Shrink Sleeve Silicone Hose Bonding Without Tape Wrapping
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Solution Overview
Problem
The existing wrapped silicon hose manufacturing process requires a time-consuming and labor-intensive taping subprocess for adhesion between silicone layers, necessitating skilled operators, specialized equipment, and generating significant waste, which complicates the production of reinforced silicone hoses.
Innovation Solution
The shrink tension method uses industrial-grade polyolefin shrink sleeves to tighten and bond reinforced silicone layers instead of adhesive tape, eliminating the need for taping and de-taping processes, and allowing for easier recyclability and reduced equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive tape is used to ensure adhesion between silicone layers, then bonding between layers is achieved, but production time increases and labor intensity increases
Solution Approach 1:
The patent removes the adhesive tape step entirely from the manufacturing process. Instead of applying tape to ensure layer adhesion and then removing it after curing, the invention uses a single-layer silicone construction where the inner layer is directly bonded to the outer layer through vulcanization, eliminating the need for intermediate binding materials and their associated application and removal steps.
Solution Approach 2:
The patent introduces a release agent as an intermediary substance that enables easy separation of the hose from the mold after curing without requiring adhesive tape. The release agent is applied to the mold surface rather than using tape on the hose, achieving the same goal of facilitating demolding while avoiding the tape-related productivity losses.
2Strength
If adhesive tape is used to consolidate silicone layers, then layer adhesion is achieved, but equipment complexity increases
Solution Approach 1:
The patent eliminates the need for orbital winders, tape wetting machines, de-taping equipment, and specialized chucks by removing the adhesive tape process entirely. The simplified construction method requires only basic wrapping and vulcanization equipment, significantly reducing equipment complexity.
Solution Approach 2:
The patent segments the manufacturing process into simpler, more discrete steps: preparing the inner silicone layer, wrapping the outer silicone layer directly onto it, and vulcanizing the assembly. This segmentation removes the complex intermediate steps of tape application and removal that require specialized equipment.
3Strength
If adhesive tape is used for layer consolidation, then adhesion is achieved, but waste generation increases
Solution Approach 1:
The patent removes the source of waste by eliminating adhesive tape from the process entirely. Without tape application and removal, there is no cellulose or other tape material to discard, significantly reducing waste generation and improving environmental sustainability.
Solution Approach 2:
The patent eliminates the cycle of consuming tape material and then discarding it after use. By using direct silicone-to-silicone bonding, the process becomes materially more efficient, with no intermediate consumable materials to discard.
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 reduces production time, manpower needs, and waste generation, while providing mechanical and abrasive protection to the hoses, and is applicable to both shaped and linear hose designs, with fewer opportunities for human error.
Implementation Method 1
A shrink sleeve is pulled over the preform and is preheated in order to enable a tight/snug fit of the shrink sleeve over the preform
Implementation Method 2
the shrink sleeve may be used to control the shape of the uncured hose, and provides necessary pressure for vulcanization
Data Source
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AI summary
A hose (22) includes an outer cover layer (20) and at least one ply (16) disposed inward from the outer cover layer (20), characterized in that the outer cover layer (20) is a shrink sleeve, and where the at least one ply (16) is formed from a reinforced silicone rubber sheet (10) which includes a reinforcement (12). The hose (22) may further include an inner layer (18) disposed within the at least one ply (16), and which defines a lumen (32). The shrink sleeve may be a polyolefin shrink sleeve. The layers of the hose are tensioned together with the shrink sleeve. The hose (22) may be prepared by a shrink tension method without the use of a tape wrap. A method of preparing the above hose (22) may include wrapping the inner layer (18) around a mandrel (14), wrapping the at least one at least one ply (16) around the inner layer (18), pulling the shrink sleeve (20) over the at least one at least one ply (16), and vulcanizing the hose (22).