Flexible Plastic Hose Helical Winding and Cold Profile Cooling

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Solution Overview

Problem

Existing methods for producing flexible plastic hoses have low axial production rates due to the need for hot winding, which limits efficiency and results in hoses with larger internal diameters and higher weights, and difficulties in incorporating electrical conductors.

Innovation Solution

A flexible plastic hose is manufactured by helically winding a cooled extruded profile with upright parts and a web part, where the weld is located between the upright parts to form a helical reinforcement rib, allowing for higher production rates, smaller diameters, and easier incorporation of conductors, and the profile can be cooled before winding to prevent additional cooling requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If profiles are wound hot as in prior art, then welding is achieved, but axial production rate is limited to 1-1.5 m/min

Engineering Contradiction:

Improveaxial production rateVSAvoidprofile temperature during winding

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The profile is cooled before winding, preparing it in advance for cold-forming operations. This preliminary cooling action enables higher production rates by eliminating the need for hot winding and subsequent cooling during the winding process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the temperature parameter from hot (prior art) to cold (current invention). By winding the profile at ambient temperature rather than elevated temperature, the production rate increases from 1-1.5 m/min to 5 m/min or higher.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If hot winding is used, then profiles can be welded, but additional cooling is required during or after winding

Engineering Contradiction:

Improvewelding capabilityVSAvoidcooling system requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Cooling is performed in advance before winding, so that when the winding occurs, no additional cooling is needed. This eliminates the complexity of managing cooling systems during or after the winding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling function is extracted from the winding process itself and performed separately beforehand. This separation eliminates the need for integrated cooling systems during winding, simplifying the manufacturing process.

Inventive Principle:

Principle #2Taking out (Extraction)

3Shape

If hot winding is used, then profiles can be formed, but the hose internal diameter is larger and weight is higher

Engineering Contradiction:

Improvehose internal diameterVSAvoidhose weight

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

Changing from hot winding to cold winding alters the physical state of the profile material, enabling tighter tolerances and smaller final dimensions. The cold-formed hose achieves smaller internal diameters and reduced weight compared to hot-wound alternatives.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If hot winding is used, then profiles can be welded, but incorporation of electrical conductors is difficult

Engineering Contradiction:

Improveconductor incorporationVSAvoidprofile temperature during conductor placement

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

Changing the temperature parameter from hot to cold during winding creates a more favorable condition for incorporating electrical conductors. The cooler, more stable profile material allows for easier and more precise conductor placement without the difficulties associated with hot material handling.

Inventive Principle:

Principle #35Parameter changes

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 enables higher production rates, reduced hose weight, smoother interiors, and improved conductor integration, allowing for hoses with smaller diameters and enhanced structural integrity and flexibility.

Implementation Method 1

The weld is located between the upright parts of adjacent windings and together with these upright parts forms a helical reinforcement rib on the flexible wall of the hose

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

the extruded profile can be cooled before the helical winding and hence, no extra cooling is required during or after the helical winding of the profile

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS9230712B2Flexible plastic hose and method for its manufacture

Publication Date: 2016.01.05 PLASTIFLEX GRP NV

AI summary

Flexible plastic hose comprising a flexible wall made out of a plurality of laterally connected windings of a helically wound profile, wherein the windings of the profile are attached to each other by means of a weld, wherein the profile comprises a web part with predetermined properties for providing flexibility to the hose, and wherein the profile ends on both sides in an upright part. The weld is located between the upright part of the adjacent windings and together with these upright parts forms a helical reinforcement rib on the flexible wall of the hose with predetermined properties for providing hub strength to the hose.