Green HOSE with attributed sustainability

Abstract

The sustainable hydraulic hose comprises of an inner-tube, reinforcement which renders robustness to the hose to withstand higher pressures and finally the cover compounds which is the exterior most part of the hose. The present invention relates generally to a sustainable hydraulic hose which is substantially minimizing the use of conventional fossil fuel derived raw materials. Nitrile (NBR) / SBR based innertube is used along with Nitrile (NBR) / SBR based cover compounds and the hydraulic hose accounts for at least 50 % and extendable up to 80 % sustainability. Unlike conventional hoses, which may use petroleum-based synthetic rubbers, sustainable options often incorporate recyclable or biodegradable materials like elastomers, fillers, rubber additives, plasticizers which is derived from bio- origin without depleting the non-renewable resources and at the same time it is ensured that the hoses meet high standards for both performance and environmental impact, providing users with assurance of their eco-friendly credentials.

Description

GREEN HOSE WITH ATTRIBUTED SUSTAINABILITYFIELD OF THE INVENTION

[0001] The present invention relates generally to a sustainable hydraulic hose which substantially minimizes the use of conventional fossil fuel derived raw materials. Nitrile (NBR) / SBR based innertube is used along with Nitrile (NBR) / SBR based cover compounds and the hydraulic hose accounts for at least 50 % and extendable up to 80 % sustainability.BACKGROUND

[0002] The world is moving towards sustainable solutions to reduce the carbon footprint which is critically important to conserve mother earth and its exhaustible resources of energy. “Sustainability” is perhaps the most pressing need of the current era where our endeavor is to minimize the depletion of non-renewable sources of energy that in term will foster significant reduction in long-term energy costs. This dire need has been demonstrated in various international forums, government bodies, and scientific consortiums such as United Nations Climate Change Conference (Conference of the Parties), European Climate Change Adaptation Conference, World Climate Summit, chemical societies across the continents etc. At the current juncture, the self-propelling sustainability concept does not require any advocacy for its justification.

[0003] In line with the endeavour to offer sustainable solutions, the current invention provides articles of any application including hydraulic especially to be used for the transfer of chemicals, petroleum, air, water, water suction and discharge. 'Sustainability' has long been a buzzword in business. It's more crucial than ever to be aware of our company's industrial waste and to take all action we can to decrease it since businesses' ecological footprints, especially those of major industrial businesses, are coming under more scrutiny. Rubber hoses should only be disposed of in a facility that is authorised to handle waste because they are considered urban solid waste.Sadly, this is rarely where the hoses end up, and the consequence is bad for the environment because they are frequently packed with extra oil or poisonous chemicals.

[0004] Recently there is ongoing research to tackle the above-mentioned problem and to explore this new marketplace. Contitech USA has a patent on the development of Sustainable hose comprised of EPDM / EPR based Cover and tube compounds. US patent application number 11565494B2. Apart from these some prior arts in sustainability are EP2668105A1; US5770632, US 8487014, US 11565494, and so on.

[0005] This is an emerging field and has potential market in the global industry since it can improve the sustainability and therefore reduce impact on the environment and concomitantly save money over the life of a product or service.OBJECTIVE OF THE INVENTION

[0006] Some of the objectives of the present disclosure, which at least one embodiment herein satisfies, are as follows:- An object of the present disclosure is to develop a sustainable hydraulic hose to be used for the transfer, but not limited to, chemicals, petroleum & other oils, air, water, water suction and discharge.- An object of the present disclosure is to provide a sustainable hydraulic hose having sustainable solutions to reduce the carbon footprint.- An object of the present disclosure is to provide a sustainable hydraulic hose having robust to physical environment condition.- It is an object of the present disclosure to ameliorate one or more problems of prior art or to at least provide a useful alternative.- An object of the present disclosure is to provide a sustainable hydraulic hose which will abide by the Hose Standards like EN853 / SAE100R1 AT / SAE100R6 etc., but not limited to these standards only.Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.SUMMARY

[0007] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0008] In a first aspect of the disclosure, a single braided hose comprises of an inner-tube, a reinforcement which renders robustness to the hose to withstand higher pressures and a cover compounds which is the exterior most part of the hose.

[0009] In another aspect of the disclosure, a double braided hose comprises of an inner-tube, a first reinforcement which renders robustness to the hose to withstand higher pressures, a filler system, a second reinforcement and a cover compounds which is the exterior most part of the hose.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0010] The accompanying drawings illustrate the best mode for carrying out the invention as presently contemplated and set forth hereinafter. The present invention may be more clearly understood from a consideration of the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings wherein like reference letters, numerals indicate the corresponding parts in various figures in the accompanying drawings, and in which:- FIG. 1 illustrates in perspective view, a hose and its different layers according to some aspects of the disclosure; and,- FIG. 2 depicts in top view, a hose and its different layers according to some aspects of the disclosure;- FIG. 3 illustrates in perspective view, a single braided hose according to some aspects of the disclosure;- FIG. 4 depicts in perspective view, a double braided hose according to some aspects of the disclosure; and- FIG. 5 illustrates in cross-sectional view, a hose and its different layers according to some aspects of the disclosure;

[0011] While the present invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.DETAILED DESCRIPTION

[0012] Embodiments of the present invention disclosure will be described more fully hereinafter with reference to the accompanying drawings in which the numerals represent the elements throughout the figure and in which example embodiments are shown.

[0013] The detailed description and the accompanying drawings illustrate the specific exemplary embodiments by which the disclosure may be practiced. These embodiments are disclosed in detail to enable those skilled in the art to practice the invention illustrated in the disclosure. It is to be understood that other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the present disclosure . The following detailed description is therefore not to be taken in a limiting sense.

[0014] The present invention will now be described by referencing the appended figures representing a preferred embodiment. Referring now to FIG. 1, Fig. 2 and Fig. 5 of the present invention illustrating a perspective view, top view and cross section view respectively, of a hose (100) havingdifferent types of layers. A hose (100) comprises of an inner-tube layer (101), a reinforcement layer (102) which renders robustness to the hose to withstand higher pressures and a cover layer (103) which is the exterior most part of the hose.

[0015] Referring now to FIG. 3 of the present invention illustrating a perspective view of a single braided hose (200) having three layers i.e. an inner-tube layer (201), a reinforcement layer (202), and a cover layer (203) which is the exterior most part of the hose.

[0016] Also, referring now to FIG. 4 of the present invention illustrating a perspective view of a double braided hose (300) having five layers i.e., i.e. an inner-tube layer (301), a first reinforcement layer (302), a filler layer (303), a second reinforcement layer (304) and a cover layer (305) which is the exterior most part of the hose.

[0017] In one embodiment, the tube and cover compound are essentially composed of elastomers like natural rubber, or synthetic rubbers sourced from biological origin. The synthetic elastomer may be either made from Polybutadiene rubber, Styrene butadiene rubber, Nitrile Rubber, Butyl or Halobutyl rubber or may be a blend of all of these or some of the mentioned rubbers. All the synthetic elastomers mentioned above used are sustainably derived from biological sources like sugarcane or biofuels. For example, the ACN content in NBR is obtained from recycled acrylonitrile and butadiene is sustainably derived by cracking biofuels aiding in sustainability of the rubber. All other elastomers including but not limited to SBR, PBR, CR, Butyl, Halobutyl etc are sourced from biological origin.

[0018] In one embodiment, the filler system may be either from sustainable recycled carbon black, Silica, Calcium carbonate, clay, nanomaterials like but not limited to nanoclay, or may be a hybrid filler system comprising either all or at least two of them. Basically, in this embodiment, the hybrid filler concept has been introduced in order get the advantages of both the fillers & incorporating nanofillers which is probably the first time beingincorporated into the hose system. This synergy renders better mechanical property to the said sustainable hose.

[0019] In alternate embodiment, the filler system used can be also have other nanomaterials like but not limited to graphene, CNT, MMT, nanoclay etc added to them enabling high performance application with aided weight reduction thus contributing to sustainable development of hoses.

[0020] In other embodiment, bio sourced plasticizers are used for the tube elastomer compounds; Sunflower Oil, Soyabean Oil and epoxidized Soyabean oil, Castor Oil; either of the oils or a blend of at least two of them may be used in the hose compounds.

[0021] In alternate embodiment, special plasticizers from vegetable oil have been deployed in NBR based compounds for better compatibility in the rubber matrix. The current invention does not employ any mineral oils, synthetic oils, or chemical plasticizers such as mercaptan or sulphide type since the hose system is kept sustainable by using a physical softener or a combination of two physical softeners or plasticizers.

[0022] The filler (insulation) rubber is made with sustainable grades Elastomers of NBR / NR / SBR / Butyl / Halobutyl (obtained from bio sources) with sustainable origin fillers, vegetable oil plasticizers and antioxidants and designed for better adhesion which is perhaps the first time implemented in Sustainable Hose.

[0023] The curing system may be either peroxide based or sulphur curing system using nitrosamine free vulcanization system. The sulphur curing system may be a conventional, efficient, or semi-efficient curing system as decided by sulphur accelerator ratio.

[0024] Steel wires of sustainable origin and Polyester fibre also 100% sustainable used in fibre reinforced and Steel wire reinforced whichever applicable as per design and is perhaps the first time used for development of Sustainable green hose.

[0025] Also, much attention is paid to the anti-degradant, especially since eco-friendly amine -functionalized lignin (AL) has replaced N-(l,3-dimethylbutyl)-N’-phenylp- phenylenediamine [6PPD] as the environmentally favourable alternative. This incorporation of AL is first time in hoses. In synergy with the conventional antioxidants this renders better ageing properties to the sustainable hydraulic hose.

[0026] The NBR has been sourced sustainably where the butadiene in NBR is sourced by cracking biofuel and ACN is also derived sustainably from recycled materials. The mixture further comprises recovered carbon black and silica is sustainably derived from rice husk. The tube & cover compound is comprised of advanced bonding system which forms robust resinous material to achieve enhanced adhesion to the reinforcement & form better crosslinks in the matrix.

[0027] The Cover compound is essentially 50 - 80% sustainable of the total hose cover weight considering the raw materials sourced from sustainable origin. The inner tube compound is essentially 40 - 80% sustainable of the total hose tube weight considering the raw materials sourced from sustainable origin. The Hydraulic hose made from sustainable resources can be estimated 50 - 80% sustainable. The reinforcement material used in the sustainable hydraulic hose is derived from recycled material. The sustainable hydraulic hose can be up to 25 - 30% lighter than the regular hydraulic hose. The Sustainable hydraulic hose can be operated between - 25°C to +100°C but is not limited to and can be extended up to -40°C to +120° C and can withstand an Ozone atmosphere up to 50 pphm. The Tensile strength can vary from min. lOOKg / cm2to 200 KG / cm2, Modulus has min value of 50kg / cm2 and elongation min value of 150 % min. and ideally have a hardness range up to 90 Shore A. Typical sustainable hydraulic hose can have at least one braiding but is not limited to only one and can have multiple braids comprising of sustainable carbon steel wires. The Max working pressure will range from 22.5 MPa- 4MPa for -4 to -32 size in case of single braided wire reinforced hose. Similarly, double braided wire reinforced hose, the maximum pressure rating will range from 40MPa-8MPa for -4 size to -32 size. The max. pressure rating range is 2.8 - 2.1 MPa for fiber reinforced hose for -4 to -12 size.

[0028] A typical 1 metre of Hydraulic Hose compound material design and tentative calculation for sustainability % (ECO Series Hose) may vary from 50-80% but not only limited to this range as per designTable 1 - For Wire Reinforced HoseTable 2 - For Fibre Reinforced Hose

[0029] Furthermore, the formulation of the tube, cover and filler are given in the table below:TUBE FormulationCOVER FormulationFILLER Formulation

[0030] The advantages inter alia in the present invention are as under: - i. The new straightforward process has been adopted for improvement of sustainability of the hose matrix. ii. The concept can be readily implemented in the existing system without adding any extra equipment. iii. The intricacy of mixing procedure and mixing efficiency could be improved in the presence of special additive. iv. Ingredients to be used for the purpose would not affect or hamper the essential properties of the aforesaid blend. v. The present invention relates generally to a sustainable hydraulic hose which substantially minimizes the use of conventional fossil fuel derived raw materials. Mid or Low ACN content biobased Nitrile rubber along with biobased SBR for innertube and outer cover compound is used and the hose accounts for at least 50% and extendable up to 80 % sustainability.

[0031] It is understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention. Other aspects, advantages, and modification are within the scope of the present invention.

[0032] The aforementioned sustainable Wire Braided hoses meets EN853 / SAE100R1 AT and Fiber Braided Hoses meets SAE 100R6 standards and all properties adhere to stringent condition of the standards.

[0033] Also, these hoses are REACH Compliant & and reduces Carbon Footprint.

Claims

CLAIMS1) A sustainable hydraulic hose comprising: a. an inner tube, b. a plurality of reinforcement layers disposed outwardly from the inner tube, and c. a cover layer disposed outwardly from the reinforcement layer, d. wherein the inner tube and cover layer consists of Nitrile (NBR / SBR) based compounds having a sustainable fdler system, a bio sourced plasticizers and a sulfur or peroxide based curing system, wherein the reinforcement layer comprises a fibre reinforced, or Steel wire reinforced.2) The hose as claimed in claim 1, wherein the biobased nitrile rubber is used to prepare hose having less ACN content.3) The hose as claimed in claim 1, wherein the filler system comprises either sustainable recycled carbon black, Silica, Calcium carbonate, clay, nanomaterials or combination.4) The hose as claimed in claim 1 , wherein the bio sourced plasticizers for tube comprises of either Sunflower Oil, Soyabean Oil and epoxidized Soyabean oil, Castor Oil or combination.5) The hose as claimed in 1, wherein the sustainable inner tube compound content is 40-80% by weight of the total hose inner tube weight.6) The hose as claimed in claim 1, wherein the sustainable cover compound content is 50 - 80% by weight of the total hose cover weight.7) The hose as claimed in 1 , wherein operates in the temperature range between -25°C to +100°C and is not limited to and can be extended to -40°C to +120°C.8) The hose as claimed in 1, wherein operates between 4.0MPa to 40.0MPa for wire reinforced braid for sizes having internal diameter ranging from 6.4mm to 51mm.9) The hose as claimed in 1, wherein operates between 2. IMPa to 2.8MPa for textile reinforced braid for sizes having internal diameter ranging from 6.4mm to 19.0mm.10) A sustainable hydraulic hose composition comprising: an inner tube, wherein the tube consisting of Biobased Nitrile rubber (Mid / Low ACN Content) with about 70 - 100 PHR, Biograde SBR 1502 with 0 - 30 PHR, ZNO Activator with 2.5 - 6.0 PHR, Stearic Acid with 0.8- 3.0 PHR, Biobased Vegetable Oil with 2.0 - 12 PHR, AL Antioxidant with 0.5 -2.5 PHR, Conventional Antioxidant with 0.8 - 5.0 PHR, CI Resin with 2.5 - 8.5 PHR, Green Carbon Black with 10 - 60 PHR, Conventional Carbon Black with 70 - 120 PHR, Nanofiller with 2.2 - 10.2 PHR, Sulphur with 1.1-5.0 PHR, Nitrosamine free accelerator with 0.2 - 2.2 PHR, Retarder with 0.2 - 1.0; a plurality of reinforcement layer, wherein the reinforcement layer comprises a fibre or Steel wire reinforced; a cover layer wherein the cover consisting of Biobased Nitrile rubber (Mid / Low ACN Content) with about 50 - 100 PHR, Biograde SBR 1502 with 0 - 50 PHR, Clay based Filler with 40 - 70 PHR, Nano filler with 0.5- 1.5 PHR, Silica with 10 - 40 PHR, Green Carbon Black with 20 - 70 PHR, Conventional Carbon Black with 10 - 30 PHR, Stearic Acid with 0.5- 3.5 PHR, Glycol with 1.5 - 6.0 PHR, Resin with 1.5 - 5.5 PHR, AL Antioxidant with 1.0 - 6.0 PHR, Biobased Oil with 10 - 30 PHR, Bonding Agent with 2.5 - 5.5 PHR, Sulphur with 1.5 - 5.5 PHR, Nitrosamine free accelerator with 0.5 - 2.5 PHR, Retarder with 0.2 - 1.0; and a filler system wherein the filler consisting of Biograde SBR 1502 with 70- 100 PHR, Biobased Nitrile rubber (Mid / Low ACN Content) with 0 - 30 PHR, ZNO with 1.0- 10.0 PHR, ST ACID with 1.0 - 8.0 PHR, AL Antioxidant with 1.0- 5.0 PHR, Conventional Carbon Black with 25 - 50 PHR, Green Carbon Black with 70 - 100 PHR, Clay based Filler with 10 -20 PHR, Silica Green with 10 - 50 PHR, PEG4000 with 0 - 4 PHR, Biobased Oil with 5 - 20 PHR, Sulphur with 0.5 - 4.5 PHR, Nitrosamine free Accelerator with 0.5 - 2.5 PHE.11) The hose composition as claimed in claim 10, wherein the tube comprises bio sourced plasticizers having either Sunflower Oil, Soyabean Oil and epoxidized Soyabean oil, Castor Oil or combination.12) The hose composition as claimed in claim 10, wherein the sustainable material content is 50 - 80% by weight of the total hose weight.13) The hose composition as claimed in claim 10, wherein the inner tube and cover layer consists of Nitrile (NBR / SBR) based compounds having a sustainable filler system.14) The hose composition as claimed in claim 10, wherein the hose having a a sulfur or peroxide based curing system.15) The hose composition as claimed in Claim 10, wherein the tensile strength varies from lOOkg / cm2to 200kg / cm2, Modulus has minimum value of50kg / cm2 and elongation at break has minimum value of 150%, hardness has range upto 90 Shore A and withstand ozone atmosphere up to 50pphm.

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