High-compression-resistance, high-tensile and high-elasticity composite zero-buoyancy hose for deep sea

Abstract

The utility model relates to a high-compression-resistance, high-tensile-resistance and high-elasticity composite zero-buoyancy hose for deep sea. The hose wall of the composite zero-buoyancy hose comprises a hose inner wall base material layer, a first tensile-compression-resistance layer, a reinforcing layer, a second tensile-compression-resistance layer and a hose outer wall base material layer which are sequentially arranged from inside to outside. Each of the first tensile and compressive layer and the second tensile and compressive layer is composed of a base material layer and a polyester fiber reinforcement layer arranged in the base material layer. The reinforcing layer is composed of a base material layer and a spiral steel wire arranged in the base material layer. The hose inner wall base material layer, the hose outer wall base material layer and the base material layer are all made of rubber or synthetic resin. The adhesive hose has high compressive strength, high tensile strength and high elasticity, has the density smaller than that of fresh water / seawater, can generate positive buoyancy or zero buoyancy, can be used for deep sea, can bear large pressure and tension and load tension under the working condition, and has the characteristics of high elasticity, positive buoyancy or zero buoyancy.

Description

Technical Field

[0001] This utility model relates to the field of hose technology in shipbuilding and marine engineering, and in particular to a high-pressure-resistant, high-tensile-resistant, and high-elasticity composite material zero-buoyancy hose for use in deep sea. Background Technology

[0002] In the fields of shipbuilding and marine engineering, hoses are often used to transport fluids, such as water, oil, liquid chemicals, liquefied natural gas, compressed gas, or dredging slurry. However, hoses produced under current technology cannot fully meet the specific application requirements of shipbuilding, 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 or zero buoyancy in the deep sea.

[0003] Under current technological conditions, hoses can be classified into three main categories based on their material:

[0004] (1) Rubber hose:

[0005] Ordinary rubber hoses: Generally made of natural or synthetic rubber. These hoses have good flexibility and elasticity and can withstand certain pressure. For example, in the freshwater transport system of ships, they can be used to connect water storage tanks and water-using equipment to transport domestic water, etc. Their working pressure is usually between 0.1-0.6 MPa, and their inner diameter ranges from 6 mm to 150 mm.

[0006] Oil-resistant rubber hoses: Primarily composed of oil-resistant rubber materials such as nitrile rubber. They play a crucial role in marine fuel delivery systems, such as fuel lines from fuel storage tanks to engines, effectively preventing fuel leaks due to their excellent resistance to various fuels (e.g., diesel, heavy oil). Operating pressures are typically 0.6-15 MPa. The inner diameter varies depending on the application, but is commonly used in pipes with diameters of 6-150 mm.

[0007] To improve durability, rubber hoses are often covered with a braided metal wire layer in practical applications. Pipeline interfaces of equipment that experiences significant vibration during operation are often connected to external pipelines via rubber hoses to prevent the vibration force from being transmitted to the pipeline and causing severe vibration. Pipeline interfaces on equipment components that undergo displacement or movement during operation are also often connected to external pipelines via hoses to compensate for the resulting displacement or movement.

[0008] (2) Plastic hose:

[0009] PVC (polyvinyl chloride) hoses are lightweight and corrosion-resistant. They are widely used in ship drainage systems, such as for collecting and draining rainwater from the deck or water from the bilge. They operate at relatively low pressures, typically around 0.5-1.6 MPa, and come in a variety of inner diameters, ranging from a few millimeters for fine drainage to tens of millimeters for large drainage areas.

[0010] PE (polyethylene) hoses: These hoses have good wear resistance and impact resistance. They are used in the connection of some underwater equipment in marine engineering, such as protective sleeves for connecting data transmission lines and power lines of underwater robots. Their working pressure varies depending on factors such as wall thickness, ranging from approximately 1-5 MPa. 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 flexible hose:

[0012] Stainless steel flexible hoses: Made of stainless steel, they are resistant to high temperatures, high pressures, and corrosion. In high-temperature steam transport systems on ships, such as steam pipelines in marine propulsion systems, they can withstand the pressure (working pressure up to 10-30 MPa) and temperature (up to 200-500℃) of high-temperature steam, while also exhibiting excellent resistance to corrosive environments such as seawater. The inner diameter is typically around 10-100 mm, used for transporting large volumes of high-temperature steam.

[0013] Copper alloy flexible hoses: possess excellent conductivity and flexibility. In marine electrical systems, they serve as protective and connecting components for electrical wires, especially in areas requiring frequent movement or bending, such as the electrical connections of marine cranes. Operating under relatively low pressure, their conductivity and mechanical properties are the primary considerations, and their inner diameter is generally between 5-20 mm.

[0014] Under current technological conditions, hoses can be mainly classified into the following four categories according to the medium they are transported:

[0015] (1) Oil delivery hose:

[0016] Used for oil transfer between ships, between ships and docks, or between ships and platforms. These hoses typically have a multi-layered structure, including an oil-resistant rubber inner layer, a reinforcing layer (such as a steel wire braided layer), and an outer protective layer. The reinforcing layer improves the hose's pressure resistance, enabling it to withstand the pressure during oil transfer. Its working pressure is generally between 0.6 and 1.6 MPa, and its length can be customized according to the actual transfer distance, ranging from a few meters to hundreds of meters. The inner diameter depends on the required oil flow rate and is generally between 50 and 300 mm.

[0017] (2) Water delivery hose:

[0018] Primarily used for transporting fresh water, seawater, and fire-fighting water on ships or offshore platforms. Fire-fighting water hoses need to withstand high water pressure to ensure effective water spraying for fire suppression. Typical operating pressures are between 0.8 and 1.6 MPa, with inner diameters typically ranging from 40 to 100 mm. Lengths vary depending on the size of the vessel and the layout of the fire-fighting system, and good resistance to aging and wear is required.

[0019] (3) Ventilation duct:

[0020] These are temporary or permanent ventilation systems used on ships or offshore platforms, such as temporary ventilation during construction, engine room ventilation, cargo hold ventilation, and compartment ventilation. These hoses typically require good flexibility and ventilation performance, and are generally made of plastic or fiber fabric. For example, plastic film ventilation hoses used during ship construction, and PVC ventilation hoses used in engine rooms, cargo holds, and compartments, can effectively deliver fresh air and reduce indoor temperature and humidity. Their operating pressure is relatively low, with ventilation flow rate being the primary consideration; inner diameters range from 100-500 mm, and lengths depend on the layout of the ventilation ducts.

[0021] (4) Cable protection flexible conduit:

[0022] Primarily used to protect cables on ships from mechanical damage, chemical corrosion, and electromagnetic interference. PE carbon corrugated flexible conduits and metal flexible conduits (such as stainless steel or copper alloy conduits) are commonly used in this field. They enhance aesthetics, protect cables, shield against external electromagnetic interference, and ensure stable cable signal transmission. The inner diameter is determined based on 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 current technological conditions, hoses can be classified into three main categories based on their structure:

[0024] (1) Non-adhesive flexible hose:

[0025] Non-bonded hoses are widely used in marine risers and subsea oil pipelines. In offshore oil and gas development, they can be used as risers connecting offshore platforms to subsea oil wells, as well as pipelines transporting oil and gas resources on the seabed. They can also be used in locations requiring frequent movement or bending, such as refueling pipes on ships, because their interlayer relative displacement characteristic allows them to better adapt to the swaying of ships and the bending deformation of pipelines. Non-bonded hoses consist of multiple independent layers without fixed connections between them, allowing for relative displacement between layers when bent, thus better meeting the special requirements of field applications. They typically have six layers, from the outside in:

[0026] Outer coating: usually made of polymer material, its function is to prevent external fluids from entering the flexible tube structure and protect the internal layers.

[0027] Tensile layer: using flat, round or shaped metal, wound in a 20-60° spiral to provide the required tensile strength to the pipe.

[0028] Wear-resistant layer: Located between metal layers, it reduces wear between metals and improves the service life of the hose.

[0029] Pressure-resistant layer: Interlocking metal layer used to withstand internal pressure loads. When the pressure is high, a reserve pressure-resistant layer can be added to enhance the pressure resistance.

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

[0031] Skeleton: Interlocking metal layer, mainly resisting external pressure loads and maintaining the shape and structural stability of the hose.

[0032] (2) Adhesive hose:

[0033] Adhesive-bonded hoses are generally made of rubber or other polymer hoses and are commonly used in engineering applications involving shorter lengths, such as floating pipes and jumpers. They may also be used in some localized systems on ships, such as small vibration isolation pipes, motion compensation pipes, cooling water pipes, and short-distance chemical delivery pipes within the ship. In marine engineering, they are also used in situations where long pipes are not required and where structural integrity and sealing are critical, such as connecting pipes between specific equipment on offshore platforms.

[0034] If the adhesive hose is made of rubber, it typically uses rubber as the base material, with layers of fiber and spiral steel wire embedded within to increase its resistance to external pressure, internal pressure, and axial tensile strength. The manufacturing process requires vulcanization, resulting in high adhesive strength between the base material and the reinforcing layers. If the adhesive hose is made of other polymers, it is usually extruded into a single unit using physical methods such as extrusion or molding, resulting in high adhesive strength between the base material and the reinforcing layers.

[0035] Adhesive hoses have a relatively low base material density and are 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 as a single unit, eliminating the need to install buoyancy units during use. The disadvantage is that the diameter is larger after adding the buoyancy layer, which increases the difficulty of operation and storage. The second method is to install independent hollow floats or floats filled with foam material on the outer surface of the adhesive hose. The advantage is that the buoyancy units can be disassembled and installed more flexibly. The disadvantage is that the workload of disassembling and assembling buoyancy units during entry and exit from the site is relatively large.

[0036] Under current technological conditions, it is neither possible to obtain nor produce high-pressure-resistance, high-tensile-resistance, and high-elasticity positive or zero-buoyancy hoses suitable for deep-sea applications. The reasons are as follows:

[0037] Although non-adhesive hoses have high compressive and tensile strength, the use of a large amount of high-density polymer or metal materials results in a high average density, which is much greater than the density of water. Therefore, they cannot generate positive or zero buoyancy in water.

[0038] Adhesive hoses, commonly used in the manufacture of floating hoses, use relatively little metal and have a relatively low average density. After being coated with a suitable thickness of foam material, they can float on the water surface. However, the commonly used foam buoyancy materials have low compressive strength. While they can be used normally on the surface or in water depths of 10 meters or less, when entering deep water where the pressure increases, these materials, due to their low compressive strength, will be crushed, resulting in a reduced drainage volume and loss of buoyancy. This causes the hose to sink, unable to remain floating or suspended, and thus fails to meet usage requirements. Utility Model Content

[0039] To address the shortcomings of existing technologies, the purpose of this invention is to provide a high-compression, high-tensile, and high-elasticity composite material zero-buoyancy hose for deep-sea applications. This hose is an adhesive hose that simultaneously possesses high compressive strength, high tensile strength, high elasticity, and a density lower than freshwater / seawater, enabling it to generate positive or zero buoyancy. It can be used in deep-sea applications (depths of 200m and above), can withstand significant pressure and tension (withstanding deep-sea water pressure (2-40MPa) and tensile loads under operational conditions (tensile stress not less than 20MPa, etc.), possesses high elasticity (compensating for movement / displacement under operational conditions and facilitating winding and storage), and exhibits positive or zero buoyancy (providing positive buoyancy to the associated device or protecting it from the adverse effects of its own positive buoyancy / gravity).

[0040] The above-mentioned utility model objective is achieved through the following technical solution:

[0041] A composite material zero-buoyancy hose with high compressive strength, high tensile strength, and high elasticity for deep-sea applications, wherein the hose wall comprises, from the inside out, a hose inner wall substrate layer, a first tensile and compressive strength layer, a reinforcing layer, a second tensile and compressive strength layer, and a hose outer wall substrate layer.

[0042] As a further technical solution of this utility model: both the first tensile and compressive layer and the second tensile and compressive layer are composed of a substrate layer and a polyester fiber reinforcement layer disposed inside the substrate layer.

[0043] As a further technical solution of this utility model: the reinforcing layer is composed of a substrate layer and a spiral steel wire disposed inside the substrate layer.

[0044] As a further technical solution of this utility model: the inner wall substrate layer of the hose, the outer wall substrate layer of the hose, and the substrate layer are all made of rubber.

[0045] As a further technical solution of this utility model: the inner wall substrate layer of the hose, the outer wall substrate layer of the hose, and the substrate layer are all SBS synthetic resin.

[0046] As a further technical solution of this utility model: hollow glass microspheres are uniformly distributed inside the inner wall substrate layer of the hose, the first tensile and compressive layer, the reinforcing layer, the second tensile and compressive layer, and the outer wall substrate layer of the hose.

[0047] As a further technical solution of this utility model: the hollow glass microspheres have a compressive strength of 110MPa, an actual density of 0.46g / cm3, an average diameter of 20μm, and a softening temperature of 600℃.

[0048] A method for manufacturing a high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose using rubber as a base material for deep-sea applications, as described above, includes the following steps:

[0049] Step 1: Raw material preparation. Select one of natural rubber, styrene-butadiene rubber, or chloroprene rubber as the base material, and select polyester synthetic fiber, hollow glass microspheres, compounding agents, and steel wire.

[0050] Step 2, mixing: Rubber, hollow glass microspheres and compounding agents are added to mixing equipment, such as open mill or internal mixer, according to a certain formula ratio. Through mechanical stirring and shearing, the hollow glass microspheres and compounding agents are evenly dispersed in the rubber to form a compound.

[0051] Step 3: Calendering. The compounded rubber is calendered through a calender to form a rubber sheet of a certain thickness and width. The pretreated polyester synthetic fiber wire is introduced into the calender so that it is tightly bonded to the rubber sheet during the calendering process to form a rubber sheet blank with polyester fiber sandwiched in it. According to the target size of the flexible composite material board, the size of the rubber sheet is cut by a cutting machine.

[0052] Step 4: Winding. Install flanges at both ends of the iron core mold. Use a winding machine to wind long strips of film, polyester synthetic fiber wire or mesh rolls onto the iron core of the seat hose mold 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 iron core mold that has been partially wound with material at a certain pitch. After the spiral steel wire is wound, wind other materials in sequence. After all materials are wound, wrap the outermost layer with outer fabric.

[0053] Step 5: Vulcanization. Push the hose and iron core wrapped with raw material into the vulcanization furnace or vulcanization tank together. The vulcanization reaction will be carried out under certain temperature and pressure to further vulcanize and cure the rubber. The vulcanization temperature is set between 140℃ and 180℃.

[0054] Step 6: Post-processing. Rotate the iron core in the opposite direction to remove the outer wrapping cloth, apply pressure to remove the iron core, and inspect the appearance, dimensions, and physical and mechanical properties of the rubber hose. Then, package the qualified rubber hoses with rubber as the base material.

[0055] A method for manufacturing a high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications using SBS synthetic resin as a base material, as described above, includes the following steps:

[0056] Step S1: Raw material preparation. SBS synthetic resin is selected as the base material, and polyester synthetic fiber, hollow glass microspheres, compounding agents and steel wire are selected.

[0057] Step S2, mixing: SBS synthetic resin, hollow glass microspheres and compounding agents are added to a mixing equipment, such as an open mill or internal mixer, according to a certain formula ratio. At a temperature range of 150-200℃, the hollow glass microspheres and compounding agents are uniformly dispersed in the SBS synthetic resin through mechanical stirring and shearing to form a mixture.

[0058] Step S3, calendering: The mixed SBS synthetic resin material is placed into a calender and pressed into a sheet of a certain thickness and width by rollers. The roller temperature is adjusted to between 160-180℃. The pretreated polyester synthetic fiber wire is introduced into the calender so that it is tightly bonded to the SBS synthetic resin sheet during the calendering process to form an SBS synthetic resin blank with polyester fiber sandwiched in it. According to the target size of the flexible composite hose, the sheet SBS synthetic resin is cut to size by a cutting machine.

[0059] Step S4: Winding. Install flanges at both ends of the iron core mold. Wind long strips of SBS synthetic resin, polyester synthetic fiber wire or mesh rolls onto the iron core of the seat hose mold in a predetermined order and number of layers using a winding machine. Use the mold and wire guide device to wind the steel wire onto the surface of the iron core mold that has been partially wound with material at a certain pitch. After the spiral steel wire is wound, wind other materials in sequence. After all materials are wound, wrap the outermost layer with outer fabric.

[0060] Step S5: Hot pressing. Place the wound intermediate product in a hot press furnace or autoclave and hot press it at a temperature of 180-220℃ and a pressure of 10-30MPa for 5-30 minutes.

[0061] Step S6, Post-processing: After hot pressing, the intermediate product is taken out of the hot press furnace or hot press tank for cooling to allow the hose to cool down and solidify, maintaining the shape after molding. The iron core is rotated in the opposite direction to remove the outer wrapping cloth, and the iron core is released under pressure. After the hot-pressed SBS synthetic resin hose undergoes trimming and inspection, the qualified hoses with SBS synthetic resin as the base material are packaged.

[0062] In summary, this utility model has at least one of the following beneficial technical effects:

[0063] 1. Existing technologies cannot manufacture high-compression, high-tensile, and high-elasticity positive or zero-buoyancy hoses for deep-sea applications, failing to meet certain specific application requirements in shipbuilding, marine engineering, and other industrial fields. This invention develops a flexible composite material hose structure and preparation method using rubber or SBS synthetic resin and similar materials as the base material. By selecting material components with appropriate properties and their proportions, the components are mutually compatible and form a unified whole. The resulting flexible composite material hose simultaneously possesses four properties: high compressive strength, high tensile strength, high elasticity, and an average density equal to or equal to water, enabling positive or zero buoyancy. This meets certain specific application requirements in shipbuilding, marine engineering, and other industrial fields. Its compressive strength can reach no less than 40 MPa, tensile strength no less than 20 MPa, with high resilience and an average density as low as 0.7-1.03 t / m³. 3 This composite material hose can meet certain specific application requirements in the shipbuilding and marine engineering and other industrial fields. For example, it can be used in deep sea (depths of 200m and above), can withstand large pressure and tension (withstand deep sea water pressure (2-40MPa) and load tension under operating conditions (tensile stress not less than 20MPa), etc.), has high elasticity (compensates for movement / displacement under operating conditions and is easy to roll up and store), and has positive buoyancy or zero buoyancy characteristics (provides positive buoyancy to the device or protects the device from the adverse effects of positive buoyancy / gravity generated by the hose itself).

[0064] 2. The base material of this composite hose is rubber or SBS synthetic resin or similar materials. The finished product made with this as the base material according to a specific formula can meet the requirements of high compressive strength. In addition, the tensile strength of the polyester fiber introduced in the preparation process of this composite hose is generally between 350-700MPa. The high tensile strength of the polyester fiber, after it is well combined with the rubber or SBS synthetic resin or similar materials as the base material, ensures the high tensile strength, high compressive strength and high shear strength of the composite hose.

[0065] 3. The hollow glass microspheres introduced during the preparation of this composite material hose have an extremely small diameter (around 20 μm), comparable to the diameter of flour particles. This characteristic allows them to be fully mixed with other compounding agents or additives, as well as similar materials such as rubber or SBS synthetic resin used as the base material, and to be distributed as evenly as possible. This prevents discontinuities and cracks in the base material, thus ensuring the high tensile strength, high compressive strength, high shear strength, and high elasticity of the composite material hose.

[0066] 4. The hollow glass microspheres introduced are made of glass, which has stable physical and chemical properties. They will not react physically or chemically with the substrate or other compounding agents or additives, nor will they have a negative impact on the mechanical properties of the composite material hose. This ensures that the composite material hose has high compressive strength, high tensile strength, high compressive strength, high shear strength and high elasticity.

[0067] 5. The actual density of the introduced hollow glass microspheres is as low as 0.46 t / m³. 3 Furthermore, its glass material is a special glass with good thermal stability, and its softening temperature is not lower than 600℃. When rubber is used as the base material for this composite material hose, the vulcanization temperature of commonly used rubber is lower than 200℃. When SBS synthetic resin or similar materials are used as the base material, the melting temperature is also lower than 200℃. Neither of these will cause the hollow glass microspheres to soften and lose their ability to maintain their shape, thereby ensuring the low density and buoyancy characteristics of the composite material hose.

[0068] 6. In the mixing, calendering, winding, vulcanization / hot pressing, and post-processing stages of this composite material hose manufacturing method, no impact loads or impact forces are applied. Furthermore, the introduced hollow glass microspheres themselves have a compressive strength as high as 110 MPa, ensuring that the vast majority of the hollow glass microspheres will not shatter. This guarantees the low density and buoyancy characteristics of the composite material, while also ensuring the high compressive strength of the composite hose. In the composite material hose manufacturing method, a spiral steel wire layer with appropriate wire diameter, major diameter, and pitch is introduced. This spiral steel wire layer, when properly treated in the production process, forms a good and tight bond with the rubber or SBS synthetic resin and similar materials used as the base material, enhancing the composite hose's resistance to internal and external pressure, as well as its elasticity. Attached Figure Description

[0069] Figure 1 This is a longitudinal sectional view of the wall of the composite material zero-buoyancy hose of this utility model.

[0070] Reference numerals: 1. Inner wall substrate layer of hose; 2. First tensile and compressive strength layer; 3. Reinforcing layer; 4. Second tensile and compressive strength layer; 5. Outer wall substrate layer of hose. Detailed Implementation

[0071] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0072] In the description of this application, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0073] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" 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 an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0074] This utility model relates to the field of hose technology in shipbuilding and marine engineering, and in particular to an adhesive hose that simultaneously possesses high compressive strength, high tensile strength, high elasticity, and a density less than that of freshwater / seawater, enabling it to generate positive buoyancy or zero buoyancy, and its manufacturing method.

[0075] This utility model relates to a flexible hose that simultaneously possesses high compressive strength, high tensile strength, high elasticity, a density lower than that of freshwater / seawater, and the ability to generate positive or zero buoyancy. Its compressive stress is not less than 40 MPa, its tensile stress is not less than 20 MPa, and its average density can be as low as 0.7-1.03 t / m³. 3 The advantages of this hose are that it can be used in deep sea (depths of 200m and above), 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 (compensates for movement / displacement under operating conditions and is easy to roll up and store), and has positive buoyancy or zero buoyancy characteristics (provides positive buoyancy to the device or protects the device from the adverse effects of positive buoyancy / gravity generated by it).

[0076] The structure and manufacturing method of this hose are described below:

[0077] Example 1:

[0078] Reference Figure 1 This utility model discloses a high-compression, high-tensile, and high-elasticity composite material zero-buoyancy hose for deep-sea applications. The hose wall comprises, from the inside out, an inner wall substrate layer 1, a first tensile and compressive strength layer 2, a reinforcing layer 3, a second tensile and compressive strength layer 4, and an outer wall substrate layer 5. The inner wall substrate layer 1 enhances wear resistance and seawater resistance, while the outer wall substrate layer 5 enhances wear resistance, seawater resistance, UV resistance, and weather resistance.

[0079] Both the first tensile and compressive strength layer 2 and the second tensile and compressive strength layer 4 are composed of a base layer and a polyester fiber reinforcement layer disposed inside the base layer. The first tensile and compressive strength layer 2 and the second tensile and compressive strength layer 4 enhance the tensile and compressive strength properties. The reinforcement layer 3 is composed of a base layer and a spiral steel wire disposed inside the base layer, which enhances the resistance to internal and external pressure of the pipe and provides high elasticity.

[0080] The inner wall substrate layer 1, the outer wall substrate layer 5, and the substrate layer of the hose are all made of rubber. Hollow glass microspheres are uniformly distributed inside the inner wall substrate layer 1, the first tensile and compressive strength layer 2, the reinforcing layer 3, the second tensile and compressive strength layer 4, and the outer wall substrate layer 5. The compressive strength of the hollow glass microspheres is 110 MPa, and their actual density is 0.46 g / cm³. 3 It has an average diameter of 20 μm and a softening temperature of 600℃.

[0081] A method for manufacturing a high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose using rubber as a base material for deep-sea applications, as described above, includes the following steps:

[0082] Step 1: Raw material preparation. Select one of natural rubber, styrene-butadiene rubber, or chloroprene rubber as the base material, and select polyester synthetic fiber, hollow glass microspheres, compounding agents, and steel wire.

[0083] Among them, rubber: Select the appropriate rubber type as the base material according to the application requirements of the sheet, such as natural rubber, nitrile rubber, butadiene rubber / butyl rubber, chloroprene rubber, and styrene-butadiene rubber. The rubber should have good elasticity, abrasion resistance, corrosion resistance, and other properties.

[0084] Polyester synthetic fiber: Based on the performance requirements of the hose, select polyester fiber yarns, felts, or sheets with appropriate specifications (such as fiber density, monofilament fineness, and fabric structure) and properties (such as tensile strength, abrasion resistance, and chemical resistance) as reinforcing materials. Pre-treat the polyester fibers, such as removing surface oil, impurities, and moisture, using methods like washing and drying, to enhance adhesion to rubber. Note that the density of the synthetic fibers should not be too high; sufficient space must be left so that adjacent rubber sheets on both sides of the polyester synthetic fiber can fully bond together.

[0085] Hollow glass microspheres: Primarily used to reduce the average density of the flexible tube, enabling it to generate sufficient buoyancy when used in water. Based on the stress conditions and water depth under which the flexible tube is used, the required tensile strength, compressive strength, density, and other specifications are determined. The compressive strength, density, diameter, and melting point of the hollow glass microspheres are then selected, and the model and quantity of hollow glass microspheres are determined accordingly.

[0086] Compounding agents include vulcanizing agents, accelerators, activators, antioxidants, and fillers. These compounding agents can improve the processing properties and physical and mechanical properties of rubber.

[0087] Steel wire: High-strength galvanized steel wire is generally selected, and the wire diameter is chosen according to the pressure resistance requirements of the hose. The steel wire needs to be pre-treated, such as pickling to remove surface rust, and then phosphated to increase the adhesion between the steel wire and the rubber.

[0088] Step 2: Mixing. Rubber, hollow glass microspheres, and compounding agents are added to the mixing equipment according to a certain formula ratio. The formula ratio of rubber, hollow glass microspheres, and compounding agents is 7:2:1. A two-roll mill or internal mixer is used. Through mechanical stirring and shearing, the hollow glass microspheres and compounding agents are evenly dispersed in the rubber to form a compound. During the mixing process, it is necessary to control parameters such as temperature, time, and feeding sequence to ensure the quality of the compound.

[0089] Step 3: Calendering. The compounded rubber is calendered using a calender to produce a sheet of a certain thickness and width. During calendering, parameters such as the roller gap, speed, and temperature of the calender can be adjusted to control the thickness and surface quality of the sheet. Simultaneously, a small amount of pretreated polyester synthetic fiber yarn is introduced into the calender to ensure close adhesion between the rubber sheet and the yarn. By adjusting the fiber conveying speed and calender parameters, a good bonding effect is ensured, forming a rubber sheet blank containing a small amount of polyester fiber. The sheet is then cut to the desired size using a cutting machine according to the target dimensions of the resulting flexible composite material sheet.

[0090] Step 4: Winding. Install flanges at both ends of the core mold. Using a winding machine, wind the long strips of film, polyester synthetic fiber wire, or mesh rolls onto the core of the seat hose mold in a predetermined order and number of layers. During winding, ensure the material is even and balanced; avoid excessive height differences. Use the mold and wire guide device to wind the steel wire onto the surface of the partially wound core mold at a specific pitch. Control the speed of the steel wire and rubber material using a traction device to ensure uniformity and tightness. After the spiral steel wire is wound, wind the other materials sequentially. After all materials are wound, wrap the outermost layer with an outer fabric.

[0091] Step 5: Vulcanization. Push the hose and iron core wrapped with raw materials into the vulcanization furnace or vulcanization tank together. The vulcanization reaction is carried out under certain temperature and pressure to further vulcanize and cure the rubber. At the same time, good adhesion is formed between the synthetic fibers and the rubber, and between the rubbers. The vulcanization temperature is set between 140-180℃.

[0092] Vulcanization is a crucial step in the production of rubber hoses. It causes cross-linking reactions in rubber molecules, forming a three-dimensional network structure, thereby improving the physical and mechanical properties and chemical stability of the rubber hose. During vulcanization, parameters such as temperature, time, and pressure need to be carefully controlled. The vulcanization temperature is generally between 140-180℃, and the vulcanization time varies from tens of minutes to several hours, depending on the thickness of the sheet and the type of rubber.

[0093] Step 6: Post-processing. Rotate the iron core in the opposite direction to remove the outer wrapping cloth, apply pressure to remove the iron core, and inspect the appearance, dimensions, and physical and mechanical properties of the rubber hose. Then, package the qualified rubber hoses with rubber as the base material.

[0094] Remove the outer sheath: Rotate the iron core in the opposite direction to remove the outer sheath, and apply pressure to remove the iron core. The vulcanized rubber hose may have some burrs and flash, which need to be trimmed to ensure its size and shape meet requirements.

[0095] Inspection: The appearance, dimensions, and physical and mechanical properties of the rubber hoses are inspected to ensure that the product quality meets standards and customer requirements. Inspection items include diameter, wall thickness, length, hardness, density, whether steel wires are exposed, tensile strength, elongation at break, adhesive strength, and water tightness / air tightness.

[0096] Packaging: The inspected and qualified rubber hoses are 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.

[0097] Example 2:

[0098] Reference Figure 1A high-pressure-strength, high-tensile-strength, and high-elasticity composite zero-buoyancy hose for deep-sea applications differs from Example 1 in that the inner wall substrate layer 1, the outer wall substrate layer 5, and the substrate layer are all made of synthetic resin.

[0099] A method for manufacturing a high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications using synthetic resin as a base material, as described above, includes the following steps:

[0100] Step S1: Raw material preparation. SBS synthetic resin is selected as the base material, and polyester synthetic fiber, hollow glass microspheres, compounding agents and steel wire are selected.

[0101] For SBS synthetic resin: Based on the application requirements of the hose, select a suitable type of SBS synthetic resin as the base material, fully considering its molecular weight, molecular structure, and the ratio of styrene to butadiene to meet the final performance requirements of the hose, such as hardness, elasticity, and tensile strength. Check that the raw materials are free of impurities and lumps, and then dry them to control the moisture content below 0.5%.

[0102] Polyester synthetic fibers: Based on the performance requirements of the hose, select polyester fiber yarns, felts, or sheets with appropriate specifications (such as fiber density, monofilament fineness, and fabric structure) and properties (such as strength, abrasion resistance, and chemical resistance) as reinforcing materials. Pre-treat the polyester fibers, such as removing surface oil, impurities, and moisture, using methods like washing and drying, to enhance adhesion to SBS synthetic resin. Note that the density of the synthetic fibers should not be too high; sufficient space must be left so that adjacent synthetic resin fibers on both sides can fully bond together.

[0103] Hollow glass microspheres: Their main function is to reduce the density of the flexible hose, enabling it to generate sufficient buoyancy when used in water. Based on the stress conditions and water depth under which the flexible composite hose is used, the required tensile strength, compressive strength, density, and other indicators are determined. The compressive strength, density, diameter, and melting point of the hollow glass microspheres are then selected, and the model and quantity of the hollow glass microspheres are determined accordingly.

[0104] Compounding agents: Additives such as plasticizers, anti-aging agents, lubricants, and fillers are added as needed. Plasticizers improve the flexibility and processing performance of SBS synthetic resin; anti-aging agents prevent SBS synthetic resin from aging and deteriorating during use, extending the service life of the hose; lubricants help improve flowability during processing; fillers can reduce costs and improve certain properties of the hose, such as hardness and dimensional stability. These compounding agents can improve the processing performance and physical and mechanical properties of SBS synthetic resin.

[0105] Steel wire: High-strength galvanized steel wire is generally selected, and the wire diameter is chosen according to the pressure resistance requirements of the hose. The steel wire needs to be pre-treated, such as pickling to remove surface rust, and then phosphated to increase the adhesion between the steel wire and the rubber.

[0106] Step S2: Mixing. SBS synthetic resin, hollow glass microspheres, and compounding agents are added to a mixing device, such as an open mill or internal mixer, according to a certain formula ratio. The formula ratio of SBS synthetic resin, hollow glass microspheres, and compounding agents is 7:2:1. Mixing is carried out under the conditions of 150-200℃ and appropriate speed. Through mechanical stirring and shearing, the hollow glass microspheres and compounding agents are evenly dispersed in the SBS synthetic resin to form a mixture. During the mixing process, it is necessary to control parameters such as temperature, time, and feeding sequence to ensure the quality of the mixture.

[0107] Step S3, calendering: The mixed SBS synthetic resin material is placed into a calender and pressed into sheets of a certain thickness and width by rollers. The roller temperature is adjusted between 160-180℃, and the appropriate speed and gap are controlled to ensure the thickness, uniformity, and surface quality of the material. Simultaneously, a small amount of pretreated polyester synthetic fiber is introduced into the calender, allowing it to adhere tightly to the SBS synthetic resin sheet during the calendering process. By adjusting the fiber conveying speed and calender parameters, a good bonding effect between the two is ensured, forming an SBS synthetic resin preform containing a small amount of polyester fiber. The sheet SBS synthetic resin is then cut to the desired size according to the target dimensions of the flexible composite hose using a cutting machine.

[0108] Step S4: Winding. Install flanges at both ends of the core mold. Using a winding machine, wind long strips of SBS synthetic resin, polyester synthetic fiber wire, or mesh rolls onto the core of the seat hose mold in a predetermined order and number of layers. During winding, ensure the material is even and balanced; avoid excessive height differences. Using the mold and wire guide device, wind the steel wire onto the surface of the partially wound core mold at a specific pitch. Control the speed of the steel wire and rubber material using a traction device to ensure uniformity and tightness. After the spiral steel wire is wound, wind the other materials sequentially. After all materials are wound, wrap an outer layer of fabric around the outermost layer.

[0109] Step S5: Hot pressing. Place the wound intermediate product in a hot press or autoclave and hot press it at a temperature of 180-220℃ and a pressure of 10-30MPa. The hot pressing time depends on the thickness of the sheet and the size of the mold, and is generally 5-30 minutes. During this process, the SBS synthetic resin further melts and flows, forming a stronger bond with the polyester fiber, and giving the hose the required shape and dimensional accuracy.

[0110] Step S6, Post-processing: After hot pressing, the intermediate product is removed from the hot press or autoclave and cooled. Natural cooling or forced cooling (such as air cooling or water cooling) can be used to cool and solidify the hose and maintain its shape. During cooling, the hose should be protected from external impact or deformation. The iron core is rotated in the opposite direction to remove the outer cloth and pressure is applied to remove the iron core. After the hot-pressed SBS synthetic resin hose undergoes trimming and inspection, the qualified hoses with SBS synthetic resin as the base material are packaged.

[0111] The SBS synthetic resin hoses formed by hot pressing may have some burrs and flash, which need to be trimmed to remove edge burrs and uneven parts, so that the surface is smooth, the dimensions are accurate, and the technical requirements are met.

[0112] Inspection: The appearance, dimensions, and physical and mechanical properties of the SBS synthetic resin hoses are inspected to ensure that the product quality meets standards and customer requirements. Inspection items include diameter, wall thickness, length, hardness, density, whether steel wires are exposed, tensile strength, elongation at break, adhesive strength, and water tightness / air tightness.

[0113] Packaging: The qualified SBS synthetic resin tubing is packaged using materials such as plastic film, woven bags, and wooden crates to prevent damage during transportation and storage.

[0114] The implementation principle of this utility model is as follows: The inherent properties of rubber or SBS synthetic resin and similar materials used as the hose substrate determine that the hose material has high compressive strength (not less than 40MPa); the spiral steel wire of the reinforcing layer 3 is tightly bonded to the substrate, giving the hose high resistance to internal and external pressure, and the inherent properties of the spiral steel wire and the substrate itself give the hose high elasticity; the polyester fibers of the first tensile and compressive layer 2 and the second tensile and compressive layer 4 are tightly bonded to the substrate, giving the hose high tensile strength (not less than 20MPa); high-strength hollow glass microspheres are uniformly mixed in all substrates of the hose inner wall substrate 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 substrate layer 5, making the average density of the entire hose (including joints and connecting bolts) as low as 0.7-1.03t / m³. 3 The pressure should be less than or equal to water to allow the hose to achieve positive or zero buoyancy in the water.

[0115] The rubber or SBS synthetic resin and similar materials throughout the hose are tightly bonded to the adjacent polyester synthetic fibers, spiral steel wires, hollow glass microspheres, etc., and through the gaps between the polyester synthetic fibers, spiral steel wires, hollow glass microspheres, they are tightly bonded to the adjacent rubber or SBS synthetic resin and similar materials, forming a unified and continuous overall structure. Figure 1The dimensions of each layer do not represent actual dimensions, but only indicate relative positional relationships, and the order can be adjusted appropriately. In terms of material mass proportions, rubber or synthetic resin constitutes the majority, while synthetic fibers constitute a smaller portion. Rubber or synthetic resin provides compressive strength and shear strength to this composite material, while synthetic fibers provide tensile strength. Hollow glass microspheres (compressive strength 110 MPa, actual density 0.46 g / cm³) are uniformly mixed into the main component of this composite material, namely the rubber or synthetic resin raw material, at a mass ratio of 100:5-100:40. 3 With an average diameter of 20 μm and a softening temperature of 600℃, it has a low density, which makes the average density of the composite material less than that of water, thus generating positive buoyancy; it has high compressive strength and a high melting point, resulting in an extremely low breakage rate during production; its small average diameter means that when it is uniformly mixed in the main material, it has little impact on the bonding between the molecules of the original main material; its composition is glass, and its chemical properties are stable, so it will not react chemically with other components during production.

[0116] The embodiments described herein are preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. Therefore, all equivalent changes made to the structure, shape, and principle of this utility model should be included within the scope of protection of this utility model.

Claims

1. A composite material zero-buoyancy hose with high compressive strength, high tensile strength, and high elasticity for deep-sea applications, characterized in that: The wall of the composite zero-buoyancy hose includes, from the inside out, a hose inner wall substrate layer (1), a first tensile and compressive layer (2), a reinforcing layer (3), a second tensile and compressive layer (4), and a hose outer wall substrate layer (5).

2. The high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications according to claim 1, characterized in that, Both the first tensile and compressive layer (2) and the second tensile and compressive layer (4) are composed of a substrate layer and a polyester fiber reinforcement layer disposed inside the substrate layer.

3. The high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications according to claim 1, characterized in that, The reinforcing layer (3) consists of a substrate layer and a spiral steel wire disposed inside the substrate layer.

4. A high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications according to any one of claims 1-3, characterized in that, The inner wall substrate layer (1), the outer wall substrate layer (5), and the substrate layer are all made of rubber.

5. A high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications according to any one of claims 1-3, characterized in that, The inner wall substrate layer (1), the outer wall substrate layer (5), and the substrate layer are all made of SBS synthetic resin.

6. The high-compression, high-tensile, and high-elasticity composite zero-buoyancy hose for deep-sea applications according to claim 1, characterized in that, Hollow glass microspheres are uniformly distributed inside the inner wall substrate layer (1), 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.

7. A high-compression, high-tensile, and high-elasticity composite material zero-buoyancy hose for deep-sea applications according to claim 6, characterized in that, The hollow glass microspheres have a compressive strength of 110 MPa and an actual density of 0.46 g / cm³. 3 It has an average diameter of 20 μm and a softening temperature of 600℃.

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