JP2003145634A - Method for manufacturing hose - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a hose which can be easily applied to a conventional method for plastic mold vulcanization or the like and which can be preferably applied to the hose using all manufacturing methods without bringing about a fault in a line producing speed or the like. SOLUTION: The method for manufacturing the hose comprises a step of laminating at least an inner surface rubber layer, a reinforcing layer, an outer surface rubber layer and an ultra-high molecular weight polyethylene layer from an inner layer side. The method further comprises the steps of laminating to the outer surface rubber layer, then vulcanizing the laminate, buff polishing the surface of the vulcanized outer surface rubber layer, laminating the ultra- high molecular weight polyethylene layer on the buff polished outer surface rubber layer, further winding a lapping cloth on its outside, and then heating the cloth to adhere the outer surface rubber layer to the ultra-high molecular weight polyethylene layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a hose, and more specifically, a hydraulic hose for construction machinery, a high-pressure hose for civil engineering works, a hose for cleaning, etc. The present invention relates to a method for manufacturing a hose having excellent wear resistance, which is used in

[0002]

2. Description of the Related Art Conventionally, as a hose used for applications requiring high wear resistance such as hydraulic hoses for construction machinery, high pressure hoses for civil engineering works, hoses for cleaning, etc. Abrasion resistant hoses are known (described in Japanese Patent Application Laid-Open No. 4-191042). As a method for producing such an ultra-wear resistant hose, there is known a method in which an ultra-high molecular weight polyethylene is laminated on an upper layer of an unvulcanized hose, and a wrapping cloth is coated on the hose to apply pressure, and melt bonding is performed during vulcanization. ing.

[0003]

However, although this method has the advantage that the rubber hose can be vulcanized and the ultra high molecular weight polyethylene can be bonded simultaneously by heating once, it does not use a wrapping cloth. However, when applied to a hose manufactured by, for example, plastic mold vulcanization, a production line is restricted because a process different from the conventional one must be performed. That is, the plastic mold vulcanization cannot be practically used on the production line of the above manufacturing method, and when it is used, the production speed of the line is greatly restricted.

Therefore, an object of the present invention is to provide a conventional method such as plastic mold vulcanization by giving a degree of freedom in process selection in a method of manufacturing an ultra-wear resistant hose in which an ultra-high molecular weight polyethylene is laminated on the outer surface of the hose. To provide a hose manufacturing method that can be easily applied to the hose and that does not hinder the production speed of the line, and can be favorably applied to hoses using any manufacturing method. is there.

[0005]

[Means for Solving the Problems] In order to solve the above problems, the present invention is as follows. <1> In a method for producing a hose in which at least an inner rubber layer, a reinforcing layer, an outer rubber layer, and an ultrahigh molecular weight polyethylene layer are laminated from the inner layer side, the outer rubber layer is laminated and then vulcanized, and then vulcanized. The surface of the vulcanized outer surface rubber layer is buffed, the ultra high molecular weight polyethylene layer is laminated on the buffed outer surface rubber layer, and a wrapping cloth is further wound on the outer side thereof, followed by heating. A method for producing a hose, characterized in that an outer rubber layer and an ultra high molecular weight polyethylene layer are adhered to each other.

<2> The manufacturing method according to the above <1>, wherein plastic mold vulcanization is performed as the vulcanization.

<3> The method according to the above <1> or <2>, wherein the ultra high molecular weight polyethylene layer is laminated by spirally wrapping the ultra high molecular weight polyethylene film.

<4> The production method according to <1> or <2>, wherein the ultrahigh molecular weight polyethylene layer is laminated by sushi-rolling the ultrahigh molecular weight polyethylene film.

<5> The manufacturing method according to any one of <1> to <4>, wherein the lapping cloth is wetted with water and then wound.

<6> In the manufacturing method according to any one of <1> to <5>, the heating is performed at a temperature of 145 to 160 ° C.
It is a manufacturing method performed in.

According to the invention of the above <1>, the conventional method such as plastic mold vulcanization can be easily applied in the production of the super wear resistant hose, and the production speed of the line is restricted. It never happens. That is, in the prior art, the ultra high molecular weight polyethylene layer had to be laminated in the intermediate step of manufacturing the hose, whereas in the present invention, the ultra high molecular weight polyethylene layer is substantially laminated even in the final product. As a result, it is possible to apply the hose of any production method without being restricted by the conventional manufacturing process of the super wear resistant hose.

Further, the invention of the above <2> can widen the range of choice of the vulcanization method, and the invention of the above <3> or <4> can appropriately laminate the ultra high molecular weight polyethylene layers. You can

Furthermore, according to the invention of <5> above, the winding tension of the lapping cloth can be increased to improve the pressure effect, and a stronger adhesion can be realized. According to the invention of <6>, The damage (heat aging) of the vulcanized hose can be minimized.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail with reference to the drawings. The manufacturing method of the present invention relates to a hose having excellent wear resistance, which is formed by laminating at least an inner rubber layer, a reinforcing layer, an outer rubber layer and an ultrahigh molecular weight polyethylene layer from the inner layer side.

In the conventional method, after laminating up to the outer rubber layer in this layer structure, an ultra-high molecular weight polyethylene layer is laminated on the layer in an unvulcanized state, and then vulcanization is performed to form each interlayer. In the present invention, vulcanization is performed without laminating the ultrahigh molecular weight polyethylene layer after laminating up to the outer rubber layer. Therefore, it is also possible to use a technique such as plastic mold vulcanization which could not be applied by the conventional method.

In the present invention, the layer structure of the hose from the inner rubber layer to the outer rubber layer is not particularly limited, and an appropriate layer structure can be selected depending on the application of the hose and the like. An example of the layer structure from the inner rubber layer to the outer rubber layer is shown in FIG. In the illustrated example, two reinforcing layers 2 and 4 are laminated on the inner rubber layer 1 with the intermediate layer 3 interposed therebetween, and the outer rubber layer 5 is laminated thereon.

The rubber material of the inner rubber layer 1 and the outer rubber layer 5 is not particularly limited, and a commonly used material can be used. Specifically, for example, nitrile rubber (NBR), chloroprene rubber (CR), chlorosulfonated polyethylene (CSM), ethylene propylene diene terpolymer (EPDM), butyl rubber (II
R), styrene butadiene rubber (SBR), etc., and the inner rubber layer 1 can be prepared by blending unvulcanized rubber using a single rubber species or a plurality of rubber species appropriately selected according to use conditions.
And the outer surface rubber layer 5 is formed. The thickness of the inner rubber layer is preferably about 1.0 to 2.0 mm, and the thickness of the outer rubber layer is preferably about 0.5 to 2.0 mm.
It is not particularly limited.

The reinforcing material used for the reinforcing layers 2 and 4 is not particularly limited, but preferably a metal wire,
For example, a brass-plated hard steel wire wire, a stainless steel wire, a zinc-plated known metal wire, or the like is used. Depending on the gas pressure used, known fiber materials such as aramid, polyester, vinylon, nylon, etc. can also be used by adhering them with an adhesive, and a hose using a fiber material as a reinforcing material is a hose for applications with low pressure. Can be used as

The reinforcing layer may be formed as a single layer, or
As shown, it may be formed of a plurality of layers of two or more layers.
The number of layers is preferably determined appropriately according to the pressure of the gas or liquid during use, that is, the internal pressure applied to the hose.
The structure of the individual layers in the reinforcing layer in this case is not particularly limited, but preferably, as shown in the drawing, a layer structure made of a braid of a metal wire or a fiber material, or at least a pair of alternately wound layers. Layer structure consisting of a spiral layer of metal wire or fiber material (not shown)
And When two or more reinforcing layers are provided, it is common to insert an unvulcanized rubber sheet as the intermediate layer 3 between the reinforcing layers, whereby each layer can be bonded. Further, by applying an adhesive agent or interposing a fiber layer, it is possible to prevent the wires from being separated from each other or to prevent the wires from being worn and worn due to a change in internal pressure during use. Further, during the spiral knitting, the inner rubber layer 1 including the mandrel may be cooled so that the rubber layer is not deformed or damaged depending on the knitting tension of the fibers.

The intermediate layer 3 also functions as a cushioning material for increasing the durability against the fluid passing through the inner rubber layer 1 and as a cushioning material for preventing rubbing between the reinforcing layers. It should be provided.

Vulcanization of the hose obtained by laminating the inner rubber layer, the reinforcing layer and the outer rubber layer and, if desired, an intermediate layer can be carried out in a conventional manner, and the conditions thereof are not particularly limited, but wrapping is possible. Vulcanization methods other than cross vulcanization, for example, methods such as plastic mold vulcanization can be suitably used.

In the present invention, the outer rubber layer 5 after vulcanization is used.
It is important to buff the surface of the. In general,
Adhesion between rubber and ultra-high molecular weight polyethylene consists of entanglement of molecular chains. Therefore, in order to bond the vulcanized rubber to the ultra-high molecular weight polyethylene in the same manner as in the case of the unvulcanized rubber, the surface of the vulcanized rubber is buffed to increase its surface area and the rubber molecular chains are easily entangled. There is a need to. In this case, it is preferable that the surface treatment of the rubber is roughened by buffing with sandpaper of # 200 or less. Further, other treatment methods such as shot blasting may be used as long as the same surface treatment effect as that of buffing can be obtained.

Next, an ultrahigh molecular weight polyethylene layer is laminated on the outer rubber layer 5a (see FIG. 2) of the vulcanized hose which has been surface-treated by buffing. The laminating method in this case is not particularly limited, and the buffing on the outer surface rubber layer 5a,
The ultra high molecular weight polyethylene film 6 is spirally wrapped (see FIG. 3) or sushi-wound (FIG. 4).
See) and the like. Here, the ultra high molecular weight polyethylene used for forming the ultra high molecular weight polyethylene layer is a polyethylene having a molecular weight of usually 1,000,000 or more, preferably 2,000,000 or more. The thickness of the ultra high molecular weight polyethylene layer is not particularly limited as long as it can obtain desired abrasion resistance, but is usually 0.05 to 0.3 mm, preferably 0.08 to 0. Two
mm.

Further, as shown in FIG. 5, after laminating an ultrahigh molecular weight polyethylene layer, a wrapping cloth 7, for example, nylon cloth or the like is spirally lapped on the outer side thereof. At this time, the wrapping tension can be increased by wetting the wrapping cloth with water and then wrapping the wrapping cloth, and the pressure effect can be enhanced to improve the adhesiveness.

After lapping with the lapping cloth 7, the entire hose is heated to bond the outer rubber layer and the ultra high molecular weight polyethylene layer. The heating may be either dry heat or wet heat, but is preferably performed at a temperature of 145 to 160 ° C. When the heating temperature is less than 145 ° C., the outer rubber layer and the ultra high molecular weight polyethylene layer do not adhere to each other, while 1
This is because heating at a temperature of more than 60 ° C. causes damage (heat aging) to the hose structure in the portion from the already vulcanized inner rubber layer to the outer rubber layer, and deteriorates the original performance of the hose. Therefore, by heating at a temperature within this range, it is possible to obtain proper adhesion between the outer rubber layer and the high molecular weight polystyrene layer, while minimizing damage (heat aging) of the vulcanized hose. . The heating time is
Generally, a high temperature will bond in a short time, but it is about 5 to 2
It takes about 0 minutes.

As a result of manufacturing the hose according to the above procedure, the present invention has the following advantages. That is, in the prior art, the ultra-high molecular weight polyethylene had to be laminated in the intermediate step of the hose production process, whereas in the present invention, the ultra-high molecular weight polyethylene can also be laminated in the final product. Therefore, it is possible to apply to a hose of any production method such as a method using plastic mold vulcanization without being restricted by the conventional manufacturing process of an ultra-wear resistant hose.

[0027]

The present invention will be described in detail below with reference to examples. The hoses of Examples and Comparative Examples were produced under the production conditions shown in Table 1 below. In the examples, the inner rubber layer, the reinforcing layer and the outer rubber layer were laminated and then vulcanized to obtain a base hose. Then, after buffing the surface of the outer rubber layer of the base hose after vulcanization, laminating an ultra high molecular weight polyethylene layer on this, further wrapping a wrapping cloth on the outer side, and then heating the outer rubber layer. And the ultra high molecular weight polyethylene layer were adhered. Further, for the comparative example, according to the manufacturing conditions of the conventional ultra-wear-resistant hose manufacturing method, after laminating the inner rubber layer, the reinforcing layer and the outer rubber layer, the ultra-high molecular weight polyethylene layer is laminated, wrapped with a wrapping cloth, The outer rubber layer and the ultra high molecular weight polyethylene layer were adhered by vulcanization. still,
For all examples and comparative examples, the inner rubber layer was made of NBR and the outer rubber layer was made of CR / SB.
R was used. Further, brass-plated wires were all used for the wires of the reinforcing layer.

The evaluation results of the bonding state of the hoses obtained in these Examples and Comparative Examples are also shown in Table 1 below. From this result, it was confirmed that the hose manufactured according to the present invention exhibits the same good adhesion state as the super abrasion resistant hose manufactured by the conventional method.

[0029]

[Table 1] *: The adhesive force between the outer rubber layer and the ultra high molecular weight polyethylene layer was measured according to JIS K6330-6 "Adhesion test", type 8.

[0030]

As described above, according to the present invention, the conventional methods such as plastic mold vulcanization can be easily applied, and the production speed of the line is impaired. Thus, a hose manufacturing method has been realized which can be successfully applied to a hose using any manufacturing method.

[Brief description of drawings]

FIG. 1 is a partial perspective view showing an example of a layer structure from an inner rubber layer to an outer rubber layer of a hose according to the present invention.

FIG. 2 is a partial perspective view showing a state where the surface of an outer rubber layer of the hose of FIG. 1 is buffed.

FIG. 3 is a partial perspective view of an example showing a state in which an ultra high molecular weight polyethylene layer is formed on the outer rubber layer of the hose of FIG.

FIG. 4 is a partial perspective view of another example showing a state in which an ultra high molecular weight polyethylene layer is formed on the outer rubber layer of the hose of FIG.

5 is a partial perspective view showing a state in which a wrapping cloth is wound around the ultra high molecular weight polyethylene layer of the hose of FIG. 3 or FIG.

[Explanation of symbols]

1 Inner surface rubber layer 2 Reinforcement layer 3 Middle class 4 Reinforcement layer 5 outer rubber layer 5a Outer rubber layer after buffing 6 Ultra high molecular weight polyethylene layer 7 wrapping cloth

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 3H111 AA02 BA13 BA25 CA08 CA52                       CB06 CB14 CB24 CC03 CC04                       CC18 DA10 DB08 DB12                 4F100 AA01E AB03 AK04D AK04E                       AK10 AK27 AK29 AK46 AK73                       AL01 AN00A AN00C AN02                       AR00B BA05 BA07 BA10A                       BA10E DA11 DC16 EH51D                       EH51E EH71 EJ063 EJ343                       EJ422 EJ423 GB51 JA08D                       JA08E JK01B JK09 JL02                       YY002                 4F213 AA06 AA45 AC03 AD16 AG03                       AG08 WA41 WA53 WA60 WA74                       WA83 WB01 WC01

Claims (6)

[Claims] 1. A method for producing a hose comprising at least an inner rubber layer, a reinforcing layer, an outer rubber layer and an ultrahigh molecular weight polyethylene layer laminated from the inner layer side, wherein vulcanization is performed after laminating the outer rubber layer. Buffing the surface of the vulcanized outer rubber layer, laminating the ultra-high molecular weight polyethylene layer on the buffed outer rubber layer, winding a wrapping cloth on the outer side thereof, and then heating. A method for producing a hose, characterized in that the outer rubber layer and the ultra-high molecular weight polyethylene layer are adhered by the method. 2. The method for producing a hose according to claim 1, wherein plastic mold vulcanization is performed as the vulcanization. 3. The method for producing a hose according to claim 1, wherein the super-high molecular weight polyethylene layer is laminated by spirally wrapping the ultra-high molecular weight polyethylene film. 4. The method for producing a hose according to claim 1, wherein the laminating of the ultrahigh molecular weight polyethylene layer is performed by sushi winding an ultrahigh molecular weight polyethylene film. 5. The method for manufacturing a hose according to claim 1, wherein the lapping cloth is wetted with water and then wound. 6. The method for producing a hose according to claim 1, wherein the heating is performed at a temperature of 145 to 160 ° C.