Pressure Hose Reinforcement Layer With Multi-Layer Braided Beams
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Solution Overview
Problem
Existing pressure hoses with braided reinforcement layers face limitations in pressure tolerance, weight, flexibility, and consistency in hydrostatic and impulse performance due to inconsistent beam paths and geometry variations, leading to stress concentrations and performance inconsistencies.
Innovation Solution
A pressure hose design featuring a reinforcement layer with a 'superpack' construction, where beams are braided with a multi-layered end orientation to achieve a reinforcement volumetric ratio (RVR) greater than 110%, and a double layer configuration with net negative length change under pressure, utilizing identical end orientations across all beams to ensure consistent beam length and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the reinforcement layer uses traditional braided construction with bundled ends, then the manufacturing process is simpler, but the pressure tolerance and reinforcement efficiency are limited
Solution Approach 1:
The patent transitions from traditional single-layer braided reinforcement to a multi-layer reinforcement structure with ends arranged in multiple layers within beams. This dimensional reorganization allows for higher reinforcement volumetric ratio (RVR > 110%) by efficiently packing ends in a multi-layer configuration, thereby increasing pressure tolerance without proportionally increasing overall hose diameter or weight.
Solution Approach 2:
The reinforcement layer employs a composite construction combining multiple materials (e.g., steel wires, stainless steel wires, or other suitable materials) arranged in a multi-layer braid structure. This composite approach optimizes both strength and flexibility while achieving RVR greater than 110%, resolving the contradiction between pressure tolerance and structural complexity.
2Reliability
If beams follow inconsistent paths in traditional braiding, then the manufacturing process is more flexible, but geometry variation creates stress concentrations and performance inconsistency
Solution Approach 1:
The patent specifies precise geometric parameters for beam paths, including consistent braid angles and standardized end orientations across all beams. By controlling these parameters, the design eliminates geometry variations that cause stress concentrations, ensuring consistent hydrostatic and impulse performance while maintaining manufacturability through defined construction standards.
Solution Approach 2:
The reinforcement layer employs consistent multi-layer end orientation within each beam and uniform beam construction throughout the braid. This local standardization of quality ensures that all beams have identical geometry and follow consistent paths, eliminating performance inconsistencies while allowing flexibility in the overall braiding process through standardized modules.
3Strength
If higher pressure hoses are produced with traditional reinforcement, then pressure tolerance increases, but weight and flexibility are sacrificed
Solution Approach 1:
The multi-layer reinforcement structure with RVR > 110% achieves higher pressure tolerance by optimizing the spatial arrangement of reinforcement ends rather than simply increasing the amount of material. This dimensional optimization allows the hose to withstand higher pressures while maintaining lower weight compared to traditional single-layer constructions that would require more material for equivalent strength.
Solution Approach 2:
The use of composite material construction in the reinforcement layer, combining different wire materials and multi-layer arrangements, achieves superior strength-to-weight ratio. This allows the hose to tolerate higher pressures without the weight penalty associated with traditional single-material, single-layer reinforcement designs.
4Ease of operation
If traditional braided reinforcement is used, then material costs are lower, but flexibility and improved hose efficiency are compromised
Solution Approach 1:
The multi-layer reinforcement structure with optimized end orientation and RVR > 110% improves hose flexibility by distributing stresses more evenly across multiple layers. This dimensional reorganization allows the hose to bend and flex more easily compared to traditional single-layer constructions, enhancing ease of operation while maintaining a defined complex structure.
Data Source
AI summary
Described herein are embodiments of a pressure hose having an improved reinforcement layer. In some embodiments, the reinforcement layer of the pressure hose has a reinforcement volumetric ratio (RVR) of greater than or equal to 110%. The reinforcement layer can include a plurality of braided beams, with each beam comprising a plurality of ends. In some embodiments, the plurality of ends within a beam are arranged in a multi-layer orientation. In some embodiments, the number of ends and the end orientation within each beam is identical amongst all beams in the reinforcement layer. The shape, size, and arrangement of the ends within a beam can all be adjusted to increase the surface area to volume ratio and, correspondingly, the RVR of the reinforcement layer.