MXPA01006412A - Collapse-resistant hose construction - Google Patents

Abstract

A flexible hose (10) construction adapted for conveying fluids under relatively high internal pressures and capable of withstanding relatively high external pressures without collapsing. The construction includes a tubular first elastomeric layer (30) having a first inner radial surface (34) and a first outer radial surface (38), and a tubular second elastomeric layer (32) having a second inner radial surface (36) and a second outer radial surface (40). A helical reinforcement element (50) is spiral wound over the first elastomeric layer (30) as interposed between that layer and the second elastomeric layer (32). The element is wound at a predetermined pitch angle to define a series of turns each being spaced-apart from an adjacent turn to define an interstitial area therebetween. The first and second elastomeric members (30, 32) each extends into the interstitial area with the first outer radial surface (38) of the first elastomeric member (30) being bonded to the second inner radial surface (36) of the second elastomeric member (32) such that the spiral reinforcement member (50) is encapsulated therebetween.

Description

CONSTRUCTION OF RESISTANT HOSE TO COLLAPSE BACKGROUND OF THE INVENTION The present invention is broadly related to thermoplastic hose construction preferably, high pressure and flexible reinforcement, and more particularly to hose construction which is provided for especially collapse resistant by virtue of having structural reinforcement which is provided on a tubular number. as a composite of a metal wire wound helically encapsulated within the first and second elastomeric layers.

The ultra-high pressure and flexible pressure hose is used in a variety of fluid transfer applications such as in a field of oil and hydraulic applications off the shore of the beach. For example, in the recovery of crude oil from underground deposits, shale or other formations, a substantial amount of oil may remain uncovered to complete primary recovery operations such as natural depletion. Secondary methods are therefore often used to increase recovery performance. One of the most successful of these methods is here of the miscible flooded where a solvent such as methanol injected into the formation. Crude oil, which miscible with the solvent, is displaced from the solvent formation and is extracted from the formation. Secondary oil recovery methods are described in US Pat. Nos. 3,557.87 3,637,015; 3,811,501; 4,299,286; 4,558,740; 4,605,066; 4,609.04 4,678,036; 4,800,957; 4,899,817; and 5,632,336. Another method is the immiscible recovery where the water or brine is replaced by the solvent.

In general, the hoses are adapted for solvent injection and other oil field applications and not only must they be flexible, for example resistant to a relatively small bending radius, but they must also be able to withstand high internal pressures and high and of being manufacturable in relatively long stretches of 1,830 meters or more. As used herein, "high pressure" is described as a common definition of higher hydraulic working pressures around 1,500 pounds per square inch (10 MPa), c ultra-high being used here to designate the higher working pressures of about 15,000 pounds per square flea (100 MPa) or more. For a deep sea oil recovery and other underwater services, such manguer must also be able to withstand external pressures 500-4,000 pounds per square inch (3.4-28 MPa) or more, be lightweight and abrasion resistant, and for solvent injection applications, the permeation of methanol or other solvents must be resistant.

In a basic structure, the hoses of the ti here conventionally involved are constructed as having a tubular core surrounded by one or more layers of reinforcing courses of high tensile strength steel wire and synthetic fibers. The reinforcement layers, in turn, are protected by a surrounding outer shell or sheath which may be the same or a different material as the core tube. The cover also provides the hose with increased abrasion resistance.

The core tube, which may be a thermoplastic material such as a polyamide, polyolefin, polyvinyl chloride, or pyriurethane, or a synthetic rubber material such as Buna-N or neoprene is conventionally extruded and cooled or cured. As detailed in the patents of the United States of America numbers 3,116, 760; 3,159,183; 3,966,238; 4,952,262; it is necessary, the tube can be extruded cross-head on a mandrel for support, or otherwise further forming operations can be supported using reduced processing temperatures and / or air pressure.

From the extruder, the tube can be collected on a reel or other intake device for an additional process. How to get it from the reel, the optional tube can then be passed through an applicator for coating with an outer layer of an adhesive material which, in the case of the thermoplastic hose, can be polyurethane or another isocyanate base adhesive, or in the "rubber" ", for example an elastomer hose vulcanizes a vulcanizable adhesion promoter. The core tube appears to be delivered through a braider and / or spiral wound for reinforcement with one or more surrounding layers of wire and / or fibrous material such as a monofilament, or fibers for spinning. These reinforcing layers, which are applied under tension and which can be joined to the adjacent reinforcing layers and layers, typically comprise interwoven braid or a spiral wound of a nylon polyester or aramid yarn or a high steel wire. tensed from another metal.

After the application of the reinforcement layers, the outer sheath or jacket can optionally be applied to such cover, which can be formed as a cross-head extrusion or a spiral wound wrap, typically comprising an abrasion-resistant polymer material such as a polyamide. , a polyolefin, a polyvinyl chloride, a polyurethane. As before, an adhesive layer can be used to bond the outer cover to the reinforcement layers.

Representative pressure coil winding constructions and other constructions as well as manufacturing methods thereof are shown in U.S. Patent Nos. 1,281,5 3,566,924; 3,654,967; 3,682,202; 3,779,308; 3,790,419; 3,791.4 3,805,848; 3,889,716; 3,890,181; 3,905,398; 4,000,759; 4,098.2 4,175,992; 4,182,019; 4,241,763; 4,259,991; 4,294,636; 4,304.2 3,317,000; 4,342,612; 4,343,333; 4,380,252; 4,384,595; 4,444.70 4,456,034; 4,459,168; 4,463,779; 4,522,235; 4,537,222; 4,553.5 4,585,035; 4,699,178; 4,850,395; 4,898,212; 4,952,262; 5,024.25, 5,062,456; 5,361,806; 5,698,278; and 5,778,940. So far, however, it is believed that a high-pressure hose of ultra-pressure, this is having a working pressure of 10 MPa or which is both flexible and highly resistant to collapse as well as resistant to solvent permeation I was unknown in art. That is, even though the flexible hoses of the pressure thus far have been made resistant to collapse through, as generally shown in US Pat. No. 4,456,034, the incorporation of a helically wound spring received and internally into the orifice. of core tube, it is believed that such a resort will not be useful in conjunction with multiple cap core tubes which include an inner liner or a barrier layer of fluoropolymer or other chemically resistant material. In this aspect, there will be at least potential for the spring to wear through the barrier layer when the hose is subjected to bending forces. Such springs are also known because they introduce or objectionable flow restriction in the orifice of the hose.

In view of the foregoing, it will be appreciated that high pressure hose constructions must exhibit demanding balance of mechanical and other physical properties for proper operation. Indeed, as commercial applications for high-pressure hoses have increased with less intensive labor and therefore, a more economical substitute for rigid metal pipes, there have been industry requests to further improve such hoses and in materials of construction for them. Especially a construction is given which is flexible, eg resistant to external pressure folding in critical applications such as oil field applications and deep sea oil recovery.

WIDE DECLARATION OF THE INVENTION The present invention is directed to a flexible hose construction, and particularly to a reinforcing structure therefor, adapted to carry fluids under relatively high internal working pressures of from about 1,500 pounds per square inch (MPa) to about 15,000 pounds. per square inch (100 MP or more, which are also resistant to irrigated relatively high external pressures of between about 5 500-4,000 psi (3.4-28 MPa) or more vacuum.Therefore, hose construction of the invention is particularly adapted for the recovery of underwater oil and ot applications outside the shore and can be used for suction and discharge applications.

Advantageously, the hose of the present invention includes a reshaping, resilient, collapsible and structural element which is incorporated into the wall structure of the hose rather than being internally within the orifice of the hose. In this aspect, the hose is constructed as including a tubular elastomeric first layer having a first inner radi surface and a first outer radial surface and a second tubular elastomeric layer having a second inner radi surface and a second outer radial surface. A reinforcement propeller, which may be a spiral of one or more steel ends of monofilament or of another metal wire, is wound on the first elastomeric layer as interposed between the layer and the second elastomeric layer. The element is wound spirally at a predetermined angle of inclination to define a series of turns each being spaced apart from an adjacent turn to define an interstice area therebetween. The first and second elastomeric members each extend in the interstice area with the first outer radial surface of the first elastomeric member being fusion-bonded or other means to the second inter-radial surface of the second slantomeric member so that the helical reinforcement element is encapsulated between them. Co encapsulated between the first and second elastomeric layers, the spring-like helical element is capable of resisting externally imposed forces without elongating, compressing, bending or otherwise causing the hose to deform into an elliptical geometry or other non-circular geometry. In addition, encapsulation of the additional helically wound element provides an efficient soft load transfer surface upon which the subsequent fiber reinforcement layers can be braided or spirally wound to improve the internal pressure resistance of the hose.

In an illustrated embodiment, the construction of the hose of the present invention includes a tubular core on which the first elastomeric layer is superimposed, one or more layers of fibrous reinforcement or wound onto the second elastomeric layer to provide resistance to internal pressure. For methanol or other solvent-flooded oil recovery applications, the core may be provided with a layered composite that includes an inner barrier layer or liner and a more flexible outer layer. The innermost barrier layer can be extruded or otherwise formed of a fluoropolymer or other material which is resistant to solvents such as methanol, with the outer layer being formed of a lower cost thermoplastic material such as a polyolefin, a polyamide, a polyvinyl chloride or polyurethane. Advantageously, the hose construction of the present invention facilitates the provision of a fold-resistant sleeve which utilizes such a composite core without risk of the liner being damaged by the spiral wound wire or other reinforcement helix. Such a construction also allows the reinforcement helix to be wound on the nose rather than on the fibrous reinforcement layers, which both place the helix closer to the central axis of the hose and minimize the amount of wire or other material necessary for the reinforcement. roll up the propeller It is therefore a feature of the disclosed embodiment of the present invention to provide a fold-resistant hose construction adapted to carry fluids under high pressure. Such a construction includes a first tubular elastomeric layer having a first radial surface and a first outer radial surface, and a second tubular elastomeric layer having a second inner radial surface and a second outer radi surface. A helical reinforcing element is wound spirally on the first elastomeric layer as it is interposed between that layer and the second elastomeric layer. The element is wound at a predetermined angle of inclination to define a series of turns each being spaced apart from an adjacent turn to define an interstitial area therebetween. The first and second elastomeric members each extend into the interstice area with the first outer radial surface of the first elastomeric member being attached to the second inner radial surface of the second elastomeric member so that the spiral reinforcing member is encapsulated therebetween.

The present invention, therefore, comprises apparatus possessing the construction, combination of arrangement elements of parts which are exemplified in the detailed description that follows. The advantages of the present invention include a hose construction which is lightweight, abrasion resistant, and flexible, but the cu also operates under conditions of high net or high internal pressures such as to be highly resistant to collapse by forces externally. imposed such as pressure under water or a vacuum. Additional advantages include a collapsible, high-pressure hose construction which can be manufactured in relatively long tramways, and which is also particularly adapted for solvent flooding and other solvent transfer applications when used in conjunction with a pipeline. composite core that has an inner liner which is resistant to solvent permeation. These and other advantages will be readily apparent to those skilled in the art. These and other advantages will be readily apparent to those skilled in the art based upon the description contained herein.

BRIEF DESCRIPTION OF THE DRAWINGS For a complete understanding of the nature of the objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which: Figure 1 is a side elevational view of a flexible collapsible high pressure hose constructed in accordance with the present invention including a helically wound reinforcing element which is encapsulated within the prime and second elastomer layers.

Figure 2 is a view showing hose construction of Figure 1 both in a radial and axial cross section.

Figure 3 is an axial cross-sectional view of the encapsulated reinforcement element of the hose construction of Figure 2 which is amplified to reveal details of the structure thereof.

Figure 4 is a side elevation view of an alternate embodiment of the hose construction of Figure 1.

Figure 5 is a side elevation view of another alternate embodiment of the hose construction of Figure 1; Y Figure 6 is a view showing hose construction of Figure 5 both in radial and axial cross section.

The drawings will be further described in relation to the following detailed description of the invention.

DETAILED DESCRIPTION OF THE INVENTION Some terminology may be employed in description that follows for convenience rather than limiting purposes. For example, the terms "upper" or "lower" designate directions in the drawings to which the reference refers, with the terms "inside" or "inside" "outside" or "outside" referring, respectively, to directions in and toward outside the center of the reference element, and the terms "radial" and "axial" refer respectively to directions perpendicular and parallel to the longitudinal center of the reference element. Terminology of similar importance other than the specific words mentioned above in a similar manner should be considered c being used for purposes of convenience rather than any limiting sense.

For the purposes of the description that follows the precepts of the composite reinforcement layer of the invention involved herein are described in connection with their use within a representative hose construction particularly adapted for use in solvent flooded or other solvent transfer applications. . It will be appreciated, however, that aspects of the present invention may find use in other hose constructions for transporting high pressure fluid such as other oil recovery or off-shore applications, or for suction or other vacuum applications. The use within such ot applications so far has been considered to be within the scope of the present invention.

Referring now to the figures where the corresponding reference numbers are used to design the corresponding elements through the various views, or high pressure hose, representative collapse resistant according to the present invention is shown generally at point 10 in the view in section of figure 1 and in the radial and axial section and cross-sectional view of figure 2. basic dimensions, the hose 10 extends axially to infinite length along a central longitudinal axis 1 and has a selected inner and outer diameter mentioned, respectively, in "Di" and "Do" in the radial cross-sectional view of Figure 2. The inner and outer diameter dimensions may vary depending on the particular fluid transport application involved, ie they will generally be around between o.24 -5 centimeters pa Di of inner diameter, and around 0.76-7.1 centimeters pa Do of outer diameter, with a Overall wall thickness, "w between them of between about 0.66-1.0 centimeters.

As can be seen in the different views of FIGS. 1 and 2, the hose 10 is constructed as being formed around a tubular core, mentioned at point 1 Conventionally, the core tube 14 can be provided as an extrudate from a thermoplastic material , such as a polyolefin, a polyester, a fluoropolymer, a polyvinyl chloride, a thermoplastic rubber, or polyurethane, preferably, a polyamide such as nylon 12, which is selected for chemical compatibility with the fluid q being handled. Alternatively, the core tube can be extruded from a natural or synthetic rubber vulcanizab for example thermosentable or fissionable, for example thermoplastic such as SBR, polybutadiene, EPDM, butyl neoprene, nitrile, polyisoprene, buna-N, copolymer rubber or mixture of such ethylene-propylene rubber. The core tube has an inner radial surface 16 defining the inner diameter Di of the hose 10, and an outer radial surface 18. As with the overall dimensions of the hose 10, the wall thickness of the core tube 14 can vary for particular application expected but will typically be of around 0.76-2.0 millimeters.

Although the core tube 14 may be in the form of a unitary single layer construction, it is preferred for solvent-flooded or other solvent transfer applications that the core tube 14 be provided, as shown, as having a layer construction. compound multiples. In such a multi-layer construction, the core tube 14 includes a more inner barrier liner or layer 20, which defines the inner radial surface of the core 16, and its outermost layer 22, which defines the external radi surface of core 18. For Resistance of the solvents t such as methanol, the barrier layer 20 can be provided as extruded or otherwise formed of a melt processable thermoplast which can be a fluoropolymer. As used herein, "solvents" should be understood as including other alcohols and organic solvents or hydrocarbons as well as inorganic solvents such as water or brine. Preferred fluoropolymers include polytetrafluoroethylene (PT the fluorinated ethylene polypropylene copolymer (FEP), perfluoroalkoxy resin (PFA), the polychlorotrifluoroethylene copolymer (PCTFE), the ethylene chlorotrifluoroethylene copolymer (ECTFE), the ethylene tetrafluoroethylene terpolymer (ETFE), the fluoride of polyvinylidene (PVD polyvinyl fluoride (PVFE), and copolymers and mixtures thereof.) For cost considerations, the wall thickness of barrier c can be kept to the minimum necessary to provide the permeation resistance of the solvent. for most applications it will be around 2-20 thousandths of an inch (0.05-0.5 mm.).

The outermost layer 22, in turn, is provided as being formed of a processable thermoplastic polymer material with relatively flexible melting which may be a polyamide, a polyolefin, a polyvinyl chloride or polyurethane or a mixture or copolymer thereof. Alternatively, the outermost layer 22 may be formed of thermosetting or thermoplastic rubber such as an aleac rubber which is directly attachable to liner 20, or another rubber c is attachable to liner 20 by means of a tie layer in a manner that will be described hereinafter. For strength and flexibility considerations, the thickness of the outer layer 22 may be thicker than that of the inner layer 20, and will typically range from about one thousandth of an inch (0.5 mm) to about 60 thousandths of an inch (1.5 mm).

The core layers 20 and 22 can be manufactured by extrusion, co-extrusion, or extrusion in sequence and, if formed of compatible materials, cross-linked either otherwise melt-bonded or chemically joined together in an integral tubular composite structure. If they consist of chemically non-similar or other incompatible materials, however, an intermediate tie or tie layer 24 can be co-extruded, for example "tri-extruded" with the layers 20 and 22 as being formed from a material the c is compatible adhesion bond with both of the materials layers 20 and 22. Preferably, the intermediate layer 24 e formed of a material which is also resistant to solvent permeation and which is generally more elastic than the material forming the layer 20. Suitable materials include PVDF, PVF, polyvinyl acetate (PVA), urethanes, copolymers, alloys and mixtures thereof, as well as thermoplastics or thermosetting agents.The wall thickness of the intermediate c will typically be less than or about same as the wall thickness of the inner layer 20. The composite tubes of the type involved herein are further described in United States Patents No. 3,561,493, 5,076.3 5,167,259, 5,284,184; 5,383,087; 5,419,374; 5,460,771; 5,469.8 5,500,257; 5,554,425; 5,566,720; 5,622,210; 5,678,611; 5,743,304 and marketed by ITT Automotive, Inc. (of Aub Hills, Minnesota) and by Pilot Industries Inc. (of Dext Minnessota).

In accordance with the precepts of the present invention, the core tube 14 is surrounded by a first generally more flexible elastomer c 30 which is superimposed radially and circumferentially around the outer surface of core 18, and a similarly flexible second elastomer layer 32 which surrounds the first elastomeric layer 30. Each of the elastomer layers 30 and 32 is an inner radial surface 34 and 36, respectively, and outer radial surface 38 and 40, respectively. Further according to the precepts of the present invention, the helical reinforcement element 50 is spirally wound on the elastomeric first layer 30 and interposed between the layer 30 and second elastomeric layer 32. The element 50 is structurally providing the hose 10 with resistance to collapse by high net positive external pressure as it may develop from externally imposed forces as found within the submarine service environment, or by vacuum as may be formed within suction applications.

Each of the first second elastomeric layers 30 and 32, which can currently be composed of 2 or more separate layers, can be extruded or otherwise formed independently of a vulcanizable or melt processable elastomeric material which is specifically selected by the manufacturer. high temperature operation, flexibility or otherwise for compatibility with the core t 14. Suitable materials include natural ones such as Hevea and thermoplastics, for example, meltable processable or thermosettable, for example vulcanizable, synthetic rubbers such as fluoropolyme chloro sulfonate, polybutadiene, butyl, neoprene, nitrile, p isoprene, buna-N, copolymer rubbers such as ethylene-propyl (EPR), ethylene-propylene-diene monomer (EPDM), nitrile-butadi (NBR) and styrene-butadiene (SBR), or mixtures such as ethylene propylene-EPDM, EPR, or NBR. The term "synthetic rubbers" should also be understood as encompassing materials which can alternatively be broadly classified with thermoplastic or thermosetting elastomers such as polyurethanes, silicones, fluoro silicones, styrene-isoprene styrene (SIS), and styrene-butadiene-styrene (SBS). , as well as other polymers which exhibit h-type properties such as plasticized nilons, polyesters, ethylene vi acetates and polyvinyl chlorides.As used herein, the term "elastomeric" is subscribed in its conventional meaning to exhibit properties of type. rubber docility, elastic compression deflection, compression settling flexibility and a capacity to recover the posterior deformation, for example, stress relaxation In preferred embodiment, the first elastomeric layer 30 can be co-extruded with a tube of core 20 so that inner radial surface 30 of layer 30 is fused or otherwise a integrally bonded to the outer surface core 18, with the second elastomeric layer being extruded onto the first elastomeric layer in a subsequent operation after spiral winding of the element 50. Each of the cap 30 and 32 may have a wall thickness of between around 0.13-7.87 millimeters.

With the first elastomeric layer 30 being attached to the core tube 14, the helical reinforcing element 50 spirally wound on the outer surface 38 is the layer 30. In this aspect, the extended resorber type element 50 can be provided as from between axially spaced and spaced apart 1-threads or "end" which may be threads, or monofilament tapes or multiple filaments. Each of these ends, in turn, can be wound individually and spirally as it is ejected from one or more separate spools or coils on the core in a parallel orientation to form the element 50.

In a preferred construction, the element 50 provides as one end of a monofilament carbon stainless steel wire, which can be coated with plastic, having a generally circular cross section with a diametrical extension of between about 0.5 millimeters, and a resistance to the tension of between around (345-2100 MPa). The element 50 can alternatively be provided as it was formed of nylon, rigid polyvinyl chloride (PVC), aramid, or other polymeric or composite material. The element 50 is applied in one direction, for example, to the right or left, to a predetermined tilt angle mentioned a? in figure 1, which can be measured relative to the longitudinal axis 12 of the hose 10. For the typical applications the angle of inclination? it is selected to be between about 40-85 °.

Particularly, the angle of inclination? can be selected depending on the desired resistance convergence, elongation and volumetric expansion characteristics of the hose 10. In general, the upper inclination angles will result in an expansion decreased radius of the hose under pressure but at an increased axial extension. For high pressure applications a "neutral" tilt angle of about 55 ° generally preferred to minimize elongation to about percent of the original hose length. Alternatively, a slightly greater angle of inclination than neutral can be used to develop a radially inwardly directed force component for efficient load transfer.

The helical element 50, as can be seen better in the sectional view of FIG. 2 and in the amplified view, the hose portion mentioned in point 56 shown in FIG. 3, is also applied to the core 14 in less than 1 percent of the the coverage of the same, and preferably au coverage between about 30 - 85 percent. In this form, the open helix thus formed is defined by a series of turns, a pair of which is mentioned as 60 a-b. C a momentary and particular reference to the view in amplified axial cross section shown at point 56 in figure 3, each of these turns can be seen as being spaced and separated by an axial distance, mentioned at point "£" of between about 0.25-9 centimeters of an adjacent turn to define the successive turn pairs 60. An interstice arc, mentioned at point 62, is therefore defined between the adjacent turns in each of these 60 pairs. Co the element 50 being provided As shown, having a generally circular cross-sectional geometry, the interstice area 62 defined between the pairs d adjacent turns 60 will normally assume a generally hyperbolic cross-sectional geometry. The wire element 50 can alternatively be provided as a construction having a "flat wire" with a geometry of polygonal cross section which can be generally rectangular or square, or with another circular geometry the c can be oval or elliptical.

With a continued reference to Fig. 2 and particular to the amplified view of Fig. 3 the wire element 50 can be seen as being wound in espi on the first elastomeric member 30 so that the first outer radial surface 38 thereof is plastically deformed or is otherwise extended in the interstice area 62. Similarly, with the second elastomer layer 32 being extruded or otherwise formed on the wound element 50, the second inner radial surface 36 of the c 32 is made to flow or otherwise In this manner, each of turns 60 of the helical element 50 is encapsulated between the layers 30 and 30, in order to extend into the interstitial area 62 to define a median, mentioned point 64, with the first outer radial surface 38 of the first elastomeric layer. 32 to form a reinforcing structure resists bending and integral.

Although the elastomeric layers 30 and 32 can be formed of different elastomeric materials, it is preferred in the case of manufacture that each of them be made of the same material or at least of compatible materials which can be thermally bonded by melting, or chemistry. by means of cross-linking or other reactive union. Particularly preferred material for layers 30 and 32 is melt processable thermoplastic polyurethane elastomer (TPE). With the intermediate core structure 14, first elastomeric layer 30, and the reinforcing element 50 preheated, the second elastomeric layer 32 can be extruded in the form of a cross head using the similar pressure tool on the layer 30 and the element 50 so that second inner surface 36 of the layer 32 is made to flow or otherwise deformed in the interstice area 62 and brought into contact with the first elastomeric layer 30.

Advantageously, with the second elastomeric layer 32 being extruded under pressure, a fusion bond can be effected with the first elastomeric layer 30 thereby forming an integral encapsulating structure. Alternatively, for chemically unlike layers 30 and 32, an intermediate tie or tie layer, depicted in phantom in FIG. 3 by lines 66a-b, may be provided as formed of a compatibilizing or adhesive polymer, in a preferred embodiment of the invention. one of layers 20, 22, 24, 30 and 32 are integrally adhesive or melt bonded or vulcanized to form structural composite with bonding reinforcements between adjacent, eg contiguous, caps 20, 22, 24, 30 and 32 each or exceeding (2.7 kg / cm).

The encapsulation of the helical element 50 den of the elastomeric members 30 and 32 ensures efficient transfer of tension to here, and also fixes the helix inclination in place while otherwise allowing the hose to flex consistently at a radius of minimum double which can be between about 2.5-36 inches (6.5-91.5 cm) depending on the outer diameter of the hose. In addition, encapsulation eliminates the need to provide second winding element against helically the c may be necessary to counterbalance the torsional twist which may otherwise occur when the hose 10 is pressurized. With the helical element 50 thus maintained, the axial elongation and the diametric expansion of the hose are controlled for improved structural strength.

With the helical element 50 being encapsulated within the elastomer layers 30 and 32, the layer 32 per ta is formed as having a second generally smooth outer surface, eg cylindrical or even 40. surface 40 which is generally smooth with respect to With radial and longitudinal directions, it advantageously provides efficient transfer of the internal loads and for an even surface over which the optional fibrous reinforcement layers can subsequently be wound, braided or otherwise provided to increase the resistance to the internal pressure of the hose. 10. That is, the tensions which can be induced from the internal pressure or otherwise are efficiently transferred to the reinforcement layers p by virtue of the smooth surface 40.

Preferably, and as shown in the figures 1 and 2, at least 2 of such fibrous reinforcing layers 70a are provided on the second elastomeric layer 30. As shown, each of the fibrous reinforcing layers 70 can be conventionally formed as in braided or alternatively woven or rolled into spiral, from about 1 about 20 ends of monofilament, of continuous multifilament, for example, of yarn, ribbon or stratum or of short "basic" yarns of natural or synthetic fiber material, which may be nylon, cotton, polyester, aramid, polyvinyl acetate (PVA), or polyphenylene bezobisoxazo (PBO) or a steel or other metal wire material or a mixture thereof. With respect to the spirally wound layers, such layers can be wound in opposite directions to counterbalance any torsional effect. In a preferred construction each of the reinforcing caps is braided at an inclination angle of ent about 48-60 ° using from between 24-96 carriers ca one having from 1 to about 24 ends of an aramid thread of multifilaments of 720-600 deniers (800-6600 decitex) For spirally wound layers, from about 1 around 12 ends can be rolled as having twisted from 0 to about 200 turns per meter which can be either the direction from left to right or from right to left as supplied by the manufacturer for example the twisting of the manufacturer or how it is imparted to the wires. As known in the art, the twisted fiber can be varied, for example, to optimize resistance to hose flexing fatigue or to minimize the cost or diameter of the hose.

Even though nature or other synthetic fib fibers, such as polyesters or other polyamides such as nylons, can be substituted, an aram material generally should be considered preferred in comparison to such other fibers, since a higher loading support is involved here. and a radial or axial dimensional stability, within the hose constructions. In aspect, the aramid fibers, as marketed under the Kevlard® and Nomex® brands (of The DuPont of Nemours and Co., Wilmington, Delaware, USA), Technora® (Teijin Limited of To Japan), and Twaron® (from Akzo Nobel, Arnhe, The Netherlands), exhibited a relatively high tenacity or tensile modulus of around 190 cN tex and a relatively low stretch with elongation at break of about 3%.

To better control the elongation and contraction of the hose 10, and to impose an improved pulse life, in at least the innermost 70a, of the reinforcing layers 70 is attached to the corresponding outer radial surface 40 of the second elastomeric layer 3. Preferably such a joint will exhibit a strength of less than about 1.43 kg / cm and can be effected by solvating the elastomeric layer 32 with an appropriate solvent t such as n-Methyl pyrrolidone or with the use of urethane or another adhesive having an affinity for the materials that form chap 32 and 70.

The outermost reinforcing layer 70v at its side is sheathed within a surrounding coaxial protective cover 80. The cover 80 can be extruded crosswise or otherwise conventionally, or sheathed or braided onto the reinforcing layer 70b as a layer of reinforcement. 0.5-3.8 millimeter thick, tape or braid of a processable thermoplastic material with preferably abrasion-resistant melting such as a polyamide, polyolefin, polyester, polyvinyl chloride, or more preferably a thermoplastic polyurethane elastomer (TPU). By "abrasion resistant" it is meant that such thermoplastic material to form the cover 3 has a hardness or durometer of between about 60-95 Shore As with the core 14, the cover 80 can alternatively be formed of a natural rubber or vulcanizable synthetic such as SBR, polybutadiene, EPDM, butyl, neoprene, polyisoprene nitrile, silicone, fluorosilicone, buna-N, copolymer rubbers or mixtures such as ethylene-propylene rubber. cover 80 can be attached to the backing layer plus exter 70b either mechanically or with a urethane or other adhesive material. In a preferred embodiment, each of the hose ca 10 is attached to its subsequent layer immediately so as to provide a more efficient transfer of induced internal or external stresses.

Therefore, an illustrative sleeve construction is described which results in an efficient load transfer between the respective component layers thereof. Such a construction, which may be complete thermoplastic, rubber or a combination thereof, is particularly suited for solvent pressure transfer applications and, as a result of a unique reinforcement construction, is believed to exhibit flexibility, resist improved collapse and operating life compared to those hoses hitherto known in the art.

Even when the hose construction illustrates As described herein, the composite reinforcement of the present invention is positioned as an innermost layer around core 14, other arrangements may be provided based on the description contained herein. For example, two or more composite reinforcement layers may be provided as either innermost or intermediate layers. In particular, one or more intermediate reinforcing layers can be interposed between the core and a first composite layer and without departing from the scope of the invention involved herein.

Looking again at Figure 4, a representation of these alternate embodiments of the hose 10 of Figure 1 is generally mentioned at point 100. In a basic construction, the hose 100 is similar to that of the hose 10 with the exception that one or more fibrous reinforcement layers 70, one of which is mentioned at the point 70c s provided directly on the outermost layer 22 d core tube 14, with the first elastomeric layer 30 being provided as an intermediate covering on the outer surface 102 of the reinforcing layer 70c. It will be appreciated that hose 100 is somewhat simplified in construction the hose 10 in which the core tube 14, the reinforcing layer 70c and the layer 70 can be formed as a unit with reinforcing element 50 and a second elastomeric layer 40 which now it works as the outermost cover for hose 100 can be formed in a separate operation.

Considering finally Figures 5 and 6, ot representative alternate incorporation of the hose 10 of Figure 1 is mentioned generally at point 200. Again the hose 200 is similar in a basic construction to that of the hose 10 with the exception that the helical reinforcement element 50 is provided as a spiral wound armature cover generally mentioned with the number 20 of the type which is described in United States Patents Nos. 5,143,123; 4,862,924; 4,620.56 4,739.801; 4,396,797; 4,213,485; and 3,908,703.

In the hose construction 200, the armor cover 202 is spirally wound from an aluminum strip of steel or other metal 204, to define a series of cylindrical joints or links one of which is mentioned in item 206. As can be seen better in the cross-sectional view of Figure 6, the strip 204 is rolled as stamped, passed through a die or otherwise formed in such a manner that each of the link links 206 includes a part turned towards down defined on one edge of the strip 204 and an upturned part 210 defined on the other edge of the strip 204. A pair of upper wall 212 and lower 214 extend each or respectively from the parts turned upward and turn towards below and are joined in a later intermediate wall part 216.

The upwardly facing portion 208 of each of the joints 206 is interlocked at the point 220 with an upside down portion of an adjacent link 206 as to form a generally continuous but flexible envelope. Preferably, one or both of the lower upper wall portions. 212 and 214 are formed as having one or openings, one of which is mentioned at point 22. As can be seen again in the cross-sectional view of Figure 6, a gap area 224 is defined by ac one of the openings 222 With the strip 204 being wound spirally over the first elastomeric member 30, the first outer radial surface 38 thereof will be substantially deformed or otherwise extended in the interstice areas 224. Similarly, with the second elastomeric layer 32 being extruded or otherwise formed on strip 204, second radial inner surface 36 of layer 32 may be made to flow or otherwise extend to within the interstitial areas 224 to define an interface, mentioned phantom at point 230, with the first external radi surface 38 of the first elastomeric layer 30. In this case each of the articulations 206 of the cover 202 encapsulated between the layers 30 and 32 to form a reinforcement structure resistant to integral collapse.

It is anticipated that various changes can be made to the present invention without departing from the precepts involved, it is intended that all the subject matter contained in the foregoing description be interpreted as illustrative and not co in a limiting sense. All references cited herein are expressly incorporated by reference.

Claims (25)

R E I V I N D I C A C I O N S

1. A hose resistant to collapse and flexi adapted to carry fluids under pressure, said hose extends in a direction along a central longitudinal axis to an indefinite length, and in a radially circumferential direction around said axis length said hose comprises: a first tubular elastomeric layer, said first elastomeric layer having a first interior radi surface, and a first exterior radial surface; a helical reinforcing element winds spirally over the first elastomeric layer at a predetermined inclination angle measured in relation to said longitudinal e; a second tubular elastomeric layer that rolls said helical reinforcing element, said second elastomeric ca has a second inner radial surface and a second outer radial surface; Y a tubular core having an inner radial core surface that defines the inner diameter of the hose and an outer radial core surface, said core being surrounded by said first elastomeric layer with the first radial inner surface thereof being attached to the radial core surface exterior, said hose are characterized because: said helical reinforcement element is of metal and is encapsulated between the first outer radial surface said first elastomeric layer and the second inner radi surface of said second elastomeric layer.

2. The hose as claimed in clause 1, characterized in that said helical reinforcement element is wound in a spiral to define a series of turns each one being spaced and separated from an adjacent one said turns to define an interstice area between them, said first outer radial surface of said first elastomeric layer extends into said interstice area, and said second surface given to the interior of said second elastomeric layer extends into said interstice area and being joined thereto said first outer radi surface of said first elastomeric layer to encapsulate ca one of said turns of said helical reinforcement element

3. The hose as claimed in clause 1, characterized in that said core is formed of thermoplastic material selected from the group consisting of polyamides, polyolefins, fluoropolymers, polyvinyl chloride polyurethanes, and copolymers and mixtures thereof.

4. The hose as claimed in clause 1, characterized in that said core is a composite which comprises at least one innermost layer which defi the inner radial core surface, and one outermost layer which defines the radial core surface Exterior.

5. The hose as claimed in clause 4, characterized in that said innermost layer is formed of a polymeric material which is resistant to solvents, and wherein said outermost layer is formed of flexible polymeric material.

6. The hose as claimed in clause 5, characterized in that said polymeric material which is resistant to solvents comprises a fluoropolymer wherein said flexible polymeric material is selected from the group consisting of polyamides, polyolefins, polyvinyl chlorides, polyurethanes, and copolymers and mixtures of the same

7. The hose as claimed in clause 6, characterized in that said core furthermore comprises an intermediate layer interposed between said outermost and more outer layers and joining said innermost layer to said outer layer m.

8. The hose as claimed in clause 7, characterized in that said intermediate layer is formed of a polymeric material selected from the group consisting of polyvinylidene fluorides, polyvinyl fluoride acetates, polyurethanes, and copolymers and mixtures thereof.

9. The hose as claimed in clause 2, characterized in that said helical reinforcement element is wound from one or more ends of a monofilament wire.

10. The hose as claimed in clause 9, characterized in that said wire is formed of steel material having a tensile strength of about 50,000-300,000 pounds per square inch (345 2, 100 MPa).

11. The hose as claimed in clause 9, characterized in that said wire has a generally circular, elliptical or polygonal cross-sectional geometry with a diameter between 0.5-10 millimeters.

12. The hose as claimed in clause 1, characterized in that the angle of inclination (?) Of between about 40-85 ° and where each of dich turns is spaced apart from said adjacent turn p between about 0.25- 9 centimeters

13. The hose as claimed in clause 7, characterized in that it also comprises one or more fibrous reinforcement cap surrounding said second elastomeric layer at least one innermost of said fibrous reinforcement layers being attached to the second outer radial surface of said fibrous reinforcement layer. second elastomeric layer.

14. The hose as claimed in clause 13, characterized in that each of said fibrous reinforcement layers is wound or spirally wound from one or more monofilament or multiple filament yarns of material selected from the group consisting of nylon polyesters, aramides, polyphenylene bezobisoxazoles, metal wires and combinations thereof.

15. The hose as claimed in clause 13, characterized in that the second outer surface of said second elastomeric layer is generally smooth.

16. The hose as claimed in clause 1, characterized in that it comprises a cover that ro an outermost of said fibrous reinforcement layers.

17. The hose as claimed in clause 16, characterized in that said cover is formed of a material selected from the group consisting of polyurethane polyamides, polyolefins, silicones, polyvinyl polyurethanes chlorides, natural and synthetic rubbers, and mixed copolymers thereof.

18. The hose as claimed in clause 17, characterized in that the material forming said cover has a hardness of between about 60-95 Durometer Shore A.

19. The hose as claimed in clause 1, characterized in that the first interior radi surface of said first elastomeric layer is fused to the outer core radial surface.

20. The hose as claimed in clause 2, characterized in that the second interior radi surface of said second elastomeric layer is fused to the first outer radial layer of said first elastomeric ca.

21. The hose as claimed in clause 1, characterized in that said first and second elastomeric layers are each formed of a selected elastomeric material, independently of the group consisting of natural and synthetic rubbers.

22. The hose as claimed in clause 21, characterized in that said first and second elastomeric layers are each formed of said same elastomeric mater.

23. The hose as claimed in clause 1, characterized in that it also comprises one or more fibrous reinforcement layers interposed between said core and the first elastomeric layer.

24. The hose as claimed in clause 1, characterized in that said helical reinforcement element is wound to define a series of links each of said links being interlocked with adjacent said links.

25. The hose as claimed in clause 24, characterized by each said core has at least one opening formed therethrough to define an interstice area, said first outer surface of said first elastomeric layer extending beyond said interstice area, and said second inner rad surface of said second elastomeric layer extends beyond said interstice area and is joined thereto to said outer radial outer surface to encapsulate each of said links of said helical reinforcement element. E U M E N A flexible hose construction adapted to carry fluids under internal pressures relatively to and capable of withstanding relatively high external pressures to collapse. The construction includes a first tubular elastomeric c having a first inner rad surface and a first outer radial surface, and a second tubular elastomeric layer having a second inner rad surface and a second outer radial surface. A helical reinforcing element is spirally wound on the elastomeric first layer as interposed between that layer and the elastomeric follow layer. The element is wound at a predetermined inclination angle to define a series of turns c a being spaced apart from an adjacent turn p define an interstice area therebetween. The first and second elastomeric members each extend in the interstitial area with the first outer radial surface first elastomeric member being joined to the second inner radial surface of the second elastomeric member so that the spiral reinforcement member is encapsulated therebetween.