Fiber-Reinforced Hose Composite for Void-Free Pressure Extrusion
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Solution Overview
Problem
Current hose assembly manufacturing processes are slow, capital-intensive, and prone to quality issues such as inhomogeneous mixtures and burst strength inconsistencies, particularly when dealing with thermoset rubber compounds and extreme environmental conditions.
Innovation Solution
Fiber-reinforced composites with low viscosity and molecular weight resin-binders, such as metallocene polyethylene or polypropylene, are used to treat reinforcement fibers, filling voids and improving compatibility between fibers and polymeric matrices, allowing for continuous extrusion and cross-linking without a mandrel, thereby enhancing mechanical properties and reducing processing artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermoset hose assembly manufacturing processes are used, then the hoses can withstand extreme pressures and temperatures, but the manufacturing process is slow, capital-intensive, and produces inhomogeneous mixtures with burst strength inconsistencies
Solution Approach 1:
The patent changes the fundamental parameters of the manufacturing process by switching from batch-mode thermoset processing to continuous thermoplastic extrusion. This involves changing material parameters (using thermoplastic polymers instead of thermoset rubber), processing temperature parameters (lower extrusion temperatures), and production mode parameters (continuous extrusion instead of batch processing). These parameter changes enable faster manufacturing while improving homogeneity and burst strength consistency.
Solution Approach 2:
The patent replaces the complex mechanical system of multi-step thermoset processing (cross-head extrusion, wire braiding, steam autoclave cross-linking, blowout operation) with a simplified continuous extrusion system. The continuous extrusion process integrates multiple operations into a single streamlined process, eliminating the need for separate braiding and cross-linking steps, thereby increasing productivity while maintaining reliability.
2Reliability
If thermoset rubber compounds are used in hose assembly, then the hoses can withstand extreme environmental conditions, but the chemical bonding of brass coated wire to rubber is interfered with by moisture and results in pin-hole failures
Solution Approach 1:
The patent changes the material parameter from thermoset rubber to thermoplastic polymer, which fundamentally alters the bonding mechanism. Thermoplastics do not suffer from moisture interference during bonding, eliminating pin-hole failures. The material parameter change also simplifies the manufacturing process by eliminating the need for complex cross-linking operations and moisture control measures.
Solution Approach 2:
The patent uses a tie layer or adhesion promoter as an intermediary between the reinforcement fibers and the thermoplastic matrix. This intermediary layer ensures proper bonding and compatibility between materials, preventing pin-hole failures while maintaining the simplicity of the continuous extrusion process.
3Strength
If reinforcement fibers are used in hose assemblies, then the tensile strength is improved, but the interstices, voids, and air bubbles form at interfaces between fiber and polymeric matrix
Solution Approach 1:
The patent changes the viscosity parameter of the polymeric matrix by selecting thermoplastic polymers with appropriate melt flow characteristics. The lower viscosity of thermoplastic melts compared to thermoset compounds allows better penetration into fiber interstices and more complete void elimination during continuous extrusion, resulting in improved interface homogeneity while maintaining high tensile strength.
Solution Approach 2:
The continuous extrusion process maintains constant pressure and flow throughout the molding operation, ensuring continuous and uniform impregnation of reinforcement fibers. This continuous action prevents the formation of voids and air bubbles at fiber-matrix interfaces, improving manufacturing precision while preserving the tensile strength benefits of fiber reinforcement.
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 results in hoses with improved tensile strength and flexural modulus, reduced failure modes, and a more efficient, cost-effective manufacturing process capable of withstanding extreme pressures and temperatures.
Implementation Method 1
the one or more resin-binders, having sufficiently low molecular weight and viscosity, can fill or otherwise reduce interstices, voids, air bubbles, or flaws within the reinforcement fiber
Implementation Method 2
thereby reducing interfacial surface tension and providing greater compatibility between the materials
Data Source
AI summary
A flexible fiber reinforced hose adapted for conveying fluids under pressure. The reinforced hose has a core tube having at least one reinforcement layer surrounding an outer core tube surface. Each reinforcement layer has one or more woven mats, unwoven mats, or bundle of fibers comprising a plurality of reinforcement fibers that have a binder-resin filling at least a portion of the voids of the reinforcement fibers. In some aspects, the binder-resin adheres to the reinforcement fibers and displaces the air voids at the interface between the reinforcement fibers and the binder-resin. The binder-resin has a relatively low viscosity less than at least about 20,000 centipoise at 176° C. and low molecular weight, which allows the reinforcement layer to maintain a low flex modulus while maintaining or increasing tensile modulus. The reinforced hose also has at least one polymer layer that bonds to the binder-resin of the reinforcement layer, preferably being cross-linkable or cross-linked to the polymer layer.