WO2024089655A1

WO2024089655A1 - Flexible hose with low environmental impact and high aesthetic appeal

Info

Publication number: WO2024089655A1
Application number: PCT/IB2023/060842
Authority: WO
Inventors: Luca Battaglia; Gianfranco Battaglin
Original assignee: Fitt S.P.A.
Priority date: 2022-10-28
Filing date: 2023-10-27
Publication date: 2024-05-02

Abstract

A flexible hose for transporting fluids, in particular liquids, comprising: an exposed outer layer (20) consisting of a first low environmental impact thermoplastic elastomer and of at least one second polymeric material compatible with said first low environmental impact thermoplastic elastomer; and at least one inner layer (10) consisting of a third low environmental impact thermoplastic elastomer and possibly of at least one second virgin polymeric material compatible with said first low environmental impact thermoplastic elastomer. The at least one second polymeric material is present in the exposed outer layer (20) in a weight percentage comprised in the range from 5% by weight to 45% by weight.

Description

FLEXIBLE HOSE WITH LOW ENVIRONMENTAL IMPACT AND HIGH AESTHETIC APPEAL DESCRIPTION

Field of the invention

The present invention relates to the technical field of flexible hoses, and in particular it relates to a flexible hose with low environmental impact and high aesthetic appeal.

Definitions

In the present document, the expression "post-consumer material" and the derivatives thereof is used to indicate a recycled material, that is reprocessed from recovered material, according to the UNI EN ISO 14021 and UNI EN 15343 standards and possible updates of such standards subsequent to the date of filing of the present document, whose recycling is subject to traceability according to the standards in question.

In the present document, the expression "percentage of post-consumer material" and the derivatives thereof present in a compound or product, is used to indicate the ratio expressed in % between the mass of the recycled post-consumer component or material present in the compound or product and the total of the mass of the compound or product, according to the UNI EN ISO 14021 and UNI EN 15343 standards and possible updates of such standards subsequent to the date of filing of the present document, according to the following formula:

(I) Percentage of post-consumer material (%) = — x 100 %

P where:

- A is the mass of the component/s or of the post-consumer material;

- P is the mass of the compound or product.

In the present document, the expression "at least partially post-consumer" and derivatives relating to a material, is used to indicate the fact that the latter is a material with an amount of postconsumer material equal to at least 90% of the weight thereof.

In the present document, the expression "compatible materials" or its derivatives is used to indicate materials which have mutual chemical and/or physical compatibility, that is materials which, once coupled, give rise to a joint suitable to withstand the transfer of tensile or shear forces through the contact surface. Thus, the maximum compatibility will be observed in identical materials or materials having matrices of the same base.

In the present document, the expression "virgin" and the derivatives thereof relating to a component is used to indicate that the latter has not been subjected to any recycling or regeneration process.

In the present document, the expression "mineral oil" and the derivatives thereof is used to indicate an oil produced starting from petroleum or derived from chemical synthesis, that is a paraffinic oil.

In the present document, the expression "% by weight" relating to one or more components in a composition of interest is used to indicate the percentage of the dry weight of such one or more components with respect to the total dry weight of the composition.

In the present document, the term "matrix" and the derivatives thereof is used to indicate a polymeric material suitable to provide the molecular structure of the finished product.

In the present document, the expression "polymeric material" or the derivatives thereof is used to indicate both the single polymer and a mixture of polymers, for example a blend or a compound.

In the present document, the term "plasticising agent" and the derivatives thereof is used to indicate a compound or a mixture of compounds which can increase the flexibility, processability and extension of the polymer in which it is incorporated. A plasticising agent may reduce the viscosity of the mixture, lower the phase transition temperatures of the second order, and the elastic modulus of the product.

In the present document, the expression "additive" and the derivatives thereof is used to indicate a substance which, when added to a compound, improves one or more characteristics thereof.

In the present document, the term "stabilising agent" and the derivatives thereof is used to indicate a compound or a mixture of compounds which can intercept small molecules resulting from the degradation of the polymer, to form a more stable intermediate compound.

In the present document, the expression "antioxidant agent" and the derivatives thereof is used to indicate a compound or a mixture of compounds capable of inhibiting thermo-oxidative and photo- oxidative reactions by reducing and/or hindering, for example, the formation of radical reactions and free radicals.

In the present document, the expression "filler" and the derivatives thereof is used to indicate solid materials made of particles or fibrous materials, substantially chemically inert, with the function of fillers.

In the present document, the expression "bulking agent" and the derivatives thereof is used to indicate a compound or a mixture of compounds embedded in a polymer to improve the performance thereof relating, for example, to resistance and elasticity.

In the present document, the expression "textile reinforcement layer" or "reinforcement layer" or the derivatives thereof is used to indicate a layer consisting of at least one textile yarn arranged on the underlying layer. The "reinforcement layer" is arranged on the load-bearing layer so as to leave portions thereof - generally square, rectangular or rhomboidal-shaped - vacant.

In the present document, the expression "cross-hatched textile layer" or "cross-hatched layer" or "cross-hatching" or the derivatives thereof is used to indicate a layer consisting of at least two yarns or groups of yarns spiral-wound on the load-bearing layer with opposite inclinations and mutually superimposed but not connected. Therefore, a cross-hatching consists of two or more superimposed spirallings.

In the present document, the expression " knitted textile layer" or "knitted layer" or "knitting" or the derivatives thereof is used to indicate a layer consisting of at least two yarns or groups of yarns deposited on the load-bearing layer and connected together to form a plurality of chain stitches, known as "tricot" type stitches.

State of the Art

Manufacturing flexible hoses starting from virgin thermoplastic elastomers plasticised with mineral oil, is for example disclosed by documents US2020/147920, US10495434 or JP2020/023127.

Such hoses are relatively expensive and with high hardness, and they have a relatively high environmental impact.

In order to limit the environmental impact of the hose, the use of thermoplastic elastomers, for example TPE-s or TPV, to manufacture reinforced or spiralled flexible hoses, in which the thermoplastic part of the polymer matrix is recycled, is known. For example, the polypropylene contained in such matrix is a post-consumer material and it is therefore present both in the thermoplastic elastomer and in the hose made starting from the latter.

However, the percentage of post-consumer material present in the hose is extremely limited, due to the low presence of polypropylene.

This results in an environmental impact that is still significant, linked both to the production chain of the hose and to the disposal thereof.

A further disadvantage of using such thermoplastic elastomers with thermoplastic part made of post-consumer material lies in the colour, which is tendentially black or dark in any case. Therefore, the aesthetic appeal of the hose is rather low, same case applying to the possibility of customising it by the manufacturers.

Summary of the invention

The object of the present invention is to overcome the drawbacks outlined above by providing a flexible hose that is highly effective and relatively cost-effective.

A further object of the present invention is to provide a low environmental impact flexible hose.

A further object of the present invention is to provide a flexible hose having high aesthetic appeal, acceptable by the market.

A further object of the present invention is to provide a low environmental impact and high aesthetic appeal flexible hose with mechanical and quality properties comparable to a flexible hose according to the state of the art.

A further object of the present invention is to provide a flexible hose with relatively low manufacturing and/or disposal costs.

These and other objects which will be more apparent hereinafter, are attained by a flexible hose according to claim 1.

In a further aspect of the invention, there may be provided for the use of thermoplastic elastomers selected for manufacturing a flexible hose according to claim 13. The dependent claims define advantageous embodiments of the present invention.

Brief description of the drawings

Further characteristics and advantages of the invention will be more apparent in the light of the detailed description of some preferred but non-exclusive embodiments thereof, shown by way of nonlimiting example with reference to the attached drawings, wherein:

FIG. 1 is a front schematic view of a preferred but not exclusive embodiment of a flexible hose 1;

FIG. 2 is a front schematic view of a further preferred but not exclusive embodiment of a flexible hose 1;

FIG. 3 is a front schematic view of a further preferred but not exclusive embodiment of a flexible hose 1;

FIG. 4 is a front schematic view of a further preferred but not exclusive embodiment of a flexible hose 1.

Detailed description of some preferred embodiments

With reference to figure mentioned above, the flexible hose 1 may be useful for transporting any fluid, in particular any liquid. In particular, the flexible hose 1 may be a reinforced or non-reinforced irrigation hose or garden hose for transporting water, which may be drinkable or non-drinkable.

Suitably, the flexible hose 1 may comprise an exposed outer layer 20, designed to be grasped by a user, an inner layer 10 and a reinforcement layer 30.

Although described hereinafter is a flexible hose with the structure mentioned above, it is clear that the inner layers 10 may be more than one without departing from the scope of protection of the attached claims. In the event of several layers inside the exposed outer layer 20, the inner layers may be in any position, for example inside the load-bearing inner layer 10, for example as shown in FIGS. 3 and 4, or interposed between the inner 10 and outer 20 layers, without particular restrictions.

On the other hand, the hose may be without reinforcement layer 30 or it may include one or more without departing from the scope of protection of the attached claims.

The reinforcement layer 30 may be made with textile yarns which, in a per se known manner, may be made knitted, cross-hatched and/or spiralled.

Suitably, the reinforcement layer 30 may be made of a virgin or post-consumer polymer, selected from: PET, PP, polyamide, PE, P A, PLA, aramid fibres, polyurethane.

For example, a textile reinforcement layer 30 made of post-consumer polyester may have the following characteristics:

- linear density: 1012 - 1237 dtex according to the BISFA standard;

- tensile strength: 76 - 93 N according to the BISFA standard;

- mean tenacity: 68 - 83 cN/tex according to the BISFA standard;

- elongation at a specific force (45 N): 4 - 5 % according to the BISFA standard;

- elongation at break: 10 - 12% according to the BISFA standard; - hot air shrinkage (180°C, for 2 minutes, 0.5 CN/tex): 7 - 9% according to the ASTM D4974 standard.

The exposed outer layer 20 may include or consist of one or more base portions 21 made of a first polymeric material and one or more ornamental portions 22 made of a second polymeric material compatible with the first. Suitably, both the first and the second polymeric material may be thermoplastic elastomers.

The one or more ornamental portions 22 may for example be bands and/or strips having a colour different from that of the one or more base portions 21, transparent or translucent bands and/or strips so as to allow a user to see the reinforcement layer 30 and possibly the inner one 10, smooth, satinated or expanded bands and/or strips or tactile effects in relief .

For example, FIG. 1 shows an example of a flexible hose 1 wherein the exposed layer 20 includes four ornamental portions 22, three upper strips 22', 22" which have a different colour with respect to the base portions 21 and a lower translucent strip 22"', which allows to see the underlying reinforcement layer 30.

The one or more ornamental portions 22 may be made of a thermoplastic elastomer substantially without thermoplastic part made of post-consumer material, so as to allow an effective colouring thereof using an appropriate dyeing agent.

By way of example, the thermoplastic elastomer of the one or more ornamental portions 22 may contain less than 2% by weight of thermoplastic part made of post-consumer material with respect to the total weight thereof.

Advantageously, the thermoplastic elastomer of the one or more ornamental portions 22 may include a plasticising agent made of virgin, post-industrial or post-consumer material.

Suitably, the thermoplastic elastomer of the one or more ornamental portions 22 may have a Shore A hardness comprised between 50 ShA and 85 ShA.

For example, the thermoplastic elastomer of the one or more ornamental portions 22 may be NILFLEX® SHR A72 E220 AU 03R 577 and/or NILFLEX® SHR A72 E220 AU 03R 539, marketed by Taro Plast SpA, which differ only in terms of colour and with which there for example may be obtained the two upper strips 22', 22" of FIG. 1 which are respectively beige and turquoise.

Such thermoplastic elastomer may have a Shore A hardness measured in accordance with the ASTM D2240 - 3s di 72 ShA standards.

On the other hand, the translucent strip 22'" may be obtained with a NILFLEX® SH A72 E030 AU 01R 540, marketed by Taro Plast SpA, having the same hardness mentioned above.

On the other hand, the one or more base portions 21 may be made of a low environmental impact thermoplastic elastomer, which may preferably consist of:

(A) from 30% by weight to 80% by weight of a polymer matrix consisting of a thermoplastic part (Al) and an elastomeric part (A2), present in the thermoplastic elastomer in a by weight percentage respectively from 10% by weight to 35% by weight and from 20% by weight to 45% by weight;

(B) from 30% by weight to 55% by weight of at least one plasticising agent;

(C) from 0% to 30% by weight of at least one filler;

(D) from 0% to 10% by weight of at least one additive.

The total sum of the % by weight of the components from (A) to (D) is 100%.

It should be observed that the % by weight are calculated with respect to the total weight of the thermoplastic elastomer.

In the exposed outer layer 20, the virgin polymeric material of the one or more ornamental portions 22 may be present in a weight percentage comprised in the range from 5% by weight to 55% by weight with respect to the total weight of the exposed outer layer 20, preferably in a weight percentage comprised in the range from 10% by weight to 45% by weight with respect to the total weight of the exposed outer layer 20, and even more preferably in a weight percentage comprised in the range from 15% by weight to 40% by weight with respect to the total weight of the exposed outer layer 20.

The load-bearing inner layer 10 may be made of a further low environmental impact thermoplastic elastomer, which may have the same composition as that of one or more base portions 21.

Preferably, the low environmental impact thermoplastic elastomer of the load-bearing inner layer 10 and of the one or more base portions 21 may be compatible to each other and more preferably be made of the same material.

However, the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may be made of different materials, preferably compatible. In this case, each of the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may have a respective matrix (A) with a respective thermoplastic part (Al) and a respective elastomeric part (A2), a respective at least one plasticising agent (B), a respective at least one filler (C), a respective at least one additive (D), according to the composition mentioned above.

Possibly, one or more components may be the same, for example the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may have the same thermoplastic part (Al) and/or the same at least one plasticising agent (B).

Possibly, the load-bearing inner layer 10 may consist of the respective low environmental impact thermoplastic elastomer and at least one further load-bearing inner layer and by at least one further polymeric material compatible therewith.

In this case, the load-bearing inner layer 10 may have a weight percentage of at least 80% by weight with respect to the total weight thereof, of low environmental impact thermoplastic elastomer, preferably 90% by weight with respect to the total weight thereof of low environmental impact thermoplastic elastomer, even more preferably at least 95% by weight with respect to the total weight thereof of low environmental impact thermoplastic elastomer. For example, as illustrated in FIGS. 2 and 4, the load-bearing layer 10 may have a portion 11 made of low environmental impact thermoplastic elastomer and one or more portions 12 made of a further elastomeric material, which for example may be the same as the translucent ornamental portion 22"'. This allows to create a "window" in the hose to allow a user to see the water which flows through the hose.

It is clear that the material of the one or more portions 12 may vary, provided that it is compatible with that of the portion 11. For example, similarly to the description outlined above for the one or more ornamental portions 22, the one or more portions 12 may be made of a thermoplastic elastomer substantially without the thermoplastic part made of post-consumer material.

By way of example, the thermoplastic elastomer of the one or more portions 12 may contain less than 2% by weight of thermoplastic part made of post-consumer material with respect to the total weight thereof.

The thermoplastic agent of the one or more portions 12, same case applying to that of the one or more ornamental portions 22, may be partially or fully made of post-consumer material.

The low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may have Shore A hardness measured according to the UNI EN ISO 868 standard comprised between 50 Sh A and 85 Sh A, and preferably comprised between 65 Sh A and 75 Sh A.

Advantageously, with the aim of minimising the environmental impact, the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 and possibly the thermoplastic elastomer of the one or more ornamental portions 22 may have a high percentage of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards by weight with respect to the respective.

To this end, the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 and possibly the thermoplastic elastomer of the one or more ornamental portions 22 may include one or more components of the post-consumer components (A) - (D) mentioned above.

For example, the plasticising agent (B) may define the whole of the post-consumer material present in the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and f the one or more base portions 21, while both the thermoplastic part (Al) and the elastomeric part (A2) of the polymer matrix (A) may be virgin material.

In a further example, the post-consumer material present in the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may be defined by the plasticising agent (B) and by the thermoplastic part (Al).

Furthermore, as mentioned above, the thermoplastic elastomer of the one or more ornamental portions 22 may include at least one part of the plasticising agent made of post-consumer material. The percentage by weight in peso of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards present in the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 and possibly the thermoplastic elastomer of the one or more ornamental portions 22 with respect to the respective total weight may be such that the flexible hose 1 has a percentage by weight of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 40% by weight with respect to the total weight of the flexible hose 1, preferably greater than or equal to 45% by weight with respect to the total of the flexible hose 1.

In some preferred but non-exclusive embodiments, the percentage of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards may be close to 50% by weight with respect to the total weight of the flexible hose 1.

Generally, in order to meet the conditions mentioned above to have the flexible hose 1 with a percentage of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 40% by weight with respect to the total weight thereof, there arises the need for to provide formulations of the thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 with a high percentage of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards preferably in the thermoplastic part (Al) and/or in the plasticiser (B). Preferably, the elastomeric part (A2) may be of virgin material.

Advantageously, to this end each of the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may has a percentage of postconsumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 50% by weight calculated with respect to the respective total weight.

Furthermore, suitably, the low environmental impact thermoplastic elastomers of the loadbearing inner layer 10 and of the one or more base portions 21 may be present in the flexible hose 1 in an amount greater than or equal to 80% by weight with respect to the total weight thereof, preferably in an amount greater than or equal to 85% by weight with respect to the total weight thereof, even more preferably in an amount greater than or equal to 90% by weight with respect to the total weight thereof.

In particular, given that it does not perform an ornamental function, the load-bearing inner layer 10 may be almost wholly made of post-consumer material.

Therefore, the load-bearing inner layer 10 may consist of at least 90% by weight with respect to the total weight thereof of the respective low environmental impact thermoplastic elastomer, preferably of at least 95% by weight with respect to the total weight thereof. Preferably, the inner layer 10 may be wholly made of low environmental impact thermoplastic elastomer.

On the other hand, in order to perform their ornamental function, the portions 22 may be made of a thermoplastic elastomer substantially without the thermoplastic part made of post-consumer material or made of virgin material. This guarantees an effective colouring of the thermoplastic elastomer of the one or more ornamental portions 22.

In order to obtain the relatively high hardness mentioned above in the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21, in the order of 50 - 85 Sh A, there further arises the need to balance the thermoplastic part (Al), the elastomeric part (A2) and the plasticising agent (B).

As known, as a matter of fact, the elastomeric part (A2) and the plasticising agent (B) confer opposite mechanical qualities to the thermoplastic elastomer, given that the elastomeric part (A2) tends to increase the hardness thereof, as opposed to the plasticising agent (B). Furthermore, in order to obtain a percentage of post-consumer material greater than or equal to 50% by weight in the thermoplastic elastomer, there arises the need to limit the presence of the elastomeric part (A2), in favour of the plasticising agent (B) content.

Therefore, should the thermoplastic elastomer of the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 elastomer contain a significant amount of plasticising agent (B) in order to obtain a percentage of post-consumer material greater than or equal to 50% by weight, but at the same time should there be an insufficient amount of elastomeric part (A2) to obtain hardness in the order of 50 - 85 Sh A, the presence of an appropriate amount of a filler (C) may be considered.

The above will allow to obtain a flexible hose 1 having good mechanical characteristics, and in particular an appropriate Shore A hardness, a minimum environmental impact, given by the high percentage of post-consumer material present in the base portions 21 and in the inner layer 10, and a good aesthetic appeal, given by the ornamental portions 22.

By way of example, reported below is a first formulation of low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 relating to a TPE-s, whose percentages by weight of the components allow to obtain a percentage of postconsumer material greater than or equal to 50% by weight of the thermoplastic elastomer and hardness in the order of 50 - 85 Sh A, balancing the thermoplastic part (Al), the elastomeric part (A2), the plasticising agent (B) and the filler (C).

In this first non-limiting example, the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may have the following composition:

(Al) from 15% by weight to 25% by weight of a thermoplastic part;

(A2) from 25% by weight to 35% by weight of an elastomeric part;

(B) from 30% by weight to 40% by weight of at least one plasticising agent;

(C) from 10% to 30% by weight of at least one filler;

(D) from 0% to 5% by weight of at least one additive; wherein the thermoplastic part (Al) and the elastomeric part (A2) form the polymer matrix (A) and wherein the % by weight are calculated with respect to the total weight of the thermoplastic elastomer.

A second formulation, relating to a TPE-s, whose percentages by weight of the components allow to obtain a percentage of post-consumer material greater than or equal to 50% by weight of the thermoplastic elastomer and hardness in the order of 50 - 85 Sh A, balancing the thermoplastic part (Al), the elastomeric part (A2) and the plasticising agent (B).

In this further non-limiting example, the low environmental impact thermoplastic elastomers of the load-bearing inner layer 10 and of the one or more base portions 21 may have the following composition:

(Al) from 15% by weight to 25% by weight of a thermoplastic part;

(A2) from 30% by weight to 40% by weight of an elastomeric part;

(B) from 40% by weight to 50% by weight of at least one plasticising agent;

(C) from 0% to 15% by weight of at least one filler;

According to a third preferred but not exclusively formulation, relating to a TPV, the percentages by weight of the components allow to obtain a percentage of post-consumer material greater than or equal to 50% by weight of the thermoplastic elastomer and hardness in the order of 50 - 85 Sh A, balancing the thermoplastic part (Al), the elastomeric part (A2) and the plasticising agent.

(Al) from 15% by weight to 30% by weight of a thermoplastic part;

(A2) from 30% by weight to 40% by weight of an elastomeric part;

(B) from 30% by weight to 40% by weight of at least one plasticising agent;

(C) from 0% to 25% by weight of at least one filler;

In the formulations mentioned above, the thermoplastic part (Al) may be polypropylene or polyethylene at least partially post-consumer, that is at least for 90% by weight on the total of thermoplastic part (Al) as described above.

For example, post-consumer polypropylene may have the following characteristics:

- specific weight: 0.90 - 0.935 g / cm 3 according to the ASTM D792 standard; - Melt Flow at 230°C /2.16kg: 8 - 12 g / 10 min according to the ASTM D1238 standard;

- extension: 8% - 12% according to the D638 standard;

- flexural modulus: 130,000 - 190,000 psi according to the D790 standard.

Preferably, the elastomeric part (A2) may be mainly a SEBS, SBS, SEPS, SEEPS, SIPS, SIS, EPDM elastomer, butene or linear alpha olefins.

The thermoplastic elastomer may be:

- TPE-S in which the thermoplastic part (Al) is polypropylene or polyethylene and the elastomeric part (A2) is a SEBS, SBS, SEPS, SEEPS, SIPS, SIS rubber;

- TPV wherein the thermoplastic part (Al) is polypropylene and the elastomeric part (A2) is an EPDM rubber;

- TPE-O, POE or POP wherein the thermoplastic part (Al) is polypropylene or polyethylene and the elastomeric part (A2) is butene or linear alpha olefin or a polypropylene elastomer produced through metallocene catalysis.

In greater detail, the thermoplastic elastomer may be a TPE-S such as for example Nilflex SHR® marketed by Taro Plast SpA.

Even more in detail, the thermoplastic part (Al) may be SJP615 100% Post-Consumer Polypropylene marketed by St. Joseph Plastics, whereas the elastomeric part (A2) may be for example Vistaion 3702 marketed by Exxonmobil Corporation, or KRATON G 1651 marketed by Kraton Corporation.

Suitably, the plasticising agent (B) may be a mineral, synthetic and/or vegetable oil.

Preferably, the plasticising agent (B) may be a mineral oil at least partially post-consumer, that is, as specified above, for at least 90% by weight on the total of plasticising agent (B).

For example, there may be provided for the use of 90% by weight of the total plasticising agent (B) of post-consumer mineral oil and 10% by weight on the total plasticising agent (B) of virgin mineral and/or synthetic and/or vegetable oil.

Preferably, the post-consumer mineral oil may be obtained by means of a per se known regeneration process.

Among the regeneration processes, the following techniques may be provided for: acid clay rerefining, sulfuric acid-activated clay technologies, vacuum distillation, evaporation, technologies based on hydrogenation, ultrafiltration, extraction-based technologies.

In particular, according to a preferred but not exclusive example, the post-consumer mineral oil may have the following characteristics:

- density at 15°C according to the ASTM D 4052 standard equal to 0.86 - 0.88 Kg/L;

- viscosity at 40°C according to the ASTM D 445 standard equal to 30 - 34 mm²/s;

- viscosity at 100°C according to the ASTM D 445 standard equal to 5.2 - 5.3 mm²/s;

- viscosity index according to the ASTM D 2270 equal to 95 - 110.

- polycyclic aromatic content according to the IP 346 standard less than or equal to 3% by weight. Preferably, the mineral oil may be obtained by means of hydrogenation.

For example, the oil could be ORV 150 marketed by Bergoil.

Fillers (C) or additives (D) such as for example stabilising agents, antioxidant agents, dyeing agents may be considered.

More particularly, among additives (D) for example there may be considered external and/or internal lubricants, heat stabilizers, UV stabilisers, pigments, antioxidants, antimicrobials, release agents, fungicides, antibacterial agents, process adjuvants, anti-static agents.

Some types of stabilising agents may be for example of the antioxidant type.

For example, Irganox® B 225 marketed by BASF, or Irganox® 1076 and Irgafos® 168 marketed by Ciba, or peroxides such as Trigonox® 101-40D, Trigonox® 145-45B, Perkadox® 14-40B, or cross-linking agents such as Triallylcyanurate (TAC) marketed by Akzo Nobel Polymer Chemicals B.V. may be used.

Advantageously, the dyeing agent may be selected from natural food colorants.

Furthermore, any type of per se known filler (C) may be used, for example bulking agents such as calcium carbonate, talc, kaolin, mica, feldspar, wollastonite, natural silica, ceramic or glass microbeads, fibres.

If present, the bulking agent may be present in an amount less than 30% by weight so as to keep the obtained hose light and easy to handle.

In a per se known manner, the flexible hose 1 may be obtained by extruding various thermoplastic elastomers mentioned above so as to obtain the inner and outer layers 10 and 20, with the possible interposition of the reinforcement layer 30 which may be obtained in a per se known manner for example with a knitting machine, cross-hatching machine or spiralling machine.

In particular, the layers 10 and 20 may be extruded by means of a single-screw or twin-screw extruder per se known, with a specific particularly compact extrusion head with length equal to about 100 - 110 mm and an outlet neck with length equal to 35 - 40 mm.

Therefore, a high compression may be imparted into the exiting molten material, making it homogeneous, without breakage, with a significant dimensional stability.

As a result, the potential difficulties present during the extrusion of the thermoplastic elastomer due to the presence of post-consumer materials which may lead to a greater fluidity thereof, may be overcome with such solution.

In a preferred but non-exclusive embodiment, for example as shown in FIGS. 3 and 4, inside the load-bearing layer 10 there may be provided for film 40 in contact with the fluid to be transported.

Such film 40 may be made of any material and have any function. For example, the film 40 may be made of a food grade material suitable for contact with drinking water.

Possibly, the film 40 may be made of the same material as the ornamental portion 22"' and possibly also of the portion 12. In the latter case, a user may see the fluid which flows in the fluid.

The invention will be described in greater detail with reference to the following examples which, in any case, shall not be deemed to limit the scope of protection of the invention.

Examples

Samples 1 - 6

With reference to the structure of the hose in FIG. 1, there were prepared various samples of the flexible hose 1 using the following materials:

- base portions 21 and inner layer 10: NILFLEX® SHR A72 E220 AU 01R 00 NAT;

- coloured strips 22': NILFLEX® SHR A72 E220 AU 03R 539 AZURE;

- coloured strip 22": NILFLEX® SHR A72 E220 AU 03R 577 BEIGE;

- translucent strip 22"': NILFLEX® SH A72 E030 AU 01R 540 FUME;

- reinforcement layer 30: PET GLE 1100 DTEX 192 HT10

All the materials mentioned above, except for the reinforcement layer 30, are marketed by Taro Plast SpA. The reinforcement layer 30 is marketed by Brilen Tech S.A.

NILFLEX® SHR A72 E220 AU 01R 00 NAT contains a thermoplastic part and a plasticising agent made of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards (hereinafter also referred to as PCR) in an amount such that 54% by weight of such material is PCR.

The NILFLEX® SHR A72 E220 AU 03R 539 AZURE and NILFLEX® SHR A72 E220 AU 03R 577 BEIGE materials each contain 35% by weight of plasticising agent in the form of post-consumer oil according to the UNI EN ISO 14021 and UNI EN 15343 standards, while the thermoplastic and elastomeric part is made of 100% virgin material.

The NILFLEX® SH A72 E030 AU 01R 540 FUME material is 100% virgin.

All the thermoplastic elastomers mentioned above have a 72 Sh A Shore A hardness, measured according to the UNI EN ISO 868 standard.

The hose samples, all measuring the same length, were prepared in a per se known manner by extruding plastic materials and knitting the reinforcement layer.

With such materials there were prepared 6 flexible hose samples, each having the following composition.

Sample 1

Sample 2

Sample 3

Sample 4

Sample 5

Sample 6

The samples 1 - 6 of the flexible hose 1 mentioned above have the following characteristics.

Table 1

Therefore, as clear, all samples 1 - 6 fall within the scope of protection of the present invention. Furthermore, thanks to the high presence of post-consumer material in the various materials, some samples (2 and 6) have an overall amount of PCR close to 50%.

Then, with reference the structure of the hose in FIG. 2, there was calculated the % by weight of PCR in the flexible hose 1 should he inner layer 10 have a portion 11 consisting of 80% by weight or 90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT, the portion 12 respectively further consisting of 20% by weight or 10% by weight of virgin material, for example NILFLEX® SH A72 E030 AU 01R 540 FUME to be placed at the lower strip 22"' to create a "window" in the hose which allows see the water flowing in the hose.

Table 2

Therefore, as clear, when the portion 11 contains 90% of high environmental impact material, all the samples 1 - 6 fall within the scope of protection of the present invention, while when the portion 11 contains only 80% of high environmental impact material, the sample 3 barely falls within the scope of protection of the present invention, while the sample 5 does not fall within the scope of protection of the present invention.

Samples 7 - 12

Still with reference to the structure of the hose in FIG. 1, there were prepared hose samples similar to those of the previous paragraph, with the same compositions as in the previous tables "Sample 1" - "Sample 6", but in which it is also presumed that the NILFLEX® SHR A72 E220 AU 03R 539 AZURE and NILFLEX® SHR A72 E220 AU 03R 577 BEIGE materials contain 100% virgin materials.

In this case, there obviously only changes the amount of PCR in the flexible hose, which will obviously be lesser than samples 1 - 6. Therefore, the characteristics of the samples will be:

Table 3

However, also in this case, all samples 7 - 12 fall within the scope of protection of the present invention.

Similarly to the procedure applied for samples 1 - 6, with reference to the structure of the hose of FIG. 2, there was calculated the % by weight of PCR in the flexible hose 1 of samples 7 - 12 should the inner layer 10 consist of a portion 11 consisting of 80% by weight or 90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT, and a portion 12 made of virgin material, for example NILFLEX® SH A72 E030 AU 01R 540 FUME to be placed at the lower strip 22"' to create a "window" in the hose which allows see the water flowing in the hose.

Table 4

As clear, in the former case (80% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) samples 1, 3 and 5 and in the latter case (90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) sample 5 do not fall within the scope of protection of the present invention, essentially due to the high amount of virgin polymer in the hose.

Samples 13 - 18

With reference to the structure of the hose shown in FIG. 3, there were prepared hose samples similar to those of samples 1 - 6, but in which beneath the layer 10 there is a film 40 made of NILFLEX® SHR A72 E030 AU 01R 540 FUME 100% virgin material in contact with the liquid to be transported, which represents 10% by weight with respect to the sum of the weights of the layers underlying the outer layer 20, that is layers 10 and 40. Also in this case, the NILFLEX® SHR A72 E220 AU 03R 539 AZURE and NILFLEX® SHR A72 E220 AU 03R 577 BEIGE materials contain each 35% by weight of plasticising agent in the form of post-consumer oil according to the UNI EN ISO 14021 and UNI EN 15343 standards, while the thermoplastic and elastomeric part is made of 100% virgin material.

The composition of the various samples was as follows.

Sample 13

Sample 14

Sample 15

Sample 16

Sample 17

Sample 18

The samples 13 - 18 of the flexible hose 1 mentioned above have the following characteristics. Table 5

Therefore, even all samples 13 - 18 fall within the scope of protection of the present invention.

Also in this case, similarly to the procedure applied for samples 1 - 6 and 7 - 12, with reference to the structure of the hose shown in FIG. 4, there was calculated the % by weight of PCR in the flexible hose 1 of samples 13 - 18 should the inner layer 10 consist of a portion 11 consisting of 80% by weight or 90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT, and a portion 12 respectively further consisting of 20% by weight or 10% by weight of virgin material, for example NILFLEX® SH A72 E030 AU 01R 540 FUME to be placed at the lower strip 22"' to create a "window" in the hose which allows see the water flowing in the hose.

Table 6

As clear, in the former case (80% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) only the sample 14 falls within the scope of protection of the present invention, while in the latter case (90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) only the sample 5 does not fall within the scope of protection of the present invention.

Samples 19 - 24

5 Still with reference to the structure of the hose in FIG. 3, there were prepared hose samples similar to samples 13 - 18, but in which the film 40 made of NILFLEX® SHR A72 E030 AU 01R 540 FUME 100% virgin material in contact with the liquid to be transported represents 20% by weight with respect to the sum of the weights of the layers 10 and 40. Also in this case, the NILFLEX® SHR A72 E220 AU 03R 539 AZURE and NILFLEX® SHR A72 E220 AU 03R 577 BEIGE materials each contained 35% by weight of 0 plasticising agent in the form of post-consumer oil according to the UNI EN ISO 14021 and UNI EN 15343 standards, while the thermoplastic and elastomeric part was made of 100% virgin material.

The composition of the various samples was as follows.

Sample 19

Sample 20

Sample 21

Sample 22

Sample 23

Sample 24

The samples 19 - 24 of the flexible hose 1 mentioned above have the following characteristics.

Table 7

Therefore, the samples 23 do not fall within the scope of protection of the present invention, essentially due to the high content of virgin material in the ornamental portions 22', 22", 22'" and in the film 40.

Also in this case, similarly to the procedure applied above, with reference to the structure of the hose shown in FIG. 4, there was calculated the % by weight of PCR in the flexible hose 1 of samples 19 - 24 should the inner layer 10 consist of a portion 11 consisting of 80% by weight or 90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT, and a portion 12 made of virgin material, for example NILFLEX® SH A72 E030 AU 01R 540 FUME to be placed at the lower strip 22"' to create a "window" in the hose which allows see the water flowing in the hose.

Table 8

As clear, in the former case (80% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) none of the samples 19- 24 falls within the scope of protection of the present invention, while in the latter case (90% by weight of NILFLEX® SHR A72 E220 AU 01R 00 NAT) only sample 20 falls within the scope of protection of the present invention.

Sample 25

With reference to the structure of the hose in FIG. 1, there was prepared a sample of the flexible hose 1 using the following materials:

- base portions 21 and inner layer 10: "TPV1" compound (see below); - coloured strips 22': SANTOPRENE® 201-64 AZURE;

- coloured strip 22": SANTOPRENE® 201-64 BEIGE;

- translucent strip 22"': SANTOPRENE® 201-64 GREY;

- reinforcement layer 30: PET GLE 1100 DTEX 192 HT10

With regard to the materials mentioned above:

- Santoprene® is marketed by Celanese Corporation;

- the reinforcement layer 30 is marketed by Brilen Tech S.A.;

- TPVl is a compound having the following composition:

Table 9

TPVl contains a thermoplastic part (SJP615) and a plasticising agent (ORV 150) made of PCR according to the UNI EN ISO 14021 and UNI EN 15343 standards in an amount such that 58.1 % by weight of such material is PCR and it has a 61 Shore A hardness.

Santoprene 201-64 materials in the various colours are 100% virgin and it has a 69 Shore A hardness.

The hose samples, measuring the same length as the ones mentioned above, were prepared in a per se known manner by extruding plastic materials and knitting the reinforcement layer, and it has the following composition:

Table 10

The sample 25 of the flexible hose 1 mentioned above has the following characteristics.

Table 11

Therefore, as clear, such sample falls within the scope of protection of the present invention, and due to the high presence of post-consumer material in TPV1, it has an overall amount of PCR close to 50%.

Sample 26

With reference to the structure of the hose in FIG. 1 there was prepared a sample of the flexible hose 1 using the following materials:

- base portions 21 and inner layer 10: "TPV2" compound (see below);

- coloured strips 22': SANTOPRENE® 201-73 AZURE;

- coloured strip 22": SANTOPRENE® 201-73 BEIGE;

- translucent strip 22"': SANTOPRENE® 201-73 GREY;

- reinforcement layer 30: PET GLE 1100 DTEX 192 HT10

With regard to the materials mentioned above:

- Santoprene® is marketed by Celanese Corporation;

- the reinforcement layer 30 is marketed by Brilen Tech S.A.;

- TPV2 is a compound having the following composition: Table 12

TPV2 contains a thermoplastic part (SJP615) and a plasticising agent (ORV 150) made of PCR according to the UNI EN ISO 14021 and UNI EN 15343 standards in an amount such that 61.8 % by weight of such material is PCR and it has a 78 Shore A hardness.

Santoprene 201-73 materials in the various colours are 100% virgin and it has a 78 Shore A hardness.

The hose samples, measuring the same length as the ones mentioned above, were prepared in a per se known manner by extruding plastic materials and knitting the reinforcement layer, and it has the following composition: Table 13

The sample 26 of the flexible hose 1 mentioned above has the following characteristics.

Table 14

Therefore, as clear, such sample falls within the scope of protection of the present invention, and due to the high presence of post-consumer material in TPV2, it has an overall amount of PCR close to 50%.

Sample 27

- base portions 21 and inner layer 10: "TPO 9050000" compound (see below);

- coloured strips 22': NILFLEX® SHR A72 E220 AU 03R 539 AZURE;

- coloured strip 22": NILFLEX® SHR A72 E220 AU 03R 577 BEIGE;

- translucent strip 22"': NILFLEX® SH A72 E030 AU 01R 540 FUME;

- reinforcement layer 30: PET GLE 1100 DTEX 192 HT10

With regard to the materials mentioned above, for the materials of the ornamental portions 22 and the reinforcement layer 30 reference will be made to the previous examples, while TPO 9050000 has the following composition:

50% of Ciclic® 15F marketed by GCR Group (Polyethylene recycled compound Post Consumer;

40% of Exact® 5171 (Ethylene 1 octene copolymer, 1 Melt Index (190 C/ 2.16 kg), 0.868 g/cm3 density) marketed by EXXON;

10% of Elevast® D50 (Polyolefin Fluid) marketed by EXXON.

TPO 9050000 contains a thermoplastic part (Ciclic® 15F) made of PCR according to the UNI EN ISO 14021 and UNI EN 15343 standards at 50 % by weight of such material is PCR and it has an 83 Shore A hardness.

With regard to the materials of the ornamental portions 22, reference shall be made to the content above. The hose samples, measuring the same length as the ones mentioned above, were prepared in a per se known manner by extruding plastic materials and knitting the reinforcement layer, and it has the following composition:

Table 15

The sample 27 of the flexible hose 1 mentioned above has the following characteristics.

Table 16

Therefore, as clear, such sample falls within the scope of protection of the present invention.

Claims

1. A flexible hose for transporting fluids, in particular liquids, comprising:

- an exposed outer layer (20) consisting of a base portion (21) made of a first low environmental impact thermoplastic elastomer and of at least one ornamental portion (22) made of a second thermoplastic elastomer compatible with said first low environmental impact thermoplastic elastomer, said second thermoplastic elastomer including an elastomeric part and a thermoplastic part substantially free of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards;

- at least one inner layer (10) comprising or consisting of a third low environmental impact thermoplastic elastomer; wherein said second thermoplastic elastomer is present in said exposed outer layer (20) in a weight percentage comprised in the range from 5% by weight to 55% by weight with respect to the total weight of said exposed outer layer (20), said third low environmental impact thermoplastic elastomer being present in said at least one inner layer (10) in a weight percentage of at least 80% by weight with respect to the total weight of said at least one inner layer (10); wherein each of said first and third low environmental impact thermoplastic elastomers has a Shore A hardness measured according to the UNI EN ISO 868 standard comprised between 50 Sh A and 85 Sh A; wherein each of said first and third low environmental impact thermoplastic elastomer and possibly said second thermoplastic elastomer has an amount of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards such that the flexible hose (1) has a percentage of postconsumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 40% by weight with respect to the total weight of the flexible hose (1), preferably greater than or equal to 45% by weight with respect to the total weight of the flexible hose (1).

2. Flexible hose according to claim 1, wherein each of said first and third low environmental impact thermoplastic elastomer has a percentage of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 50% by weight calculated with respect to the respective total weight of said first and second low environmental impact thermoplastic elastomer.

3. Flexible hose according to claim 1 or 2, wherein said second thermoplastic elastomer is a virgin material or it includes a plasticiser which is an at least partially postconsumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards.

4. Flexible hose according to claim 1, 2 or 3, wherein said first and third low environmental impact thermoplastic elastomers are present in the flexible hose (1) in an amount greater than or equal to 80% by weight on the total weight of the flexible hose (1), preferably in an amount greater than or equal to 85% by weight on the total weight of the flexible hose (1), even more preferably in an amount greater than or equal to 90% by weight on the total weight of the flexible hose (1).

5. Flexible hose according to one or more of the preceding claims, wherein said at least one second thermoplastic elastomer is present in said exposed outer layer (20) in a weight percentage comprised in the range from 10% by weight to 50% by weight with respect to the total weight of said exposed outer layer (20), and preferably in the range from 15% by weight to 45% by weight with respect to the total weight of said exposed outer layer (20).

6. Flexible hose according to one or more of the preceding claims, wherein said third low environmental impact thermoplastic elastomer is present in said at least one inner layer (10) in a weight percentage of at least 90% by weight with respect to the total weight of said at least one inner layer (10), preferably said at least one inner layer (10) totally consisting of said third low environmental impact thermoplastic elastomer.

7. Flexible hose according to one or more of the preceding claims, wherein said at least one ornamental portion (22) is selected from the group consisting of bands and/or strips having a colour different from that of said low environmental impact thermoplastic elastomer, transparent or translucent bands and/or strips, smooth, satinated or expanded bands and/or strips, tactile effects in relief.

8. Flexible hose according to one or more of the preceding claims, wherein each of said first and third low environmental impact thermoplastic elastomers consists of:

(A) a respective polymer matrix consisting of:

(Al) 10% - 35% by weight of a respective thermoplastic part (Al);

(A2) 20% - 45% by weight of a respective elastomeric part (A2);

(B) 30% - 55% by weight of at least one respective plasticising agent;

(C) 0% - 30% by weight of at least one respective filler;

(D) 0% - 10% by weight of at least one respective additive; wherein the total sum of the % by weight of said components (Al) - (D) is 100%;; wherein the % by weight of said components (Al) - (D) are calculated with respect to the total weight of the respective first and second low environmental impact thermoplastic elastomer.

9. Flexible hose according to the preceding claim, wherein said first thermoplastic part (Al) is an amount comprised in the range between 15% by weight and 25% by weight with respect to the total weight of the respective first or third thermoplastic elastomer, said second elastomeric part (A2) being in an amount comprised between 25% by weight and 35% by weight with respect to the total weight of the respective first or third thermoplastic elastomer, said at least one plasticising agent (B) being in an amount comprised between 30% by weight and 40% by weight with respect to the total weight of the respective first or third thermoplastic elastomer.

10. Flexible hose according to any one of the preceding claims, wherein in each of said first and third low environmental impact thermoplastic elastomers, the first thermoplastic part (Al) and the at least one plasticising agent (B) are at least partially post-consumer materials according to the UNI EN ISO 14021 and UNI EN 15343 standards.

11. Flexible hose according to any one of the preceding claims, wherein each of said first and third low environmental impact thermoplastic elastomers have a Shore A hardness measured according to the UNI EN ISO 868 standard comprised between 65 Sh A and 75 Sh A.

12. Flexible hose according to any one of the preceding claims, wherein said first and third low environmental impact thermoplastic elastomers are mutually compatible and preferably identical materials.

13. The use of:

- a first and third low environmental impact thermoplastic elastomer; and

- a second thermoplastic elastomer compatible with said first low environmental impact thermoplastic elastomer comprising an elastomeric part and a thermoplastic part substantially free of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards; for making a flexible hose for transporting fluids, in particular liquids, comprising:

- an exposed outer layer (20) consisting of a base portion (21) made of said first low environmental impact thermoplastic elastomer and of at least one ornamental portion (22) made of said second thermoplastic elastomer;

- at least one inner layer (10) comprising or consisting of said third low environmental impact thermoplastic elastomer; wherein said second thermoplastic elastomer is present in said exposed outer layer (20) in a weight percentage comprised in the range from 5% by weight to 55% by weight with respect to the total weight of said exposed outer layer (20), said third low environmental impact thermoplastic elastomer being present in said at least one inner layer (10) in a weight percentage of at least 80% by weight with respect to the total weight of said at least one inner layer (10); wherein each of said first and third low environmental impact thermoplastic elastomers has a Shore A hardness measured according to the UNI EN ISO 868 standard comprised between 50 Sh A and 85 Sh A; wherein each of said first and third low environmental impact thermoplastic elastomer and possibly said second thermoplastic elastomer has an amount of post-consumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards such that the flexible hose (1) has a percentage of postconsumer material according to the UNI EN ISO 14021 and UNI EN 15343 standards greater than or equal to 40% by weight with respect to the total weight of the flexible hose (1), preferably greater than or equal to 45% by weight with respect to the total weight of the flexible hose (1).