A vibration fatigue resistant rubber hose for automobile turbocharger

Abstract

A kind of automobile turbocharger is used to vibration fatigue-resistant rubber hose, including the inner liner, vibration buffer layer, first reinforcing layer, heat insulation layer, second reinforcing layer and outer cover layer arranged in turn from inside to outside;The inner liner is made of polytetrafluoroethylene material, vibration buffer layer is made of silicone rubber foaming material, tightly covers the outer surface of inner liner;First reinforcing layer is the woven layer of stainless steel wire and aramid fiber mixed, heat insulation layer is the composite woven layer of ceramic fiber and basalt fiber, second reinforcing layer is high-density stainless steel wire woven layer, outer cover layer is the composite layer of fluorine rubber and silicone rubber.The automobile turbocharger is used to vibration fatigue-resistant rubber hose, through the synergistic effect of multilayer structure, effectively deal with the mechanical vibration and dynamic pressure load generated in the working process of turbocharger, significantly improve the vibration fatigue resistance of hose, overcome the problems such as aging, cracking, leakage of traditional rubber hose under long-term vibration fatigue working condition.

Description

Technical Field

[0001] This utility model relates to the field of rubber hose technology, specifically to a vibration-fatigue resistant rubber hose for automotive turbochargers. Background Technology

[0002] With the rapid development of the automotive industry, turbocharging technology has become a key means to improve engine performance, reduce fuel consumption, and reduce exhaust emissions. Turbochargers use exhaust gas energy to drive a turbine to rotate, thereby compressing the intake air and increasing the engine's intake air density and combustion efficiency. However, during the operation of a turbocharger, mechanical vibration places extremely stringent performance requirements on connecting components, especially rubber hoses. Traditional rubber hoses are prone to aging, cracking, and leakage under long-term vibration fatigue conditions, which seriously affect the reliability and durability of the turbocharging system and may even lead to engine failure, threatening driving safety.

[0003] During turbocharger operation, the hoses are subjected to pulsating high-pressure media impacts with large pressure fluctuations and high frequency. This dynamic pressure load causes repeated deformation of the hoses, leading to vibration fatigue. Under long-term vibration fatigue, microcracks will form inside the hoses, which gradually expand and eventually cause the hoses to rupture. Furthermore, the mechanical vibrations generated by the turbocharger are transmitted to the hoses through connecting components, exacerbating fatigue damage. Traditional rubber hoses, due to their simple structure and lack of effective vibration buffering and reinforcement mechanisms, cannot meet the high requirements of turbochargers for hose vibration fatigue resistance. Meanwhile, in recent years, the state has successively introduced standards such as GB / T 7528-2025 "Terminology for Rubber and Plastic Hoses and Hoses Assemblies", GB / T4498.1-2025 "Determination of Ash Content in Rubber - Part 1: Muffle Furnace Method", GB / T 43751-2024 "Guidelines for the Application of Statistics in Physical Testing of Rubber and Rubber Products", and GB / T 18950-2023... National standards such as "Laboratory Light Source Exposure Test Method for Rubber and Plastic Hoses: Determination of Changes in Color, Appearance and Other Physical Properties" regulate the quality of rubber hoses.

[0004] Therefore, there is an urgent need to develop a new type of rubber hose for automotive turbochargers that can significantly improve vibration fatigue resistance and extend service life while maintaining good high-temperature resistance. Summary of the Invention

[0005] To address the aforementioned problems, this utility model provides a vibration-fatigue resistant rubber hose for automotive turbochargers. This hose features a multi-layered structure consisting of an inner liner, a vibration buffer layer, a first reinforcing layer, a heat insulation layer, a second reinforcing layer, and an outer cover layer, arranged sequentially from the inside out. The layers work synergistically to effectively cope with the mechanical vibrations and dynamic pressure loads generated during turbocharger operation, significantly improving the hose's vibration fatigue resistance. This overcomes the problems of aging, cracking, and leakage that traditional rubber hoses are prone to under long-term vibration fatigue conditions, ensuring the reliability and durability of the turbocharger system, reducing the risk of engine failure, and improving driving safety.

[0006] The technical solution of this utility model is as follows: A vibration-fatigue resistant rubber hose for automotive turbochargers includes, from the inside out, an inner liner, a vibration buffer layer, a first reinforcing layer, a heat insulation layer, a second reinforcing layer, and an outer cover layer. The inner liner is made of polytetrafluoroethylene (PTFE), and the vibration buffer layer is made of silicone rubber foam, tightly covering the outer surface of the inner liner. The first reinforcing layer is a braided layer of stainless steel wire and aramid fiber, the heat insulation layer is a composite braided layer of ceramic fiber and basalt fiber, the second reinforcing layer is a high-density stainless steel wire braided layer, and the outer cover layer is a composite layer of fluororubber and silicone rubber.

[0007] The thicknesses of the inner lining, vibration buffer layer, first reinforcing layer, heat insulation layer, second reinforcing layer and outer cladding layer are 0.6-1.2mm, 0.5-1.2mm, 0.3-0.7mm, 0.5-1.0mm, 0.5-1.2mm and 1.2-2.0mm, respectively.

[0008] The foam porosity of the vibration buffer layer is 30%-50%.

[0009] The braiding ratio of stainless steel wire to aramid fiber in the first reinforcing layer is 1:2 to 1:3.

[0010] The mass ratio of ceramic fiber to basalt fiber in the insulation layer is 1:1 to 1:1.5.

[0011] The second reinforcing layer adopts a double-layer interlaced weave structure with a weave density of 85%-95%.

[0012] The mass ratio of fluororubber to silicone rubber in the outer coating is 1:1.5 to 1:2.5.

[0013] The outer surface of the outer coating is provided with a wear-resistant coating.

[0014] The wear-resistant coating is made of polyurethane material.

[0015] The thickness of the wear-resistant coating is 0.2-0.5 mm.

[0016] The beneficial effects of this utility model are as follows: 1. This utility model discloses a vibration fatigue resistant rubber hose for automotive turbochargers. This hose features a multi-layered structure consisting of an inner liner, a vibration buffer layer, a first reinforcing layer, a heat insulation layer, a second reinforcing layer, and an outer covering layer, arranged sequentially from the inside out. The layers work synergistically to effectively cope with the mechanical vibrations and dynamic pressure loads generated during turbocharger operation, significantly improving the hose's vibration fatigue resistance. This overcomes the problems of aging, cracking, and leakage that traditional rubber hoses are prone to under long-term vibration fatigue conditions, ensuring the reliability and durability of the turbocharger system, reducing the risk of engine failure, and improving driving safety.

[0017] 2. The present invention discloses a vibration fatigue resistant rubber hose for automotive turbochargers. The vibration fatigue resistant rubber hose for automotive turbochargers has a wear-resistant coating made of polyurethane material on the outer surface of the outer covering layer, which can effectively reduce the friction and wear between the hose and surrounding components during use, and further extend the service life of the hose. Attached Figure Description

[0018] The advantages and solutions of this application will become clear to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this invention.

[0019] In the attached diagram: Figure 1 This is a schematic diagram of the layer structure of a vibration-fatigue resistant rubber hose for an automotive turbocharger according to an embodiment of the present invention. The components represented by the various reference numerals in the diagram are: This utility model comprises: 100, inner lining layer; 200, vibration buffer layer; 300, first reinforcing layer; 400, heat insulation layer; 500, second reinforcing layer; and 600, outer covering layer. Detailed Implementation

[0020] like Figure 1 As shown, the vibration fatigue resistant rubber hose for automotive turbochargers is provided with an inner liner 100, a vibration buffer layer 200, a first reinforcing layer 300, a heat insulation layer 400, a second reinforcing layer 500, and an outer cover layer 600 from the inside out; preferably, the outer surface of the outer cover layer 600 is also provided with a wear-resistant coating.

[0021] The inner liner 100 is made of polytetrafluoroethylene (PTFE), which has excellent chemical stability and is resistant to corrosion from various strong acids, strong alkalis, and strong oxidants. It also has an extremely low coefficient of friction and a smooth surface, effectively reducing resistance to the flow of media within the hose and ensuring smooth media passage. With a thickness of 0.6-1.2 mm, the inner liner 100 has sufficient strength to withstand the pressure of the internal media while avoiding excessive thickness that would increase the overall weight and cost of the hose. During turbocharger operation, the high-temperature, high-pressure media flows within the hose. The inner liner 100, with its excellent chemical stability and low-friction characteristics, provides a stable, low-resistance flow channel for the media, preventing corrosion and excessive wear on the hose's inner wall.

[0022] The vibration buffer layer 200 is made of silicone rubber foam material and tightly covers the outer surface of the inner liner layer 100. Silicone rubber has excellent elasticity, high and low temperature resistance, and damping characteristics. After foaming, it forms a porous structure with a thickness of 0.5-1.2mm, which ensures that the vibration buffer layer 200 has sufficient elastic deformation capacity to absorb and buffer mechanical vibration. The foam porosity is 30%-50%. The appropriate porosity allows the internal bubbles of the vibration buffer layer 200 to deform and compress when subjected to vibration, thereby consuming vibration energy and effectively reducing the transmission of vibration to other layers of the hose. When the mechanical vibration generated by the turbocharger is transmitted to the hose, the vibration buffer layer 200 converts the vibration energy into the deformation energy of the bubbles through its porous structure and elastic properties. Then, the energy is gradually released through the slow recovery process of the bubbles, achieving the effect of buffering vibration and reducing fatigue damage to the hose caused by vibration.

[0023] The first reinforcing layer 300 is a braided layer composed of stainless steel wire and aramid fiber. The stainless steel wire has high strength, good corrosion resistance, and heat resistance, while the aramid fiber has high modulus, low density, and excellent toughness. The thickness is 0.3-0.7mm, ensuring reinforcement without excessively increasing the flexibility of the hose. The stainless steel wire is typically austenitic 304 or 316 stainless steel wire with a diameter of 0.08mm-0.15mm, possessing excellent corrosion resistance, high strength, and good fatigue resistance. The aramid fiber is selected from high-modulus aligners with a fineness of 1500D~2000D. Aramid fiber possesses extremely high tensile strength, heat resistance, and creep resistance. When blended with aramid fiber in a 1:2–1:3 ratio, the first reinforcing layer maintains flexibility while significantly improving its overall performance in terms of tensile, compressive, and vibration fatigue resistance. When the hose is subjected to dynamic pressure loads, the stainless steel wire and aramid fiber in the first reinforcing layer work together to form a stable mesh structure. The stainless steel wire mainly bears the axial and radial tensile forces, while the aramid fiber disperses the pressure through its elastic deformation, allowing the hose to maintain structural integrity during repeated deformation and improving its fatigue resistance.

[0024] The 400 heat insulation layer is a composite woven layer of ceramic fiber and basalt fiber. The ceramic fiber has extremely low thermal conductivity, good high-temperature resistance, and chemical stability, while the basalt fiber has high strength, resistance to acid and alkali corrosion, and heat insulation properties. With a thickness of 0.5-1.0 mm, it effectively blocks the high temperatures generated by the turbocharger, preventing heat transfer to the hose. The ceramic fiber is typically high-purity aluminosilicate ceramic fiber with a diameter of 3-6 μm, a length of 50-150 mm, and an alumina content ≥45%, capable of long-term operation at temperatures up to 1260℃. The basalt fiber is typically selected with a diameter of 9-13 μm and a length of 50-200 mm. The insulation layer 400 is a continuous fiber with a tensile strength ≥3000MPa. The mass ratio of ceramic fiber to basalt fiber is 1:1 to 1:1.5. The insulation layer 400 can fully utilize the excellent thermal insulation performance of ceramic fiber and enhance the structural stability of the insulation layer by utilizing the strength of basalt fiber. When the turbocharger generates high temperature during operation, the ceramic fiber and basalt fiber in the insulation layer 400 prevent heat conduction through their porous structure and low thermal conductivity. The tiny pores of ceramic fiber can scatter and absorb heat radiation, while basalt fiber forms a thermal barrier, further reducing the transfer of heat to the inside of the hose and protecting other layers of the hose from the effects of high temperature.

[0025] The second reinforcing layer 500 is a high-density stainless steel wire braided layer with a double-layer interlaced braiding structure. This double-layer interlacing makes the connection between the stainless steel wires tighter, enhancing the interlayer bonding force. The stainless steel wire diameter is 0.1-0.2mm, made of austenitic 304 or 316 stainless steel, with a braiding angle of 54°-56°, 16-20 braids per inch, and a wire bundle density of 8-12 strands per centimeter. The second reinforcing layer 500 is 0.5-1.2mm thick, providing sufficient strength to resist deformation and damage to the hose under complex working conditions. The braiding density is 85%-95%. This high braiding density gives the second reinforcing layer 500 higher strength and rigidity, effectively limiting excessive deformation of the hose. When the hose is subjected to significant external forces and vibrations, the double-layer interlaced braiding structure of the second reinforcing layer 500 and the high-density stainless steel wire form a robust framework. The mutual restraint and support between the stainless steel wires ensures that the hose maintains a stable shape in all directions, preventing hose breakage and failure due to excessive deformation.

[0026] The outer layer 600 is a composite layer of fluororubber and silicone rubber. Fluororubber has excellent high-temperature resistance, oil resistance, and chemical corrosion resistance, while silicone rubber has good elasticity and low-temperature resistance. The thickness is 1.2-2.0mm, providing sufficient protection to prevent the hose from physical and chemical damage from the external environment. The mass ratio of fluororubber to silicone rubber is 1:1.5-1:2.5, allowing the outer layer 600 to utilize the corrosion resistance and high-temperature resistance of fluororubber while maintaining the flexibility of the hose with the elasticity of silicone rubber. As the outermost layer of the hose, the outer layer 600 is in direct contact with the external environment. The fluororubber component can effectively resist external oil, chemicals, and high-temperature erosion, while the silicone rubber component gives the outer layer 600 a certain degree of elasticity, which can buffer external impact and protect the internal structure of the hose from damage.

[0027] In a preferred embodiment, the wear-resistant coating is made of polyurethane, which has high strength, high elasticity, and excellent wear resistance. With a thickness of 0.2-0.5 mm, it ensures wear resistance without affecting the overall flexibility and dimensional accuracy of the hose. During hose use, the wear-resistant coating comes into direct contact with surrounding components. The high strength and elasticity of the polyurethane material enable it to withstand friction and wear, forming a protective barrier that reduces wear on the outer coating and extends the service life of the hose.

[0028] The manufacturing process of the vibration-fatigue resistant rubber hose for this automotive turbocharger is as follows: Polytetrafluoroethylene (PTFE) raw material is placed in an extruder. Through heating and extrusion, the PTFE melts and is extruded from the die to form a tubular inner liner 100 with a thickness of 0.6-1.2 mm. Silicone rubber raw material and a foaming agent are mixed evenly in a certain proportion and placed in a foaming device. By controlling the foaming temperature and time, the silicone rubber is foamed to form a foamed material with a porosity of 30%-50%. The foamed silicone rubber material is then tightly wrapped around the outer surface of the inner liner 100 by winding or coating to form a vibration buffer layer 200 with a thickness of 0.5-1.2 mm. During the process, ensure there are no air bubbles or gaps between the vibration buffer layer 200 and the inner lining layer 100; select appropriate specifications of stainless steel wire and aramid fiber, mix them in a ratio of 1:2 to 1:3, and use professional weaving equipment to interweave the stainless steel wire and aramid fiber into a woven layer with a thickness of 0.3-0.7mm, then cover it on the outer surface of the vibration buffer layer 200; mix ceramic fiber and basalt fiber in a mass ratio of 1:1 to 1:1.5, and then weave them into a composite woven layer with a thickness of 0.5-1.0mm using a weaving machine; 400 sets of the woven heat insulation layer are then applied. On the outer surface of the first reinforcing layer 300, ensure a tight fit between the heat insulation layer 400 and the first reinforcing layer 300; select high-density stainless steel wire and use a double-layer interlaced weaving method to weave a woven layer with a thickness of 0.5-1.2mm and a weaving density of 85%-95% on a weaving machine; then fit the woven second reinforcing layer 500 onto the outer surface of the heat insulation layer 400, ensuring that the weaving structure of the second reinforcing layer 500 is uniform and tight; mix fluororubber and silicone rubber at a mass ratio of 1:1.5-1:2.5, add appropriate amounts of vulcanizing agent and accelerator, stir evenly, and then put into an extruder. During extrusion, the mixed rubber material is extruded through an extruder to form a tubular outer coating 600 with a thickness of 1.2-2.0 mm, which is then fitted onto the outer surface of the second reinforcing layer 500. In a preferred embodiment, polyurethane coating is uniformly sprayed onto the outer surface of the outer coating 600 to form a wear-resistant coating with a thickness of 0.2-0.5 mm. The assembled hose is placed in a vulcanizing tank and vulcanized under certain temperature and pressure. The vulcanization time and temperature are precisely controlled according to the characteristics of the rubber material to ensure that each layer of rubber material is fully cross-linked, thereby improving the overall performance and stability of the hose.

[0029] This hose has excellent resistance to vibration fatigue, high temperature and wear, which can meet the requirements of automotive turbochargers.

Claims

1. A vibration-fatigue resistant rubber hose for automotive turbochargers, characterized in that, It includes an inner lining layer (100), a vibration buffer layer (200), a first reinforcing layer (300), a heat insulation layer (400), a second reinforcing layer (500), and an outer covering layer (600) arranged sequentially from the inside to the outside. The inner lining layer (100) is made of polytetrafluoroethylene material, and the vibration buffer layer (200) is made of silicone rubber foam material, which tightly covers the outer surface of the inner lining layer. The first reinforcing layer (300) is a woven layer of stainless steel wire and aramid fiber, the heat insulation layer (400) is a composite woven layer of ceramic fiber and basalt fiber, and the second reinforcing layer (500) is a high-density stainless steel wire woven layer.

2. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The thicknesses of the inner lining (100), vibration buffer layer (200), first reinforcing layer (300), heat insulation layer (400), second reinforcing layer (500) and outer covering layer (600) are 0.6-1.2mm, 0.5-1.2mm, 0.3-0.7mm, 0.5-1.0mm, 0.5-1.2mm and 1.2-2.0mm, respectively.

3. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The foaming porosity of the vibration buffer layer (200) is 30%-50%.

4. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The braiding ratio of stainless steel wire to aramid fiber in the first reinforcing layer (300) is 1:2 to 1:

3.

5. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The mass ratio of ceramic fiber to basalt fiber in the insulation layer (400) is 1:1 to 1:1.

5.

6. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The second reinforcing layer (500) adopts a double-layer interlaced weave structure with a weave density of 85%-95%.

7. The vibration-fatigue resistant rubber hose for automotive turbochargers according to claim 1, characterized in that, The outer surface of the outer cover (600) is provided with a wear-resistant coating.

8. The vibration-fatigue resistant rubber hose for an automotive turbocharger according to claim 7, characterized in that, The wear-resistant coating is made of polyurethane material.

9. The vibration-fatigue resistant rubber hose for an automotive turbocharger according to claim 8, characterized in that, The thickness of the wear-resistant coating is 0.2-0.5 mm.

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