Strip for reinforcement of a hose and a method of manufacture thereof
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Solution Overview
Problem
Existing hose reinforcement methods, such as braiding and spiralling with steel wires, face challenges in achieving sufficient transverse strength and adhesion to rubber, leading to potential hose failure under pressure and dynamic loading, especially with round wires prone to erosion fatigue and flattened wires difficult to process.
Innovation Solution
A reinforcement strip comprising multiple parallel steel wires in close contact, held together by a hardened waterborne adhesive, which provides high transverse strength and adapted adhesion to rubber, allowing for efficient braiding or spiralling without the need for rewinding and facilitating the use of flattened steel wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If round steel wires are used for reinforcement, then the hose achieves required strength, but the wires are prone to erosion fatigue and loss in breaking load when subject to transversal stresses
Solution Approach 1:
The patent changes the geometric parameter of the steel wires from round cross-section to flattened cross-section. This parameter change increases the contact area between wires at crossovers, reducing transversal contact stresses and erosion fatigue, while maintaining the required tensile strength of the reinforcement
Solution Approach 2:
The patent creates a composite structure by embedding steel wires (round or flattened) into a polymer matrix to form a reinforcement strip. This composite structure provides both the high strength of steel and the protective encapsulation of polymer, preventing direct wire-to-wire contact and reducing erosion fatigue
2Shape
If flattened steel wires are used to reduce hose thickness and improve ductility, then the overall hose thickness is reduced, but the processing into ribbon is difficult as wires tend to twist
Solution Approach 1:
The patent introduces a polymer matrix as an intermediary material that binds the flattened steel wires together to form a stable ribbon structure. The polymer encapsulation prevents the wires from twisting during handling and processing, while allowing the flattened geometry to provide reduced hose thickness and improved ductility
Solution Approach 2:
The patent creates a composite material system where flattened steel wires are embedded in a polymer matrix. This composite structure maintains the advantages of flattened wires (reduced thickness, improved ductility) while the polymer binding solves the processing difficulty of wire twisting
3Strength
If steel wires are embedded in polymer matrix to form strip, then the transverse strength is improved, but the polymer encapsulation inhibits use in machine with preformers
Solution Approach 1:
The patent applies partial polymer encapsulation rather than complete encapsulation. The polymer matrix binds the wires together to provide transverse strength, but the encapsulation is controlled to maintain wire surface accessibility for preforming operations, thus achieving a balance between structural integrity and manufacturing compatibility
4Strength
If adhesive is applied to hold wires together in strip, then the transverse strength is achieved, but the adhesive must provide both wire bonding and rubber adhesion
Solution Approach 1:
The patent employs a universal adhesive system that performs multiple functions: it bonds steel wires to each other to form the strip structure, and simultaneously provides adhesion to the rubber hose material. This multi-functional adhesive reduces the need for separate coating steps and simplifies the overall manufacturing process
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 reinforcement strip enhances the burst pressure of hoses by achieving higher transverse strength and improved adhesion, reducing processing complexities and preventing hose failure due to erosion fatigue, while allowing for easier handling and integration with existing machinery.
Implementation Method 1
multiple steel wires in close contact, held together by a hardened waterborne adhesive
Data Source
Figure 1~5
Figure 6~7b
AI summary
A strip (100) intended for the reinforcement of the wall of high pressure hoses or flexible pipes is presented. The strip (100) comprises multiple wires (102) arranged side-by-side and held together by means of a hardened adhesive (104) originating from a waterborne dispersion. Different embodiments are presented wherein the wires (102) are embedded in the hardened adhesive (104), or wherein only one side of the strip (100) is covered with hardened adhesive (104) or wherein the hardened adhesive (104) is present only between the wires (102) and not on the surfaces (S1, S2) delineating the strip (100). In one preferred embodiment the wires (102) are flattened with the flats being parallel to the surfaces (S1, S2) of the strips (100).