Flexible Duct Reinforcement Using Screen Ply Angles
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Solution Overview
Problem
Existing flexible elastomer conduits face challenges in producing corrugated, flared, or bent sections with large diameters while maintaining mechanical performance and controlling swelling under pressure, as well as being cost-effective and dimensionally stable, especially when compared to fabric-based methods which are limited to straight parts.
Innovation Solution
A flexible conduit with a reinforcing element comprising at least one screened ply, where the screened web is laid edge-to-edge with an angle θ between 30° and 70°, preferably 54.7°, to minimize swelling and allow for various contours, and the conduit is coated with an elastomer and vulcanized to maintain shape and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fabric-based reinforcement is used, then mechanical performance and dimensional stability are improved, but the conduit is limited to straight parts and complex shapes cannot be produced
Solution Approach 1:
The invention changes the reinforcement structure from a fixed-angle fabric weave to a screen knit with variable mesh sizes and patterns. This allows the reinforcement to adapt to different shapes (straight, bent, corrugated, flared) while maintaining dimensional stability through the elastomer-coated screen knit structure that can accommodate various geometries without the constraints of fabric cutting angles.
2Adaptability or versatility
If tubular knit reinforcement is used, then good passage of bends and small diameters are achieved, but swelling under pressure occurs
Solution Approach 1:
The invention uses a composite structure combining an elastomer base material with an embedded screen knit reinforcement. The screen knit provides a more stable framework compared to traditional tubular knits, reducing swelling under pressure while the elastomer coating maintains flexibility for bends. This composite approach balances pressure stability with bend flexibility.
3Strength
If wire wrapping reinforcement is used, then good resistance to pressure and deformation is achieved, but the diameter is limited to very small sizes
Solution Approach 1:
The invention transitions from wire wrapping (suitable for small diameters) to screen knit reinforcement with adjustable mesh parameters. By varying the mesh size, yarn diameter, and screen knit configuration, the reinforcement can effectively support a much wider diameter range (from small to large diameters up to 50 cm) while maintaining pressure resistance through the elastomer-coated screen knit structure.
4Strength
If multiple radial layers are implemented, then mechanical performance and shape capability are improved, but production cost increases significantly
Solution Approach 1:
The invention applies reinforcement strategically through an embedded screen knit structure within the elastomer, providing necessary mechanical performance and shape capability (including bends, corrugations, and flares) without requiring multiple radial layers. This localized reinforcement approach reduces production cost by simplifying the manufacturing process while maintaining adequate mechanical performance for fluid conduit applications.
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 enables the production of flexible conduits with large diameters, optimal deformability under pressure, reduced material loss, lower costs compared to fabric-based methods, and improved mechanical performance, suitable for complex shapes and large diameters, while maintaining low material waste and abrasion resistance.
Implementation Method 1
the conduit is coated with an elastomer and vulcanized to maintain shape and performance
Data Source
Figure 1~3d
AI summary
The invention relates to a flexible elastomeric fluid transfer conduit having a reinforcing element characterized in that said reinforcing element comprises at least one woven layer (1). It also relates to a method for manufacturing a flexible elastomeric fluid transfer conduit, having a reinforcing element, characterized in that it involves laying at least one woven layer (1) on a forming cylinder (10) optionally coated with elastomeric material, then covering the woven layer(s) (1) with an elastomeric coating, and finally vulcanizing.