Braided Pressure Hose Reinforcement for High Pressure and Flexibility
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Solution Overview
Problem
Existing pressure hoses with braided reinforcement layers face limitations in pressure tolerance, weight, flexibility, and consistency in hydrostatic and impulse performance due to inconsistent beam paths, leading to stress concentrations and geometry variations.
Innovation Solution
A pressure hose design featuring a single reinforcement layer with a reinforcement volumetric ratio (RVR) greater than or equal to 126%, utilizing a 'superpack' braiding configuration where ends within beams have varying lengths and orientations to optimize surface area to volume ratio, resulting in improved reinforcement efficiency and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple reinforcement layers are used to increase pressure tolerance, then pressure capability is improved, but weight and complexity increase
Solution Approach 1:
The patent changes the volumetric ratio parameter of the reinforcement layer from conventional values (typically 40-60%) to an optimized range of 80-100%, and in some embodiments up to 120% or higher. This parameter change allows a single reinforcement layer to provide the pressure tolerance that previously required multiple layers, thereby reducing weight while maintaining strength
Solution Approach 2:
The patent merges the functions of multiple reinforcement layers into a single highly efficient reinforcement layer by optimizing the volumetric ratio and braiding configuration. This consolidation achieves the cumulative pressure tolerance effect of multiple layers while eliminating the additional weight and complexity that would result from stacking multiple layers
2Strength
If more reinforcement material is added to increase pressure tolerance, then strength is improved, but flexibility and weight are worsened
Solution Approach 1:
The patent optimizes the volumetric ratio parameter to a specific range (80-100% or higher) that achieves maximum reinforcement efficiency. This optimized parameter allows the hose to attain high pressure tolerance with a single layer that does not excessively compromise flexibility, unlike traditional approaches that would require multiple heavier layers
Solution Approach 2:
The patent employs a composite structure consisting of an inner tube layer, a single optimized reinforcement layer with specific volumetric ratio, and an outer cover layer. This composite arrangement with the optimized middle layer provides high strength-to-flexibility ratio, achieving pressure tolerance without sacrificing hose flexibility
3Ease of manufacture
If conventional braiding configuration is used, then manufacturing is simple, but performance consistency is poor due to stress concentrations
Solution Approach 1:
The patent changes the volumetric ratio parameter to an optimized range (80-100% or higher) that inherently reduces stress concentrations within the reinforcement layer. This parameter optimization improves performance consistency and eliminates the need for complex multi-layer configurations, maintaining manufacturing simplicity while achieving better quality consistency
Solution Approach 2:
The patent optimizes the local distribution and orientation of reinforcement elements within the single layer to eliminate stress concentrations. By carefully controlling the volumetric ratio and braiding configuration, the patent achieves uniform stress distribution throughout the reinforcement layer, improving performance consistency without complicating the manufacturing process
Data Source
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Figure 3A~3B
AI summary
Described herein are embodiments of a pressure hose having an improved reinforcement layer. In some embodiments, the reinforcement layer of the pressure hose has a reinforcement volumetric ratio (RVR) of greater than or equal to 110%. The reinforcement layer can include a plurality of braided beams, with each beam comprising a plurality of ends. In some embodiments, the plurality of ends within a beam are arranged in a multi-layer orientation. In some embodiments, the number of ends and the end orientation within each beam is identical amongst all beams in the reinforcement layer. The shape, size, and arrangement of the ends within a beam can all be adjusted to increase the surface area to volume ratio and, correspondingly, the RVR of the reinforcement layer.