Braided Pressure Hose Structure 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 inconsistent performance due to geometry variations in the braid, leading to stress concentrations and inconsistent hydrostatic and impulse performance.
Innovation Solution
A pressure hose design featuring a 'superpack' braided reinforcement layer with a high reinforcement volumetric ratio (RVR) of greater than or equal to 126%, achieved by optimizing the orientation and arrangement of ends within beams, which are braided in a layered configuration to provide uniform length and varying diameters and tensile strengths, resulting in improved mechanical compliance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the reinforcement layer uses a traditional braided structure with bundled ends, then the manufacturing process is relatively simple, but the pressure tolerance is limited and weight is high
Solution Approach 1:
The patent changes the fundamental parameter of reinforcement layer architecture from traditional braided structure to flat layered structure with optimized end arrangements. This structural parameter change enables higher pressure tolerance (achieving RVR ≥ 126%) while reducing weight by eliminating redundant material and optimizing the distribution of ends across multiple layers.
Solution Approach 2:
The patent employs a composite structure consisting of multiple flat layers with different end arrangements (first arrangement in inner layers, second arrangement in outer layers). This composite layered design allows optimization of both pressure resistance and weight by distributing reinforcement functions across different layers with specialized configurations.
2Reliability
If the reinforcement layer uses a traditional braided structure, then the manufacturing process is straightforward, but the geometry variation creates stress concentrations and inconsistent performance
Solution Approach 1:
The patent achieves geometric homogeneity by arranging ends in systematic patterns within each layer (first arrangement and second arrangement). This homogeneous distribution eliminates geometry variations and stress concentrations, ensuring consistent hydrostatic and impulse performance across the entire reinforcement layer.
Solution Approach 2:
The patent segments the reinforcement layer into multiple flat layers with different end arrangements. Inner layers use one arrangement while outer layers use another, allowing each segment to be optimized for its specific position. This segmentation approach maintains reliability through consistent performance while managing structural complexity through modular layer design.
3Strength
If higher pressure hoses are produced by increasing reinforcement, then pressure tolerance improves, but weight and flexibility are sacrificed
Solution Approach 1:
The patent changes the architectural parameter from traditional braiding to flat layered structure, which achieves high pressure tolerance (RVR ≥ 126%) through optimized end arrangements rather than increased material quantity. This parameter change maintains flexibility by using a streamlined structure with fewer layers compared to traditional multi-layer braided designs.
Solution Approach 2:
The patent applies different end arrangements locally to different layers: inner layers use a first arrangement while outer layers use a second arrangement. This local quality optimization ensures that each layer contributes maximally to pressure tolerance while maintaining overall flexibility. The varying RVR distribution across layers (higher in outer layers, lower in inner layers) optimizes both strength and flexibility.
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.