Hybrid High Pressure Hose with Thermoplastic Sheath

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Solution Overview

Problem

Existing high pressure hoses either lack flexibility and kink resistance like thermoplastic hoses or suffer from abrasion and temperature limitations like rubber hoses, with hybrid solutions failing to combine desirable features effectively while maintaining reasonable costs.

Innovation Solution

A high pressure hose design featuring a rubber inner tube with braided or spiraled reinforcing layers covered by a flexible thermoplastic polyurethane sheath, where the hose is cured in a steam autoclave and the temporary thermoplastic cover is removed before applying the final thermoplastic sheath, ensuring bonding between the reinforcing layers and inner tube.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If rubber hoses are used for high pressure applications, then flexibility and kink resistance are improved, but abrasion resistance and temperature capability deteriorate

Engineering Contradiction:

Improveflexibility and kink resistanceVSAvoidabrasion resistance and temperature capability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The hose combines a rubber inner tube (providing flexibility and kink resistance) with a thermoplastic outer cover (providing abrasion and ozone resistance). This composite structure allows each material to contribute its superior properties, resolving the contradiction between flexibility and durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different parts of the hose are made from different materials optimized for their specific functions: the inner tube uses rubber for flexibility and pressure containment, while the outer cover uses thermoplastic for environmental resistance. This local differentiation of material properties resolves the contradiction by assigning each material to where it performs best.

Inventive Principle:

Principle #3Local quality

2Reliability

If thermoplastic hoses are used for high pressure applications, then abrasion and ozone resistance are improved, but flexibility and kink resistance deteriorate

Engineering Contradiction:

Improveabrasion and ozone resistanceVSAvoidflexibility and kink resistance

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

3Reliability

If hybrid hose designs are implemented, then desirable features of both rubber and thermoplastic hoses are combined, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecombined performance featuresVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inner tube is pre-cured in an autoclave before the outer cover is applied. This preliminary curing action simplifies the overall manufacturing process by allowing the inner tube to be independently prepared and quality-tested before assembly, reducing the complexity of simultaneous multi-material processing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A primer layer is applied between the rubber inner tube and thermoplastic outer cover to ensure proper adhesion. This intermediary layer resolves the bonding challenge between incompatible materials without requiring complex direct bonding processes, simplifying the manufacturing procedure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 hose achieves flexibility and kink resistance similar to rubber hoses, while offering superior abrasion, ozone, and UV resistance like thermoplastic hoses, with improved temperature capabilities and reduced marking, meeting or exceeding SAE standards for high impulse applications.

Implementation Method 1

Elastomeric materials require a process of curing or vulcanization. Various methods of curing have evolved over the years and for the purposes of this invention, conventional methods known to those familiar with the art apply. One common method is curing in a steam autoclave.

Methodology Applied

Scientific EffectVulcanization:

Data Source

PatentUS8714203B2Hybrid high pressure hose

Publication Date: 2014.05.06 SCHIEFFER INT L C

AI summary

A high pressure hose and method of manufacturing the hose is disclosed. The hose is comprised of an elastomer, thermoset rubber inner tube, reinforced with one or more layers of braided or spiralized high tensile strength wire or high tenacity textile yarn and covered with a highly flexible thermoplastic sheath.