JP2009039886A - Manufacturing process of bellows rubber hose, and bellows rubber hose manufactured by the manufacturing process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To attain reduction in cost and prevention of product dispersion by mechanically manufacturing a bellows rubber hose. <P>SOLUTION: In the manufacturing process of the bellows rubber hose comprising manufacturing a sheet roll by winding a reinforced rubber sheet having rubber adhered to a reinforced cloth around an inner mold having a bellows part on the surface, pressurizing the outer circumference of the sheet roll by an outer mold having a bellows part corresponding to the bellows part of the inner mold, which is formed on the inner surface thereof, to mold the sheet roll into a bellows rubber hose of a predetermined shape, and simultaneously performing vulcanizing treatment, the outer mold is circumferentially and axially divided so that respective split molds can be independently pressurized, and the vulcanizing treatment is performed after performing operations of forming one bellows part followed by retaining the shape and successively forming the remaining bellows parts followed by retaining. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a bellows rubber hose for an intercooler used for a turbocharger of a large truck, and a bellows rubber hose manufactured by this manufacturing method.

  As is well known, exhaust gas regulations for diesel vehicles are becoming stricter year by year. New short-term exhaust gas regulations were implemented in 2003-2004 and new long-term exhaust gas regulations were implemented in 2005, followed by 2009-2010. Will be subject to post-emission regulations. In order to meet these strict exhaust gas regulations, it is necessary not only to improve the post-processing technology for post-processing the combustion gas with a catalyst, but also to improve the combustion conditions of the engine. Will be further increased in temperature and pressure.

  In an automobile turbocharger, an engine, a turbofan, and an intercooler are connected by a rubber hose. In a large truck or the like, the vibration of each device is large, so a bellows portion is formed in the rubber hose to absorb the vibration. The bellows rubber hose used for this purpose has a large caliber and a large bellows step (difference between the ridges and valleys), so that it is difficult to form mechanically and is almost manually performed. When the combustion conditions of the engine become high temperature and high pressure, the conditions of the bellows become more severe and mechanization becomes more difficult.

  Conventionally, the bellows rubber hose has been manufactured by the following procedure. a. A rubber sheet is produced by laminating silicon rubber on one or both sides of a fabric woven and knitted with aramid fibers. b. A rubber sheet is wound around a mandrel (inner mold) having a predetermined bellows shape (a fluororubber sheet may be wound around the inner layer). c. A heat shrink tape is wound around the bellows valley of the outer periphery of the rubber sheet. d. Molding and vulcanization is performed in a steam can, and at this time, the tape is contracted to form a bellows. The most difficult of these is the process c, and considerable skill and time are required to perform this process well.

In addition, it is necessary to remove the tape, and once this tape is used, it cannot be reused and the cost is high. In addition, there is variation in the contraction force of the tape, and the thickness and shape cannot be made uniform, and if the step of the bellows part is large, the valley part cannot be narrowed down to a predetermined depth. For this reason, there is a problem that the shape of the bellows part is limited, the variation among products is large, and mass production is difficult. On the other hand, if it is going to form the bellows part which has a reinforcement cloth at once with a shaping | molding die, a reinforcement cloth will be pulled between a peak part and a trough part, and a fiber will fracture | rupture.
JP 2001-277373 A

  The present invention eliminates manpower in the above steps b and c (mechanization), thereby enabling cost reduction and mass production and eliminating product variations. The above-mentioned Patent Document 1 shows a case where a large bellows rubber hose for a truck intercooler is partially molded by a machine, but in this case, taping is described as an indispensable process.

  Under the above problems, the present invention produces a sheet wound body by wrapping a reinforcing rubber sheet having a rubber cloth pasted around an inner mold having a bellows portion on the surface according to claim 1, A bellows rubber hose that pressurizes the outer periphery of the sheet winding body with an outer mold having an inner bellows portion corresponding to the inner bellows portion on the inner surface to form the sheet winding body into a predetermined shape bellows rubber hose and simultaneously vulcanizes it In this manufacturing method, the outer mold is divided in the circumferential direction and the axial direction so that each of the divided molds can be pressurized independently, and one bellows portion is formed to maintain the shape, and then the rest The present invention provides a method of manufacturing a bellows rubber hose characterized by performing vulcanization after sequentially forming and holding the bellows portions.

  Further, the present invention provides a sheet wound body by winding a reinforcing rubber sheet having a rubber coated on a reinforcing cloth around a mandrel having a smooth surface as described in claim 2, and the sheet wound body is formed on the surface. The outer periphery of the sheet winding body is extrapolated to the inner mold having the bellows portion formed thereon, and the outer periphery of the sheet winding body is pressurized with the outer mold having the bellows portion corresponding to the inner bellows portion on the inner surface, so that the sheet winding body has a predetermined shape. In the manufacturing method of the bellows rubber hose, which is molded into the bellows rubber hose and vulcanized at the same time, the outer mold is divided in the circumferential direction and the axial direction so that each of the split molds can be pressurized independently, and one bellows A method of manufacturing a bellows rubber hose is provided, in which a portion is formed and the shape thereof is maintained, and then the remaining bellows portions are sequentially formed and held, followed by vulcanization. In addition, there is provided means for inserting a rubber hose having a meshed reinforcing cloth simultaneously with extrusion into the inner mold, as described in claim 3, instead of the sheet roll of claim 2.

  Furthermore, the present invention is the above-described invention, wherein the split mold according to claim 4 is a means in which the split mold is sequentially pressed from the central bellows to the bellows at both ends, and the reinforcement according to claim 5 A means in which fluororubber or a reinforcing cloth imprinted with fluororubber is used for the inner layer of the rubber sheet, wherein the inner mold has a hollow hole in the axial direction, and the ventilating portion communicates with the hollow hole in each bellows portion. A portion is formed, and a means is provided for operating the outer mold after the cavity hole is depressurized and the sheet winding body is brought into close contact with the surface of the inner mold.

  According to the means of claims 1 to 3, since one bellows portion is formed and the remaining bellows portions are sequentially formed while maintaining the shape thereof, the reinforcement necessary for forming each bellows portion is provided. Since the rubber sheet is freely drawn (moved) from the free side where it is not formed, the fibers of the reinforcing cloth are not broken or the bellows part once formed is not extended. In this case, according to the means of claim 1, since the sheet winding body can be directly manufactured on the inner mold having the bellows portion, the process can be simplified, and according to the means of claim 2, the sheet winding body. Is manufactured in advance with a mandrel having a smooth surface (hereinafter referred to as a straight mandrel), so that it is easy to process. Furthermore, according to the means of claim 3, since the extruded rubber hose has only to be directly inserted into the inner mold, labor can be saved. According to the means of claim 5, since the pressure applied to the outer mold may be small, even a thick bellows portion can be formed into an accurate shape with a uniform thickness.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a partial cross-sectional side view showing an example of a bellows rubber hose according to the present invention. This bellows rubber hose is a bellows portion in which valleys 1a and peaks 1b are alternately formed on a sheet roll 4 described later. 1 and the straight cylinder part 2 are formed. In this, the bellows portion 1 is formed in the center, and both ends are in principle the straight tube portion 2. The entire bellows rubber hose may be a straight straight tube or a bent tube. Even in the latter case, the bellows portion 1 is formed in a straight tube portion. Furthermore, the number and level | step difference of a bellows in the bellows part 1 are determined suitably according to the objective.

There are the following two methods for manufacturing this hose, and the first manufacturing method takes the following steps.
A. Produces a reinforced rubber sheet that attaches rubber to a reinforced fabric.
Fibers are woven or knitted to form a reinforcing fabric, and knitting is preferred because it has a large stretch allowance. As the fiber, high heat resistance and high strength fiber such as aromatic polyamide, carbon fiber and glass fiber is used. In order to stick the rubber to the reinforcing cloth, the rubber is imprinted on the reinforcing cloth with a surface pressure of the roll with a wall thickness of usually 0.2 to 1.5 mm using a calendar roll. The rubber at this time is mainly silicon rubber, but there are other rubbers.

B. A sheet rubber 4 is manufactured by winding a reinforcing rubber sheet around the outer periphery of the inner mold 3 having a predetermined bellows shape.
The inner mold 3 in this case is formed with a valley portion 3a and a mountain portion 3b corresponding to the valley portion 1a and the mountain portion 1b of the bellows portion 1 of the bellows rubber hose, and a straight cylinder portion 3c corresponding to the straight cylinder portion 2 on the outer periphery thereof. ing. In addition, although the number of the bellows parts 1 in this example is four, it is not limited to this. The sheet winding body 4 manufactured by this method has a method of forming a complete or incomplete bellows shape corresponding to the valley portion 3a and the mountain portion 3b of the inner mold 3, but the thickness and shape are not uniform. In general, the processing time becomes long. In the production of the sheet roll 4, a material such as highly heat-resistant fluorine rubber or fluorosilicone rubber is wound around the innermost layer, and a reinforcing cloth imprinted with silicon rubber is wound around the outer periphery in a range of 2 to 5 layers. . FIG. 2 is a longitudinal cross-sectional view showing this state, but the straight cylindrical sheet winding body 4 is fitted on the outer periphery of the inner mold 3.

C. The sheet winding body 4 externally fitted to the inner mold 3 is divided in the circumferential direction and the axial direction, and the respective divided molds 5 _{(1) to} 5 ₍₅₎ can be independently pressurized (operated). The outer mold 5 is charged.
The outer mold 5 is divided into a circumferential direction and an axial direction. Usually, the outer mold 5 is divided into upper and lower parts in the circumferential direction. The number of the bellows portions 1 is divided as the boundary surface. The split molds 5 ₍₁₎ and 5 ₍₅₎ at both ends are also formed with a straight tube portion. Each of the above split type 5 ₍₁₎ 5 ₍₅₎ is adapted to respectively move independently.

D. Each of the divided dies 5 _{(1) to} 5 ₍₅₎ is sequentially operated to form the bellows portion 1 and the straight tube portion 2 on the sheet winding body 4, and then the outer die 5 is heated to perform vulcanization.
The bellows portions 1 are formed one by one. FIGS. 3 and 4 are perspective views showing this state, and FIG. 5 is a longitudinal sectional view. In order to move the split molds 5 _{(1) to} 5 ₍₅₎ individually, a pin 7 with a different protruding length is attached to the operating cylinder 6, and the upper and lower split molds 5 _{(1) to} 5 ₍₅₎ are attached by this pin 7. Move it. In this case, it is preferable that the central split mold 5 ₍₃₎ is moved first, and then moved in order toward the end side. Until the formation of the central bellows portion 1 is completed, the next split mold 5 ₍₂₎ , 5 ₍₄₎ is prevented from acting on the sheet winding body 4, and the previously operated split mold 5 _{(1 ) To} 5 _(5), the sheet winding body 4 is kept pressed against the inner mold 3.

  Since the sheet winding body 4 has a reinforcing cloth, in order to form the bellows part 1 in this, the fiber of the reinforcing cloth is broken unless there is a free part and it is not drawn to the bellows part 1 side. To do. Therefore, if one bellows part 1 is formed and this bellows part 1 is held by the inner mold 3 and the outer mold 5, the free end side is moved to the bellows part 1 side when the next bellows part 1 is formed. It will come close (the fiber will not break), and the already formed bellows 1 will not be stretched and its shape will not collapse. In this respect, it is preferable that the middle bellows portion 1 is formed first, and then the next one is formed in order. This is because the molding time can be shortened and the change in the overall length of the bellows rubber hose 4 can be kept small.

  Accordingly, the bellows portion 1 (also the straight tube portion 2) is formed by the inner mold 3 and the outer mold 5 in the sheet winding body 4. When the above is completed, the outer mold 5 is heated at a predetermined temperature and time for vulcanization. Along with this, the outer mold 5 is provided with a heating structure such as a heating wire. However, if this is performed in a vulcanizing can, the heating structure is unnecessary. When the vulcanization process is completed, the outer mold 5 is withdrawn, and the bellows rubber hose inside is taken out.

  The above is the first manufacturing method. In the second manufacturing method, instead of the step B, the sheet winding body 4 is first manufactured by a straight mandrel, and then the mandrel is pulled out to wind the sheet. A step of extrapolating the body 4 to the inner die 3 or a step of extrapolating a rubber hose shaded with a reinforcing cloth simultaneously with extrusion to the inner die is performed. It is quite difficult to manufacture the sheet winding body 4 by winding the reinforcing rubber sheet around the inner mold 3 that is uneven at the crest 3a and the trough 3b, but according to this, it is a straight mandrel. There is an advantage that it is easy to work. In addition, it may replace with a sheet | seat winding body and may use the extruded rubber hose which screened the reinforcement cloth simultaneously with extrusion.

  In addition, there is also a method of forming a rough bellows portion 1 in the process B. FIG. 6 is a partial cross-sectional longitudinal sectional view showing this method. A hollow hole 8 is formed at the center of the inner mold 3 and a vent 9 communicating with the hollow hole 8 is formed in the valley 3a and the like. In addition, the cavity hole 8 is sucked by a vacuum pump or the like. When the cavity hole 8 is depressurized, the sheet winding body 4 existing on the outer periphery is also drawn until it comes into close contact with the inner mold 3, and a bellows shape can be formed. According to this, since it is not necessary to increase the applied pressure of the outer mold 5 so much, it becomes possible to simplify the equipment and shorten the processing time. In this case, since the sheet roll 4 needs to seal the inner mold 3, the inner diameter thereof needs to be slightly smaller than the outer diameter of the peak portion 3b of the inner mold 3.

  Further, when the outer mold 5 is applied to the sheet winding body 4, air is taken in, and this air may act on the sheet winding body 4 during pressurization to cause unevenness on the surface thereof. Therefore, there is a method in which the outer mold 5 is also provided with a deaeration hole 10 that communicates with the outside air, and air is released from here. In addition, rubber may invade into the ventilation part 9 and the deaeration hole 10 by pressurization to form elongated protrusions on the front and back surfaces. For this reason, air can be passed through the ventilation portion 9 and the deaeration hole 10, but this can be prevented by filling a breathable material or the like (not shown) that does not allow rubber to enter. Note that the breathable material is not filled for each ventilation portion 9 or each deaeration hole 10 but can be easily constructed by winding it in a headband shape in the circumferential direction.

  By the way, it is clear that the operations of the above processes B to D can be performed mechanically. Therefore, if the delivery of intermediate products, etc. in each process is automatically performed, this type of bellows rubber hose can be manufactured fully automatically, and a large amount of stable quality can be manufactured at low cost. it can.

It is a partial cross section side view of a bellows rubber hose. It is sectional drawing of the state which extrapolated the sheet winding body to the inner type. It is a gurus figure of the state which makes an outer mold act. It is a gurus figure of the state which makes an outer mold act. It is sectional drawing of the state which makes an outer type | mold act. It is sectional drawing of the state which makes the outer type | mold of another example act.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Bellows part of bellows rubber hose 1a Valley of trough 1b Peak of trough 2 Straight cylinder part of trout 3 Inner type 3a Valley part of bellows part of inner mold 3b Peak part of bellows part of inner mold 3c Straight cylinder part of inner mold 4 Sheet Winding body 5 Outer mold 5 ₍₁₎ Split type 5 ₍₂₎ Split type 5 ₍₃₎ Split type 5 ₍₄₎ Split type 5 ₍₅₎ Split type 6 Actuating cylinder 7ピ ン Pin 8 Cavity hole 9 Vent 10 Deaeration hole

Claims (7)

  A sheet roll is produced by wrapping a reinforcing rubber sheet with rubber on a reinforcing cloth around the inner mold that has a bellows on the surface, and the outer periphery of the sheet roll corresponds to the inner bellows on the inner surface. In the manufacturing method of the bellows rubber hose which pressurizes with the outer mold formed with the bellows portion and forms the sheet winding body into a bellows rubber hose of a predetermined shape and simultaneously vulcanizes, the outer mold is divided into the circumferential direction and the axial direction. Each split mold can be pressurized independently, and one accordion portion is formed and its shape is maintained, and then the remaining accordion portions are sequentially formed and retained, followed by vulcanization treatment. A method of manufacturing a bellows rubber hose characterized by comprising:   A sheet wound body is manufactured by wrapping a reinforcing rubber sheet with rubber adhered to a reinforcing cloth around a mandrel with a smooth surface, and the sheet wound body is extrapolated to an inner mold having a bellows portion formed on the surface. The outer periphery of the sheet winding body is pressed with an outer mold having an inner bellows portion corresponding to the inner bellows section on the inner surface, and the sheet winding body is molded into a predetermined shape bellows rubber hose and simultaneously vulcanized In the rubber hose manufacturing method, the outer mold is divided in the circumferential direction and the axial direction so that each divided mold can be pressurized independently, and one bellows portion is formed and the shape thereof is maintained. A method of manufacturing a bellows rubber hose comprising performing a vulcanization process after sequentially performing operations for forming and holding the remaining bellows portions.   The method of manufacturing a bellows rubber hose according to claim 2, wherein a rubber hose with a reinforcing cloth meshed is inserted into the inner mold simultaneously with the extrusion.   The method of manufacturing a bellows rubber hose according to any one of claims 1 to 3, wherein the split mold is sequentially pressed from the central bellows portion to the bellows portions at both ends.   The manufacturing method of the bellows rubber hose according to any one of claims 1 to 4, wherein the inner layer of the reinforcing rubber sheet uses fluororubber or a reinforcing cloth imprinted with fluororubber.   The inner mold has a hollow hole in the axial direction, and a vent portion communicating with the hollow hole is formed in each bellows part. The cavity hole is depressurized so that the wound sheet is brought into close contact with the surface of the inner mold. After that, the manufacturing method of the bellows rubber hose according to any one of claims 1 to 5, wherein the outer mold is made to act.   A bellows rubber hose manufactured by the manufacturing method according to claim 1.