Non-Penetrating Multi-Layer Hose with Simultaneous Extrusion Coating
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Solution Overview
Problem
Conventional multi-layer non-penetrating hoses have complex manufacturing processes, use the same materials for inner and outer coatings, and are limited in length and turning angle, hindering their practical application, especially in lining repair pipes.
Innovation Solution
A non-penetrating multi-layer continuous hose is developed with different materials for the inner and outer coatings and an adjustable length, achieved through simultaneous extrusion coating inside and outside a reinforcement layer, using thermoplastic polyurethane or other polymers for the inner coating and flexible polyethylene or polyamides for the outer coating, with a tubular reinforcement layer of polyester or aramid fibers, and a method involving a circular loom, traction system, and cooling spray device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used for multi-layer hoses, then the production method is well-established, but the manufacturing process becomes complicated and limits production efficiency
Solution Approach 1:
The patent combines the extrusion of inner coating, outer coating, and reinforcement layer into a single integrated extrusion device. The inner coating extrusion unit, outer coating extrusion unit, and reinforcement layer forming unit are merged into one device that operates simultaneously, eliminating the need for separate manufacturing steps and reducing process complexity while maintaining high production efficiency
Solution Approach 2:
The integrated extrusion device is segmented into distinct functional units: an inner coating extrusion unit, an outer coating extrusion unit, and a reinforcement layer forming unit. Each unit operates independently but coordinates simultaneously to produce the multi-layer hose structure, allowing for simplified process control while maintaining productivity
2Adaptability or versatility
If the same material is used for both inner and outer coatings, then material selection is simplified, but the hose lacks adaptability for different application requirements
Solution Approach 1:
The patent applies different materials to different layers of the hose based on specific functional requirements. The inner coating can use materials like polyethylene or polypropylene for corrosion resistance, while the outer coating can use different materials for UV resistance, mechanical strength, or flexibility. This local differentiation of material properties enables the hose to meet diverse application requirements without overwhelming complexity in material selection
3Length of moving object
If the hose length is limited, then manufacturing and handling are easier, but the hose cannot meet long-distance piping requirements
Solution Approach 1:
The integrated extrusion device enables continuous production of the multi-layer hose structure. The inner coating, outer coating, and reinforcement layer are formed simultaneously in a continuous process, allowing the production of hoses in long lengths without interruption. This continuous manufacturing capability meets long-distance piping requirements while the automation of the process prevents excessive complexity
4Ease of operation
If a highly exact turning angle is required when used as lining repair pipe, then the hose can fit precise pipe configurations, but the ease of operation is significantly reduced
Solution Approach 1:
The multi-layer construction with flexible polymer coatings and woven reinforcement creates a hose that is sufficiently flexible to navigate pipe configurations without requiring highly exact turning angles. The flexible outer coating and inner coating allow the hose to bend and conform to existing pipe layouts, improving ease of installation while the woven reinforcement layer provides enough structural integrity to maintain adequate geometric precision
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 good adhesion between layers, high strength, and adjustable length, reducing the need for precise turning angles, enhancing its applicability in various industries such as water supply and petrochemical uses.
Implementation Method 1
passing the reinforcement layer through an extrusion mold along the length direction to coat the inner layer and the outer layer
Implementation Method 2
after the hose is formed, shaping the hose by a cooling spray device
Data Source
AI summary
A non-penetrating multi-layer continuous hose and a preparation method thereof are provided. The hose includes an outer coating, a reinforcement layer, and an inner coating. The inner coating and the outer coating can have one or more layers with different materials and have an adjustable thickness. The hose is prepared by simultaneously performing extrusion coating inside and outside the reinforcement layer rather than penetrating the fiber reinforcement layer. The hose exhibits improved layer-to-layer adhesion and has high strength, and continuous production can be achieved to meet the length requirement in various kinds of construction, which has high applicability.