Braided Hose Barrier Layer Prevents Rubber Strike Through
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Solution Overview
Problem
The production of high-performance braided stainless steel wire hoses on flexible mandrels often results in rubber 'strike through,' where rubber protrudes through the braided wire cover due to the mandrel's expansion during curing, leading to an unacceptable appearance.
Innovation Solution
Incorporating a barrier layer, such as a polymeric film, between the rubber layer and the outer cover, optionally with an intermediate porous layer and a retaining layer, to prevent rubber from reaching the outer cover during curing, and using a composite barrier/retaining layer for enhanced adhesion and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a flexible mandrel is used for hose production, then productivity and continuous length of hose production are improved, but rubber strike through occurs due to excessive mandrel expansion during curing
Solution Approach 1:
A barrier layer is introduced as an intermediary component between the rubber layer and the outer cover. This barrier layer specifically prevents rubber from migrating through the braided wire cover during curing, while allowing the flexible mandrel to maintain its expansion characteristics for continuous production.
Solution Approach 2:
The hose structure employs composite materials including a polymeric barrier layer and optionally a porous intermediate layer with specific porosity (20-80%). This composite structure combines the flexibility needed for continuous production with the barrier properties needed to prevent rubber strike through.
2Manufacturing precision
If a rigid mandrel is used for hose production, then appearance quality is improved by preventing rubber strike through, but productivity decreases and floor space requirements increase
Solution Approach 1:
The barrier layer serves as a mediator that enables the use of flexible mandrels (which improve productivity) while achieving the appearance quality previously only obtainable with rigid mandrels. The barrier layer specifically blocks rubber migration without restricting mandrel flexibility.
Solution Approach 2:
The barrier layer is implemented as a thin polymeric film that can accommodate the flexible nature of the mandrel while providing the necessary barrier function. This thin film approach maintains productivity benefits of flexible mandrels while achieving appearance quality.
3Manufacturing precision
If the flexible mandrel expansion is reduced, then rubber strike through is prevented, but the ability to produce long continuous hose lengths is compromised
Solution Approach 1:
The barrier layer acts as a mediator that decouples the relationship between mandrel expansion and rubber migration. The flexible mandrel can expand freely to enable long continuous production, while the barrier layer prevents this expansion from causing rubber strike through.
Solution Approach 2:
The hose wall structure is segmented into distinct functional layers: rubber layer, barrier layer, and outer cover. This segmentation allows each layer to perform its specific function independently - the barrier layer handles rubber containment while the flexible mandrel handles continuous production.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces or prevents rubber from protruding through the braided wire cover, maintaining an aesthetically pleasing appearance and allowing for longer hose production without labor-intensive and costly rigid mandrel methods.
Implementation Method 1
a barrier layer provided between the rubber layer and the outer cover, wherein the barrier layer is configured to prevent rubber from the rubber layer from reaching the outer cover during curing of the hose
Implementation Method 2
at least one intermediate layer provided between the rubber layer and the barrier layer, where the intermediate layer is formed from a porous material
Data Source
AI summary
A hose including at least one rubber layer, an outer cover, and at least one barrier layer provided between the rubber layer and the outer cover, wherein the barrier layer is configured to prevent rubber from the rubber layer from reaching the outer cover during curing of the hose. In one embodiment, the rubber layer is the hose inner tube and the outer cover is braided wire. In another embodiment, the barrier layer includes at least one layer of polymeric film. In another embodiment, the hose can include at least one reinforcing layer provided between the rubber layer and the barrier layer. In another embodiment, the hose can include at least one intermediate layer provided between the rubber layer and the barrier layer, where the intermediate layer is formed from a porous material. In another embodiment, the hose can include at least one retaining layer provided between the barrier layer and the outer cover, where the retaining layer is formed from a polymeric material. Optionally, a composite barrier/retaining layer can replace the separate barrier and retaining layers.