling it to generate buoyancy in water.

[0093] The composite material disclosed in the present invention adopts a multi-layer stacking and vulcanization or hot pressing molding process, has isotropic compression resistance and tensile resistance, and has high elasticity and low density (buoyancy can be generated when the density is lower than that of water) characteristics.

[0094] The multilayer composite material disclosed in the present invention adopts a vulcanization or hot pressing molding process, and different layers are tightly combined, and will not slip or fall off when subjected to force, which effectively guarantees the material's high compressive, tensile and elastic mechanical properties.

[0095] The multilayer composite material disclosed in the present invention has isotropic compression resistance and tensile resistance and high elasticity, and is particularly suitable for manufacturing elastic hoses capable of withstanding external and internal pressures.

[0096] Comparative Document 4 (CN108006334A) discloses a preparation process for a FRP pultrusion-winding composite corrugated pipe, which uses fiber and thermosetting resin, curing agent, and accelerator as raw materials, and adopts a pultrusion process to prepare FRP strips, thereby replacing metal steel strips, thereby solving the problem that metal steel strips are easily corroded and affect the service life of the pipe. Comparative Document 4 forms a corrugated pipe structure through pultrusion of glass fiber and thermosetting resin, and its reinforcement layer is spirally wound with FRP strips, which has high rigidity and corrosion resistance, but lacks flexibility. This technology is suitable for buried rigid pipeline scenarios and cannot adapt to the dynamic bending requirements of deep-sea hoses. In addition, the density of FRP is relatively high (>1.5g / cm 3 ), cannot provide buoyancy, which is quite different from the technical solution disclosed in the present invention.

[0097] The innovation and difference of the present invention are as follows:

[0098] 1. Material system innovation: The present invention adopts rubber / synthetic resin and hollow glass microsphere composite substrate (density 0.7-1.03g / cm 3), the technical solution disclosed in Comparative Document 4 is mainly based on glass fiber, and only uses two processes, pultrusion and winding, to produce intermediate materials of different forms, but their essence is glass fiber;

[0099] 2. Flexible design: The present invention achieves high elasticity of the hose (convenient for winding and storage) by elastic matching between the polyester fiber reinforcement layer and the spiral steel wire winding, while the technical solution disclosed in Comparative Document 4 is a rigid hard tube;

[0100] 3. Buoyancy integration: The present invention obtains buoyancy by evenly distributing hollow glass microspheres in the base material to reduce the density of the base material. The comparative document does not involve buoyancy design.

[0101] Reference document 5 (ES313103A1) discloses a method for manufacturing a thermoplastic hose by spiral winding, which uses a thermoplastic material strip and a steel wire to form a reinforcement layer, and the interlayer bonding is achieved by hot pressing. However, this technology does not introduce buoyancy materials, the hose density is high, and it cannot generate the buoyancy required for specific application scenarios.

[0102] The innovation and difference of the present invention are as follows:

[0103] 1. Buoyancy material integration: The present invention uniformly mixes hollow glass microspheres into the base material to reduce the density of the base material to obtain buoyancy. Comparative Document 5 does not involve density control.

[0104] Comparative Document 6 (KR101428031 B1) focuses on the field of floating oil hoses and dredging hoses, aiming to solve many problems existing in traditional hoses in terms of manufacturing, performance and connection. By changing the structural design and manufacturing process of the hose, the hose is improved in terms of buoyancy, durability, flexibility, manufacturing efficiency and raw material consumption. A floating oil hose is disclosed, which provides buoyancy and tensile strength by hot-melting a sponge layer and winding an outer layer of tempered wire. However, the technical solution disclosed in Comparative Document 6 is obviously aimed at hoses used for floating, and the buoyancy material used is a single material sponge; Comparative Document 6 does not describe the pressure resistance data of the sponge material, and can only be understood as a conventional sponge material; according to common sense, the pressure resistance of the sponge is obviously unable to withstand deep-sea pressure.

[0105] The innovation and difference of the present invention are as follows:

[0106] 1. Upgrade of buoyancy material: The present invention uses hollow glass microspheres (compressive strength 110MPa) uniformly mixed in the matrix material as buoyancy material to replace sponge. The buoyancy material prepared can maintain its shape and buoyancy under 40MPa deep sea water pressure, while the sponge layer of Reference Document 6 obviously cannot withstand the same pressure. This technical solution will be crushed and lose buoyancy in deep sea application scenarios;

[0107] 2. Tensile strength: The present invention achieves interlayer bonding of multi-layer composite materials through hot pressing and vulcanization, and is provided with a polyester fiber layer and a spiral steel wire layer, which effectively improves the tensile strength, and the tensile strength can reach not less than 20MPa; Comparative Document 6 does not mention the tensile strength data.

[0108] According to the test, the buoyancy material of the resin hollow sphere in the prior art has a crushing rate of 50% under a pressure of 1.8MPa, resulting in a buoyancy loss of more than 50%; the softening temperature of the buoyancy material of the resin hollow sphere is lower than 100°C, and it is impossible to use a processing technology that heats more than 100°C; and the crushing rate of conventional glass microspheres (compressive strength <80MPa) exceeds 15% under conventional mixing and vulcanization processes. The present invention finds that when the compressive strength of the hollow glass microspheres is ≥110MPa and the diameter is ≤25μm, the volume compression rate is ≤2.8% under a pressure of 40MPa, and the crushing rate is ≤3% under the second-stage mixing and gradient pressure vulcanization process, and more than 97% of the original buoyancy can be maintained.

[0109] Table 1 Performance comparison of different hollow spheres

[0110]

[0111] Table 2 Effect of different process parameters on hose performance

[0112]

[0113] The experiments show that the specific parameter / process combination of the present invention produces the following synergistic effects and beneficial effects:

[0114] (1) 110MPa hollow glass microspheres treated with silane coupling agent and second-stage mixing, gradient pressure vulcanization and other processes

[0115] The dispersion of the microspheres in the matrix material is improved by combining the two-stage mixing, gradient pressure vulcanization and other processes.

[0116] The combination of technology and process makes the hose compressive strength reach 45.2MPa, tensile strength reach 21.7MPa, and average density reach 0.95g / cm 3 , bending fatigue life reaches more than 2000 times;

[0117] (3) The surface treatment of hollow glass microspheres, second-stage mixing, gradient pressure vulcanization and other processes improve the dispersion uniformity of hollow glass microspheres, fully wrap the microspheres with rubber molecules, and enhance the interface bonding force, thereby reducing the breakage rate in the processing engineering;

[0118] (4) The gradient pressure vulcanization process makes the cross-linking density of the rubber gradient, with the inner layer cross-linking degree of 85% and the outer layer of 95%, taking into account flexibility, surface strength and wear resistance, and improving the overall performance;

[0119] (5) The material system reached 0.95g / cm 3 The effective density is higher than that of conventional solutions (1.07-1.15g / cm 3 ) Reduce by 12-17% to achieve true zero buoyancy;

[0120] (6) The specific parameter / process combination of the present invention adjusts the raw material ratio so that the compressive / tensile strength, average density, elasticity and bending fatigue life of the manufactured hose meet the requirements of the expected application scenario;

[0121] (7) The specific parameter / process combination adopted by the present invention enables the manufactured hose to have the unique advantage of being able to maintain buoyancy / zero buoyancy under a pressure of 40 MPa (i.e., being able to achieve a suspended state of zero buoyancy after being weighted).

[0122] The structure and manufacturing method of the hose are described below:

[0123] Embodiment 1:

[0124] Reference Figure 1 , is a composite material zero buoyancy hose disclosed in the present invention, the pipe wall of the composite material zero buoyancy hose comprises a hose inner wall substrate layer 1, a first tensile and compressive layer 2, a reinforcement layer 3, a second tensile and compressive layer 4 and a hose outer wall substrate layer 5 which are arranged in sequence from the inside to the outside. Among them, the hose inner wall substrate layer 1 enhances the performance of wear resistance and seawater resistance, and the hose outer wall substrate layer 5 enhances the performance of wear resistance, seawater resistance, ultraviolet resistance and weather resistance.

[0125] The first tensile and compressive layer 2 and the second tensile and compressive layer 4 are both composed of a substrate layer and a polyester fiber reinforcement layer arranged inside the substrate layer, and the first tensile and compressive layer 2 and the second tensile and compressive layer strengthen the tensile and compressive performance. The reinforcement layer 3 is composed of a substrate layer and a spiral steel wire arranged inside the substrate layer, which strengthens the performance of resisting the pressure inside the pipe, resisting the pressure outside the pipe and the high elasticity.

[0126] The inner wall substrate layer 1 of the hose, the outer wall substrate layer 5 of the hose and the substrate layer are all made of rubber. Hollow glass microspheres are evenly distributed inside the inner wall substrate layer 1 of the hose, the first tensile and compressive layer 2, the reinforcing layer 3, the second tensile and compressive layer 4 and the outer wall substrate layer 5 of the hose; the compressive strength of the hollow glass microspheres is 110-130MPa, and the actual density is 0.42-0.46g / cm 3 , average diameter 15-20μm, softening temperature ≥600℃.

[0127] A method for manufacturing a composite material zero buoyancy hose using rubber as a base material as described above comprises the following steps:

[0128] Step 1: Prepare raw materials, select one of natural rubber, styrene-butadiene rubber and chloroprene rubber as the base material, and select polyester synthetic fiber, hollow glass microspheres, compounding agent and steel wire;

[0129] Among them, rubber: according to the use requirements of the sheet, choose the appropriate rubber variety as the base material, such as natural rubber, nitrile rubber, butadiene rubber / butyl rubber, chloroprene rubber and styrene butadiene rubber, etc. The rubber should have good elasticity, wear resistance, corrosion resistance and other properties.

[0130] Polyester synthetic fiber: According to the performance requirements of the hose, select polyester fiber wires or felt materials or sheets with appropriate specifications (such as fiber density, single filament fineness, fabric structure, etc.) and properties (such as tensile strength, abrasion resistance, chemical resistance, etc.) as reinforcement materials. Pre-treat the polyester fiber, such as removing oil, impurities and moisture on the surface, and use methods such as washing and drying to enhance the bonding performance with rubber. It should be noted that the density of the synthetic fiber should not be too dense, and space should be left so that the adjacent rubbers on both sides of the polyester synthetic fiber can be fully bonded into one.

[0131] Hollow glass microspheres: mainly play the role of reducing the average density of the hose, so that the hose can generate sufficient buoyancy when used in water. According to the stress conditions and water depth of the use conditions, determine the tensile strength, compressive strength, density and other indexes that the hose needs to meet, select the compressive strength, density, diameter, melting point, etc. of the hollow glass microspheres, and determine the model and amount of the hollow glass microspheres.

[0132] Compounding agents: including vulcanizing agents, accelerators, activators, antioxidants, fillers, etc. These compounding agents can improve the processing performance and physical and mechanical properties of rubber.

[0133] Steel wire: Generally, high-strength galvanized steel wire is used, and the diameter of the steel wire is selected according to the pressure resistance requirements of the hose. The steel wire needs to be pre-treated, such as pickling to remove the rust on the surface, and then phosphating to increase the adhesion between the steel wire and the rubber.

[0134] Step 2, mixing, adding the rubber, hollow glass microspheres and compounding agents into a mixing device, such as an open mixer or an internal mixer, according to a certain formula ratio, and setting the mixing temperature range to 160-210°C. Through mechanical stirring and shearing, the hollow glass microspheres and the compounding agents are evenly dispersed in the rubber to form a mixed rubber; during the mixing process, parameters such as temperature, time and feeding sequence need to be controlled to ensure the quality of the mixed rubber; in step 2, the mixing equipment adopts a two-stage internal mixer unit, the first-stage mixing temperature is 160-180°C, and the second-stage mixing temperature is 190-210°C.

[0135] Step 3, calendering, calendering the mixed rubber through a calender to make a film of a certain thickness and width. During the calendering process, the roller gap, speed, temperature and other parameters of the calender can be adjusted to control the thickness and surface quality of the film. At the same time, a small amount of pre-treated polyester synthetic fiber wire is introduced into the calender to make it fit closely with the rubber sheet during the calendering process. By adjusting the fiber conveying speed and calender parameters, a good bonding effect is ensured between the two to form a rubber sheet blank with a small amount of polyester fiber. According to the target size of the flexible composite material sheet, the size of the film is cut by a cutting machine;

[0136] Step 4, winding. Install flanges at both ends of the core mold, and use the winding machine to wind the long strip of film onto the core of the seat hose mold in a predetermined order and number of layers. Pay attention to the uniformity and balance of the material during winding, and the height difference should not be too large. Use the mold and wire guide device to wind the steel wire at a certain pitch onto the surface of the core mold that has been partially wound with the material. Use the traction device to control the travel speed of the steel wire and the blank to ensure uniformity and tightness. After the spiral steel wire is wound, wind other materials in turn. After all materials are wound, wrap the outermost layer with outer cloth;

[0137] Step 5, vulcanization, push the wound hose and the iron core into the vulcanization furnace or vulcanization tank together, and carry out vulcanization reaction at a certain temperature and pressure to further vulcanize and solidify the rubber, and at the same time form good adhesion between the synthetic fiber and the rubber, and between the rubbers. The vulcanization temperature is set between 140-180°C;

[0138] Among them, vulcanization is a key process in the production of rubber hoses. It can make rubber molecules undergo cross-linking reactions to form a three-dimensional network structure, thereby improving the physical and mechanical properties and chemical stability of rubber hoses. During the vulcanization process, it is necessary to control parameters such as vulcanization temperature, time and pressure. The vulcanization temperature is generally between 140-180°C, and the vulcanization time depends on the thickness of the sheet and the type of rubber, generally ranging from tens of minutes to several hours.

[0139] Step 6, post-processing, reverse rotation of the iron core to remove the outer cloth, pressurize the iron core to remove it, inspect the appearance, size, physical and mechanical properties of the rubber hose, and then package the rubber hose with rubber as the base material that passes the inspection.

[0140] Remove the outer cloth: Rotate the core in the opposite direction to remove the outer cloth, and pressurize the core. The vulcanized rubber hose may have some burrs and flashes, which need to be trimmed to make its size and shape meet the requirements.

[0141] Inspection: Inspect the appearance, size, physical and mechanical properties of the rubber hose to ensure that the product quality meets the standards and customer requirements. Inspection items include diameter, wall thickness, length, hardness, density, whether the steel wire is exposed, tensile strength, elongation at break, bonding strength, water tightness / air tightness, etc.

[0142] Packaging: The rubber hoses with rubber as the base material that have passed the inspection will be packaged, usually using plastic film, woven bags, wooden boxes and other packaging materials to prevent the rubber hoses from being damaged during transportation and storage.

[0143] In this embodiment, the calendering in step 3 adopts a three-roller different speed ratio calendering process, the upper roller line speed is 15-20% faster than the middle roller, and the middle roller is 10-15% faster than the lower roller. In step 4, the steel wire winding adopts a variable pitch process, the pitch of the middle part of the tube body is 8-10 times the diameter of the steel wire, and the pitch of the end is 12-15 times the diameter of the steel wire. In step 5, the vulcanization adopts a gradient boost process, the initial pressure is 2-3MPa, and the pressure is increased by 0.5MPa every 10 minutes, finally reaching 8-10MPa and maintaining for 30-45 minutes. The surface of the hollow glass microspheres is treated with silane coupling agent KH-570, and the amount of the treating agent is 0.8-1.2% of the mass of the microspheres. The polyester synthetic fiber adopts a 3D orthogonal braiding structure, the warp fiber density is 80-100 roots / cm, and the weft fiber density is 60-80 roots / cm.

[0144] Embodiment 2:

[0145] Reference Figure 1 , a composite material zero buoyancy hose, which differs from the first embodiment in that the hose inner wall substrate layer 1, the hose outer wall substrate layer 5 and the substrate layer are all made of synthetic resin.

[0146] A method for manufacturing a composite material zero buoyancy hose using a synthetic resin as a substrate as described above comprises the following steps:

[0147] Step S1, raw material preparation, selecting synthetic resin as the base material, and selecting polyester synthetic fiber, hollow glass microspheres, compounding agent and steel wire;

[0148] Among them, synthetic resin: according to the use requirements of the hose, select the appropriate type of synthetic resin as the base material, and fully consider its molecular weight, molecular structure, and the ratio of styrene to butadiene and other factors to meet the final performance requirements of the hose, such as hardness, elasticity, tensile strength, etc. Check that the raw materials are free of impurities and lumps, dry them, and control the moisture content below 0.5%.

[0149] Polyester synthetic fiber: According to the performance requirements of the hose, select polyester fiber wires or felt materials or sheets with appropriate specifications (such as fiber density, single filament fineness, fabric structure, etc.) and performance (such as strength, wear resistance, chemical resistance, etc.) as reinforcement materials. Pre-treat the polyester fiber, such as removing oil, impurities and moisture on the surface, and use methods such as washing and drying to enhance the bonding performance with the synthetic resin. It should be noted that the density of the synthetic fiber should not be too dense, and space should be left so that the adjacent synthetic resins on both sides of the polyester synthetic fiber can be fully bonded into one.

[0150] Hollow glass microspheres: mainly play the role of reducing the density of the hose, so that it can generate sufficient buoyancy when used in water. According to the stress conditions and water depth of the use conditions, determine the tensile strength, compressive strength, density and other indexes that the flexible composite hose needs to meet, select the compressive strength, density, diameter, melting point, etc. of the hollow glass microspheres, and determine the model and amount of the hollow glass microspheres.

[0151] Compounding agents: Add additives such as plasticizers, anti-aging agents, lubricants, and fillers as needed. Plasticizers can improve the flexibility and processing performance of synthetic resins; anti-aging agents can prevent synthetic resins from aging and deteriorating during use, extending the service life of hoses; lubricants help improve fluidity during processing; fillers can reduce costs and improve certain properties of hoses, such as hardness and dimensional stability. These compounding agents can improve the processing performance and physical and mechanical properties of synthetic resins.

[0152] Steel wire: Generally, high-strength galvanized steel wire is used, and the diameter of the steel wire is selected according to the pressure resistance requirements of the hose. The steel wire needs to be pre-treated, such as pickling to remove the rust on the surface, and then phosphating to increase the adhesion between the steel wire and the rubber.

[0153] Step S2, mixing, adding the synthetic resin, hollow glass microspheres and compounding agents into a mixing device, such as an open mixer or an internal mixer, according to a certain formula ratio, and mixing at a temperature range of 150-200° C. and at an appropriate speed. Through mechanical stirring and shearing, the hollow glass microspheres and the compounding agent are evenly dispersed in the synthetic resin to form a mixed material. During the mixing process, parameters such as temperature, time and order of adding materials need to be controlled to ensure the quality of the mixed material.

[0154] In step 2, the mixing equipment adopts a two-stage internal mixer, the first-stage mixing temperature is 160-180°C, and the second-stage mixing temperature is 190-210°C.

[0155] Step S3, calendering, putting the mixed synthetic resin material into a calender, pressing it into a sheet of a certain thickness and width through rollers, adjusting the roller temperature between 160-180°C, controlling the appropriate rotation speed and gap to ensure the thickness, uniformity and surface quality of the material. At the same time, a small amount of pre-treated polyester synthetic fiber wire is introduced into the calender so that it fits tightly with the synthetic resin sheet during the calendering process, and by adjusting the fiber conveying speed and calender parameters, a good bonding effect is ensured between the two to form a synthetic resin blank with a small amount of polyester fiber sandwiched therein, and the size of the sheet-shaped synthetic resin is cut by a cutting machine according to the target size of the flexible composite hose;

[0156] Step S4, winding, install flanges at both ends of the core mold, and use the winding machine to wind the long strip of synthetic resin onto the core of the seat hose mold in a predetermined order and number of layers. When winding, attention should be paid to the uniformity and balance of the materials, and the height difference should not be too large. Use the mold and wire guide device to wind the steel wire at a certain pitch onto the surface of the core mold that has been partially wound with the material. The traction device controls the travel speed of the steel wire and the blank to ensure uniformity and tightness. After the spiral steel wire is wound, other materials are wound in turn. After all materials are wound, wrap the outermost layer with outer cloth;

[0157] Step S5, hot pressing molding, placing the wound intermediate product in a hot pressing furnace or hot pressing tank, and hot pressing molding at a temperature of 180-220°C and a pressure of 10-30MPa. The hot pressing time is determined according to the thickness of the plate and the size of the mold, and the hot pressing time is generally 5-30 minutes. During this process, the synthetic resin further melts and flows, forming a stronger bond with the polyester fiber, and enabling the hose to obtain the desired shape and dimensional accuracy.

[0158] Step S6, post-processing, after hot pressing forming, the intermediate product is taken out from the hot pressing furnace or hot pressing tank for cooling. Natural cooling or forced cooling (such as air cooling, water cooling) can be used to cool down and solidify the hose to maintain the shape after forming. During cooling, the hose must be prevented from being impacted or deformed by external forces; the iron core is rotated in the opposite direction to remove the outer cloth, and the iron core is pressurized to remove it. After the synthetic resin hose after hot pressing forming has been trimmed and inspected, the hose with synthetic resin as the base material that passes the inspection is packaged.

[0159] Among them, the synthetic resin hose after hot pressing may have some burrs and flashes, which need to be trimmed to remove edge burrs and uneven parts to make its surface smooth and the size precise to meet the technical requirements.

[0160] Inspection: Inspect the appearance, size, physical and mechanical properties of synthetic resin hoses to ensure that product quality meets standards and customer requirements. Inspection items include diameter, wall thickness, length, hardness, density, whether steel wire is exposed, tensile strength, elongation at break, bonding strength, water tightness / air tightness, etc.

[0161] Packaging: The synthetic resin-based hoses that have passed the inspection will be packaged, usually using plastic films, woven bags, wooden boxes and other packaging materials to prevent the synthetic resin hoses from being damaged during transportation and storage.

[0162] The implementation principle of the present invention is as follows: the inherent properties of rubber or synthetic resin or similar materials as the hose base material determine that the hose material has high compressive resistance (not less than 40MPa); the spiral steel wire of the reinforcing layer 3 is tightly combined with the base material, so that the hose has a higher ability to resist internal and external pressures, and the inherent properties of the spiral steel wire and the base material itself make the hose have high elasticity; the polyester fiber of the first tensile and compressive layer 2 and the second tensile and compressive layer 4 is tightly combined with the base material, so that the hose has high tensile resistance (not less than 20MPa); all the base materials in the hose inner wall base material layer 1, the first tensile and compressive layer 2, the reinforcing layer 3, the second tensile and compressive layer 4 and the hose outer wall base material layer 5 are uniformly mixed with high-strength hollow glass microspheres, so that the average density of the entire hose (including the joint and the connecting bolt) is as low as 0.7-1.03t / m 3 ) is less than water or equal to water so that the hose can obtain positive buoyancy or zero buoyancy effect in water.

[0163] The rubber or synthetic resin and other similar materials in various parts of the hose are tightly combined with the adjacent polyester synthetic fibers, spiral steel wires, hollow glass microspheres, etc., and through the gaps between the polyester synthetic fibers, spiral steel wires, and hollow glass microspheres, they are tightly combined with the adjacent rubber or synthetic resin layers and other similar materials to form a unified and continuous overall structure. Figure 1 The sizes of each layer do not represent the actual size, but only indicate the relative position relationship, and the order can be adjusted appropriately. In terms of the mass proportion of the materials, rubber or synthetic resin accounts for the vast majority, and synthetic fibers account for a small part. Rubber or synthetic resin provides compressive strength and shear resistance for the composite material, and synthetic fibers provide tensile strength for the composite material. Hollow glass microspheres (compressive strength 110-130MPa, actual density 0.42-0.46g / cm) are uniformly mixed into the main component of the composite material, i.e., the raw material of rubber or synthetic resin, in a mass ratio of 100:5-100:40. 3, average diameter 15-20μm, softening temperature ≥600℃), its density is low, which can make the average density of the composite material less than the density of water, so as to generate positive buoyancy; it has high compressive strength and high melting point, and the breakage rate generated during the production process is extremely low; its average diameter is small, and after being evenly mixed in the main material, it has little effect on the bonding between the original main material molecules; its component is glass, with stable chemical properties, and it will not react chemically with other components during the production process.

[0164] The embodiments of this specific implementation method are all preferred embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Therefore, any equivalent changes made based on the structure, shape, and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for manufacturing a composite material zero buoyancy hose, characterized in that: The following steps are involved: Step 1: Prepare raw materials, select rubber or synthetic resin as the base material, and select polyester synthetic fiber, hollow glass microspheres, compounding agent and steel wire; Step 2: mixing, adding the base material, hollow glass microspheres and compounding agent into a mixing device according to a certain formula ratio, and uniformly dispersing the hollow glass microspheres and compounding agent in the base material through mechanical stirring and shearing to form a mixed material; Step 3, calendering, calendering the mixed material through a calender to form a sheet of a certain thickness and width, introducing the pretreated polyester synthetic fiber wire into the calender so that it is closely attached to the sheet during the calendering process to form a blank with polyester fibers, and cutting the size of the blank through a cutting machine according to the target size of the flexible composite material sheet; Step 4: Winding: Install flanges at both ends of the core mold, and wind the long strip of blank onto the core of the seat hose mold through a winding machine in a predetermined order and number of layers. Use the mold and wire guide device to wind the steel wire onto the surface of the core mold that has been wound with some materials at a certain pitch. After the spiral steel wire is wound, wind other materials in turn. After all materials are wound, wrap the outermost layer with outer cloth. Step 5: Forming: the wound intermediate product is cured and formed into a composite material zero buoyancy hose after a vulcanization process or a hot pressing process; Step 6, post-processing, reversely rotate the iron core to remove the outer cloth, pressurize the iron core, and inspect the appearance, size, and physical and mechanical properties of the composite material zero buoyancy hose after the trimming process, and then package the qualified composite material zero buoyancy hose; When the base material in step 1 is the rubber, the mixing temperature in step 2 is set to a range of 160-210° C.; When the base material in step 1 is the synthetic resin, the mixing temperature in step 2 is set to a range of 150-200° C.; In step 2, the mixing equipment adopts a two-stage internal mixer, the first-stage mixing temperature is 160-180° C., and the second-stage mixing temperature is 190-210° C.; The hollow glass microspheres have a compressive strength of 110-130 MPa and an actual density of 0.42-0.46 g / cm 3 , average diameter 15-20μm, softening temperature ≥600℃; In the step 2, the formula ratio of the substrate, the hollow glass microspheres and the compounding agent is 7:2:

1.

2. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: When the base material in step 1 is the rubber, the vulcanization process of step 5 is adopted: the hose wrapped with the raw materials and the iron core are pushed into a vulcanization furnace or a vulcanization tank together, and a vulcanization reaction is carried out at a certain temperature and pressure to further vulcanize and cure the rubber, and the vulcanization temperature is set between 140-180°C.

3. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: When the substrate in step 1 is the synthetic resin, the hot pressing molding process in step 5 is adopted: the wound intermediate product is placed in a hot pressing furnace or an autoclave, and hot pressing molding is performed at a temperature of 180-220°C and a pressure of 10-30MPa for 5-30min. After hot pressing molding, the intermediate product is taken out of the hot pressing furnace or the autoclave for cooling, so that the hose is cooled and solidified to maintain the shape after molding.

4. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: In step 4, the steel wire winding adopts a variable pitch process, the pitch in the middle of the tube body is 8-10 times the diameter of the steel wire, and the pitch at the end is 12-15 times the diameter of the steel wire.

5. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: In step 5, the vulcanization adopts a gradient pressure-increasing process, with an initial pressure of 2-3 MPa, an increase of 0.5 MPa every 10 minutes, and finally reaching 8-10 MPa and maintaining it for 30-45 minutes.

6. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: The surface of the hollow glass microsphere is treated with silane coupling agent KH-570, and the amount of the treating agent is 0.8-1.2% of the mass of the microsphere.

7. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: The polyester synthetic fiber adopts a 3D orthogonal weaving structure, with a warp fiber density of 80-100 fibers / cm and a weft fiber density of 60-80 fibers / cm.

8. The method for manufacturing a composite material zero buoyancy hose according to claim 1, characterized in that: The calendering in step 3 adopts a three-roller different speed ratio calendering process, the upper roll line speed is 15-20% faster than the middle roll, and the middle roll is 10-15% faster than the lower roll.

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