Multi-Layer Hose Shaping via Internal Heating and Elastic Recovery
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Solution Overview
Problem
Existing methods for shaping multi-layer hoses with a vulcanized rubber or gum outer layer are complex, unreliable, and often damage the inner layers due to excessive pressure or temperature, and fail to accurately achieve desired bends and radii, especially when using external heating and mandrels.
Innovation Solution
A method involving internal heating of the hose to the lowest bending softening temperature, followed by insertion into a rigid mould with smaller radii and larger angles than desired, and subsequent tempering and cooling to allow the hose to naturally deform into the final shape, utilizing the synergistic effects of the outer and inner layers to achieve the desired radii and angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If external heating and mandrels are used for shaping hoses, then the hose can be shaped, but the inner layers are damaged due to excessive pressure or temperature
Solution Approach 1:
Instead of heating from the outside, the patent heats the hose from the inside using a heating medium that flows through the hollow interior. This reverses the heating direction, allowing controlled temperature increase without external pressure that could damage inner layers. The heating medium (hot water or steam) circulates through the hose cavity, transferring heat internally while the hose is constrained by a mandrel with shaping grooves.
Solution Approach 2:
The patent introduces a heating medium (hot water or steam) as an intermediary to transfer thermal energy to the hose. This mediator allows controlled heating through the hose wall from the interior, avoiding direct contact with high-temperature external sources that could damage the inner layers. The heating medium acts as a buffer, providing uniform and controllable heat transfer.
2Shape
If complex devices with multiple movable nodes and benders are used for hose shaping, then the desired spatial shape can be achieved, but the device complexity increases significantly
Solution Approach 1:
The patent divides the shaping function into two independent components: a mandrel that provides the shaping grooves (fixed structure) and a hose that is heated and forced into the grooves (flexible element). This segmentation eliminates the need for complex movable nodes and benders, as the shaping is achieved by the interaction between the heated hose and the pre-formed grooves in the mandrel, rather than by active mechanical manipulation.
Solution Approach 2:
The mandrel in the patent serves as a physical copy or template of the desired hose shape. The shaping grooves in the mandrel replicate the target spatial arrangement, and the heated hose is forced to conform to this template. This copying approach simplifies the device by replacing complex movable shaping mechanisms with a static template that defines the final shape.
3Stability of the object's composition
If excess pressure of heating medium is used inside the hose to retain circular cross-section, then the hose shape stability is improved, but the risk of damage to inner layers increases
Solution Approach 1:
The patent carefully controls the pressure parameter of the heating medium to be sufficient for shape retention but not excessive to cause damage. By optimizing the pressure level and using a mandrel with appropriately designed shaping grooves, the system achieves circular cross-section stability without subjecting the inner layers to harmful excessive pressure. The mandrel provides mechanical support that allows lower heating medium pressure compared to systems without a mandrel.
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 allows for precise, economic, and efficient shaping of multi-layer hoses with pre-vulcanized rubber or gum outer layers, eliminating the need for additional vulcanization and reducing the risk of damage to inner layers, while achieving high-quality, accurately formed products.
Implementation Method 1
the hose is then internally heated by the passage of a heating medium through the empty cavity of the hose
Implementation Method 2
the hose is inserted into a mould in which it is cooled, after which it is removed from the mould and the hose by its natural deformation changes its spatial arrangement
Implementation Method 3
subsequently the hose, still inserted in the rigid shaping mould, is cooled
Implementation Method 4
the hose by its natural deformation changes its spatial arrangement determined by the mould into the final desired spatial arrangement
Data Source
Figure 1~1a
Figure 1b~1c
Figure 2~2a
AI summary
The invention relates to a method of shaping a multi-layer hose (1) composed of an outer layer of rubber or gum, and an inner layer of a thermoformable material, and optionally composed of at least one intermediate layer between the outer layer and the inner layer, in which the hose (1) is heated from the inside, then inserted into a mould (F) in which it is cooled and after that it is removed from the mould, and the hose (1), by its natural deformation, changes its spatial arrangement determined by the mould (F) into the final desired spatial arrangement. A straight multi-layer hose (1) with a vulcanized rubber or gum outer layer is used as a starting semi-finished product, the hose (1) is internally heated to the lowest softening temperature selected from the softening temperatures for the bending of the inner layer and the optional intermediate layer, subsequently the hose (1) is disconnected from the heating and is inserted into a rigid mould (F), in which the hose (1) is brought into a spatial arrangement with radii (rF) of the individual bends of the hose (1) determined by the mould (F) and with the angles of the individual bends of the hose (1) determined by the mould (F), whereupon the hose (1) is tempered and cooled in the mould (F) and subsequently it is removed from the mould (F), whereby after removal from the mould, the hose (1), depending on the synergistic effect of the outer layer of pre-vulcanized rubber or gum and the inner layer and the optional intermediate layers, spontaneously changes its spatial arrangement and acquires an arrangement with final desired radii of the individual hose bends and the final desired angles of the hose (1) bends. In addition, the invention relates to a device for performing this method.