Braided Pressure Hose Reinforcement for Higher Pressure and Flexibility
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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, using identical end orientations across all beams to ensure consistent length and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the reinforcement layer uses a conventional braided construction with bundled ends, then the manufacturing process is simple, but the pressure tolerance is limited and geometry variations cause stress concentrations
Solution Approach 1:
The patent transitions from a conventional single-layer braid to a multi-layer braid construction with ends arranged in multiple layers within each beam. This dimensional organization increases the reinforcement volumetric ratio (RVR) to greater than 110%, allowing higher pressure tolerance while maintaining consistent beam geometry and eliminating stress concentrations caused by variable end lengths.
2Strength
If more reinforcement material is added to increase pressure tolerance, then the strength improves, but the weight of the hose increases
Solution Approach 1:
The patent employs a composite reinforcement structure combining multiple layers of braided beams with multi-layered end orientations. This composite construction achieves an RVR greater than 110% with optimized material distribution, providing high pressure tolerance while minimizing unnecessary material usage and maintaining hose weight efficiency.
3Reliability
If the reinforcement layer uses inconsistent beam paths, then the manufacturing process is easier, but the hydrostatic and impulse performance becomes inconsistent
Solution Approach 1:
The patent standardizes critical geometric parameters of the reinforcement layer, including beam path consistency, end length uniformity through multi-layer orientation, and braid angle control. By maintaining consistent RVR greater than 110% and uniform end orientations across all beams, the design achieves reliable and consistent hydrostatic and impulse performance while remaining manufacturable through controlled braiding processes.
4Ease of operation
If a single layer reinforcement layer with high RVR is used, then the hose flexibility improves, but the pressure tolerance may be insufficient compared to multi-layer configurations
Solution Approach 1:
The patent optimizes the local quality of the reinforcement layer by implementing multi-layered end orientations within each beam, creating zones of enhanced reinforcement where needed. This allows a single-layer construction to achieve RVR greater than 110% with improved flexibility, while the localized multi-layer end arrangement provides sufficient pressure tolerance without requiring additional outer layers.
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.