High-Pressure Hose Ply Layout for Flexibility and Burst Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high-pressure hoses face challenges in achieving high flexibility while maintaining high burst pressure and low bending stiffness, which are essential for large bore sizes and easy installation, often requiring compromises in design and manufacturing processes.
Innovation Solution
A high-pressure hose design featuring at least four helically laid reinforcing plies with adjacent plies directed in the same direction and the follow-up ply pair laid in the opposite sense, along with a rubberized textile ply between the unidirectional reinforcement pairs, and embedding polymer layers to reduce shear stress and bending stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional hose constructions use alternating left-to-right and right-to-left reinforcing plies optimized for highest burst pressure, then burst pressure is maximized, but flexibility deteriorates and bending stiffness increases
Solution Approach 1:
The reinforcing plies are segmented into pairs with identical lay direction, rather than using alternating directions. This segmentation allows each pair to work together synergistically while reducing overall bending stiffness, thereby improving flexibility without sacrificing burst pressure capability
Solution Approach 2:
The lay angles of the reinforcing plies are optimized within specific ranges (first ply pair: 15°-45°, second ply pair: 45°-75°) rather than using conventional alternating patterns. This parameter optimization enables the hose to achieve both high burst pressure and improved flexibility simultaneously
2Strength
If hose design prioritizes high burst pressure with multiple reinforcing plies, then pressure resistance is improved, but bending stiffness increases and installation becomes more difficult
Solution Approach 1:
The hose structure is designed to be dynamically responsive, with embedding polymer layers that can deform and adapt during bending. This dynamic behavior reduces bending stiffness and facilitates easier installation while maintaining high pressure resistance through the structured ply arrangement
3Ease of operation
If embedding polymer layers are used to reduce shear stress between plies, then flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
Embedding polymer layers are introduced as intermediary materials between the reinforcing plies. These polymer layers act as mediators that reduce shear stress between adjacent plies, enabling flexibility improvement without requiring complex manufacturing process changes
Solution Approach 2:
The embedding polymer layers provide homogeneous bonding between the reinforcing plies, creating a unified structure that simplifies the manufacturing process. The homogeneous material distribution ensures consistent shear stress reduction across all ply interfaces
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention concerns a high-pressure hose comprising a liquid and gas tight inner liner made from rubber, plastic or thermoplastic elastomer, at least four helically laid reinforcing plies embedded in polymer material, and an outer cover layer made from rubber, plastic or thermoplastic elastomer, wherein adjacent reinforcing cable plies are directed in the same direction and the follow-up ply pair is laid in opposite sense. Additionally, the pitch of filaments of adjacent unidirectional reinforcement plies is the same and the number of filaments is equal or different. The present invention further concerns methods for the production of such hoses and the use of such hoses.