Hose Assembly Kink Resistance via Melted Binding Fibers
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Solution Overview
Problem
Existing hose assemblies for conveying corrosive fluids face issues with kinking, flexibility, and durability due to low tensile strength and inconsistent bonding between polymeric tubes and reinforcing layers, which are costly and complex to produce.
Innovation Solution
A method involving the extrusion of a polymeric tube with a commingled braid of reinforcing fibers and binding fibers, where the binding fibers have a peak melting temperature between 200 to 400 °C, are heated to partially melt and solidify, forming a binder that adheres the reinforcing fibers to the tube, enhancing strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing layers are added to increase tensile strength and kink resistance, then strength and durability are improved, but the hose assembly becomes less flexible and more complex to manufacture
Solution Approach 1:
The patent changes the physical state of the binding emulsion composition from liquid to solid through controlled cooling, transforming it into a binder that sets upon cooling. This parameter change allows the reinforcing layers to be bonded together firmly once set, while the hose maintains flexibility during operation because the binding process occurs only during manufacturing, not during use.
Solution Approach 2:
The patent utilizes phase transition of the binding emulsion composition from liquid state during application to solid state after cooling. The binding emulsion composition is applied in liquid form to allow easy coating and penetration, then cooled to freeze and set the binder, creating strong bonds between reinforcing layers. This phase transition enables both strong bonding and operational flexibility.
2Reliability
If multiple reinforcing layers are added to improve durability and kink resistance, then reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the functions of multiple reinforcing layers into a single integrated structure by using a binding emulsion composition that penetrates and bonds all layers together. Instead of treating each layer separately with individual binding agents, the composition is applied to bond multiple layers simultaneously, reducing manufacturing steps and complexity while maintaining the durability benefits of multiple reinforcing layers.
Solution Approach 2:
The binding emulsion composition performs multiple functions automatically: it penetrates the reinforcing layers, bonds them together, and sets upon cooling without requiring additional binding agents for each layer. The composition self-adapts to bond the layers together through its penetration and freezing mechanism, eliminating the need for complex multi-step binding processes.
3Strength
If binding emulsion composition is used to bond reinforcing layers, then adhesion between layers is improved, but consistent wetting is difficult to achieve and delamination can occur
Solution Approach 1:
The patent utilizes the porous or absorbent nature of the binding emulsion composition that allows it to penetrate into the reinforcing layers. The composition is formulated to wick and penetrate the layer structures, ensuring consistent distribution and bonding throughout. This penetration mechanism ensures reliable adhesion and prevents delamination by creating bonds within the layer structure rather than just on the surface.
4Reliability
If reinforcing layers are added to prevent kinking, then kink resistance is improved, but the hose assembly exhibits reduced flexibility after thermal conditioning
Solution Approach 1:
The patent changes the temperature parameter during the binding process, using controlled cooling to freeze the binding emulsion composition. This temperature parameter change creates strong bonds between reinforcing layers that maintain kink resistance. However, the bonding occurs only during manufacturing, allowing the hose to maintain flexibility during operational thermal conditioning because the binding structure is already established and does not require continuous high-temperature maintenance.
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 method results in a hose assembly that is resistant to kinking, flexible, and durable, maintaining structural integrity and adhesion at higher temperatures, with improved cohesive strength between the reinforcing layer and the tube.
Implementation Method 1
heating the reinforced tube to a temperature (T1) equal to or greater than a peak melting temperature of the binding fibers to at least partially melt the binding fibers
Implementation Method 2
cooling the reinforced tube to solidify the melted binding fibers
Implementation Method 3
pressurizing an interior cavity of the tube with a fluid during the step of heating. The step of pressurizing the tube maintains the dimensional integrity of the tube during the step of heating and also facilitates adhesion of the reinforcing layer to the tube because the pressure forces the fixed braid against the out peripheral surface of the tube
Data Source
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AI summary
A method of forming a hose assembly is disclosed. The hose assembly comprises a tube formed from a polymeric material and defining an outer peripheral surface, and a reinforcing layer disposed about the outer peripheral surface of the tube. The reinforcing layer comprises reinforcing fibers and a binder formed from binding fibers. The method includes the steps of extruding the tube, forming a commingled braid from the reinforcing fibers and the binding fibers, and disposing the commingled braid about the outer peripheral surface of the tube to form a reinforced tube. The method also includes the steps of heating the reinforced tube to a temperature (T1) equal to or greater than a peak melting temperature of the binding fibers to at least partially melt the binding fibers, and cooling the reinforced tube to solidify the melted binding fibers and form the hose assembly.