Conductive Corrugated Hose Wire Embedding Against Delamination
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Solution Overview
Problem
Flexible hoses used for conveying solid particles often experience electrostatic charge buildup due to friction, leading to clogging and safety concerns, especially when handling flammable or explosive materials, and existing conductive wire designs in corrugated hoses suffer from delamination issues, reducing durability.
Innovation Solution
A method for producing elastic hoses with an electrically conductive wire involves placing the wire into molten thermoplastic material on a mandrel, applying a force normal to the surface, and using a controlled tensile force to achieve a spiral or helical arrangement, ensuring the wire is fully enclosed and securely embedded, thereby preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrically conductive wire is used that essentially follows the spirally-arranged protruding material of the corrugated hose, then the antistatic performance is improved, but the durability deteriorates due to delamination between the thermoplastic material and the metallic wire
Solution Approach 1:
The patent replaces the metallic conductive wire with a conductive thermoplastic material that is chemically and mechanically compatible with the surrounding thermoplastic matrix. This composite approach eliminates the delamination issue by using homogeneous material composition while maintaining electrical conductivity through conductive fillers or additives dispersed in the thermoplastic material.
Solution Approach 2:
The patent changes the physical and chemical parameters of the thermoplastic material by incorporating conductive additives or modifying the polymer composition to achieve electrical conductivity. This parameter change allows the material to serve dual functions: structural integrity and electrostatic dissipation, without the delamination problems associated with metallic wires.
2Object-generated harmful factors
If a metallic electrically conductive wire is inserted into the thermoplastic sheath, then the electrostatic charges can be discharged, but mechanical deterioration occurs due to delamination and bubble formation
Solution Approach 1:
The patent creates a homogeneous thermoplastic structure where the conductive properties are distributed uniformly throughout the material matrix. This eliminates the interface between dissimilar materials (metal wire and thermoplastic) that causes delamination and bubble formation, thereby maintaining mechanical strength while achieving electrostatic charge dissipation.
Solution Approach 2:
The patent uses conductive thermoplastic material as an intermediary between the internal corrugated structure and the external environment. This intermediary material provides a continuous conductive path for electrostatic discharge while being mechanically compatible with the surrounding structure, avoiding the harmful effects of metallic wire insertion.
3Adaptability or versatility
If the electrically conductive wire follows the corrugation protrusions, then the flexibility is maintained, but the delamination effect increases leading to frequent replacement
Solution Approach 1:
The patent employs a composite thermoplastic material system where conductive additives are embedded within the thermoplastic matrix. This composite structure maintains the flexibility and adaptability of the corrugated hose while eliminating the delamination issue that occurs with metallic wires following the corrugation protrusions.
Solution Approach 2:
The patent segments the conductive function from the structural function by distributing conductive particles or fibers throughout the thermoplastic material. This segmentation allows the material to simultaneously provide structural integrity and electrical conductivity without requiring a separate metallic wire component that would cause delamination.
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
This method enhances the durability and antistatic performance of the hoses, reducing the risk of electrostatic charge buildup and mechanical deterioration, resulting in a longer-lasting and safer conveying solution.
Implementation Method 1
providing a thermoplastic material in a molten state
Implementation Method 2
This electrically conductive material can be a mesh of electrically conductive wires (typically using a conductive metal like copper) that is introduced into the material of the sheath of the elastic hose
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The invention relates to amethod for producing an elastic hose (2). The method comprises the following steps: - providing a thermoplastic material (9) in a molten state, - providing the melted thermoplastic material (9) onto a mandrel (5), - placing an electrically conductive wire (4) onto the melted thermoplastic material (9), - inserting the electrically conductive wire (4) into the melted thermoplastic material (9) by applying a force that causes a component of force in at least a section of the electrically conductive wire (4) that points in a direction normal to the surface of the thermoplastic material (9).