Ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose and manufacturing method thereof

Abstract

The present invention relates to an ultra-high molecular weight polyethylene enhanced high-flow delivery high-pressure hose and manufacturing method thereof. The hose includes an outer rubber layer, a reinforcing layer and an inner rubber layer from outside to inside. A thickness of the outer rubber layer is 0.3-6.0 mm. A thickness of the reinforcing layer is 1.0-5.0 mm. A thickness of the inner layer is 0.3-5.0 mm. The outer rubber layer and the inner layer are obtained by co-extruding onto the reinforcing layer using a coextrusion equipment. The manufacturing method includes the following steps: rubber mixing, preparing the reinforcing layer, producing a finished product, vulcanizing and pressure testing. The hose of the invention has the advantages of light weight, good flexibility, abrasion resistance, corrosion resistance and good weather fastness. The hose can be connected through a plurality of standard buckles, which is easy to wind up, easy to assemble and disassemble.

Claims

1. A manufacturing method of an ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose, comprising the following steps: (1) rubber mixing wherein a technical formulation of a rubber is by mass fraction 90-110 parts of the rubber, 5-10 parts of zinc oxide, 1-2 parts of stearic acid, 1-2 parts of a microcrystalline wax, 2-5 parts of a PVC stabilizer, 1-2 parts of an antioxidant, 12-20 parts of a white carbon black, 5-10 parts of titanium dioxide, 1.5-3 parts of a resorcinol, 1.5-3 parts of hexamethylenetetramine as an accelerant, 1.5-5 parts of a resin, 1.5-3 parts of an accelerant CZ, 0.4-0.8 parts of an accelerant TMTM, 1.8-2.5 parts of sulfur, 15-30 parts of dioctyl phthalate, and a pigment is replenished, comprising: putting the technical formulation, except the sulfur, the accelerant TMTM and the accelerant CZ, into an internal mixer, and mixing on an open mill for 2-3 times, wherein a mixing time is greater than or equal to 7 minutes, and a discharging temperature is between 100-120 C., entering into a rubber filter for straining, adding the accelerant TMTM and the accelerant CZ intoa filtered rubber compound in proportion, sheeting out to obtain a rubber material, and cooling and standing by for application; (2) preparing the reinforcing layer, comprising: mixing an ultrahigh molecular weight polyethylene and a polyester filament in a certain ratio, wherein a mixing ratio thereof is 0-100%, wherein the ultrahigh molecular weight polyethylene and the polyester filament are made into warps and wefts respectively, and braiding into a tubular reinforcing layer using a circular loom; (3) co-extruding, comprising: putting the reinforcing layer on a core of a coextrusion mold, putting the rubber material in step (1) into an extruder, wherein a temperature of the extruder is set at 45-85 C., starting the extruder, wherein a squeezing speed of the extruder is 10-50 rpm, and then starting a dragger so that the reinforcing layer squeezes out of the coextrusion mold with a base, wherein the rubber material penetrates the reinforcing layer and forms the inner rubber layer along with the base when passing through the coextrusion mold, at the same time, attaching to a surface of the reinforcement layer to become the outer rubber layer, and wherein the dragger drags the outer rubber layer to a cooling device in a speed of 2-5 m/min, and then reaches a vulcanization line to be vulcanized; (4) vulcanizing, comprising: applying clamps on two ends of a semi-product of step (3) on an ultralong vulcanization line, steaming on one end, wherein a vapor pressure of a vulcanization is 0.1-0.3 MPa with a time of 10-600 minutes to obtain a finished product; (5) pressure testing, comprising: dragging the finished product to a dedicated pressure test machine, applying clamps on two ends, injecting water, testing the finished product under a pressure of 1.5-2 times of a design pressure to check leakage, wherein the ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose comprises the outer rubber layer, the reinforcing layer and the inner rubber layer from outside to inside; wherein a thickness of the outer rubber layer is 0.3-6.0 mm, a thickness of the reinforcing layer is 1.0-5.0 mm, a thickness of the inner rubber layer is 0.3-5.0 mm; the outer rubber layer and the inner rubber layer are obtained by co-extruding onto the reinforcing layer using a coextrusion equipment.

2. The manufacturing method of claim 1, wherein the rubber in step (1) is a natural rubber or a synthetic rubber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic structural view of the present invention;

(2) wherein: 1: the outer rubber layer, 2: the reinforcing layer, 3: the inner rubber layer.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(3) The present invention will be further described with reference to the following embodiments:

Embodiment 1

(4) As a first embodiment of the present invention, the present embodiment provides an ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose including an outer rubber layer 1, a reinforcing layer 2, and an inner rubber layer 3. A thickness of the outer rubber layer 1 is 0.3 mm, a thickness of the reinforcing layer 2 is 1.0 mm, a thickness of the inner rubber layer 3 is 0.3 mm. The outer rubber layer 1 and the inner rubber layer 3 are obtained by co-extruding to the reinforcing layer 2 via a coextrusion equipment.

(5) The manufacturing method of an ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose, including the following steps:

(6) (1) rubber mixing: a technical formulation of the rubber are as follows by mass fraction: 90 parts of rubber, 5 parts of zinc oxide, 1 part of stearic acid, 1 part of microcrystalline wax, 2 parts of pvc stabilizer, 1 part of antioxidant, 12 parts of white carbon black, 5 parts of titanium dioxide, 1.5 parts of resorcinol, 1.5 parts of accelerant hexamethylenetetramine, 1.5 parts of resin, 1.5 parts of accelerant CZ, 0.4 parts of accelerant TMTM, 1.8 parts of sulfur, 15 parts of dioctyl phthalate, and the pigment is replenished as needed; putting the above materials, except the sulfur, accelerant TMTM and accelerant CZ, into an internal mixer, wherein the mixing time is greater than or equal to 7 minutes, the discharging temperature is 100 C., and mixing on the open mill for 2 times, then entering into the rubber filter for straining, adding accelerants TMTM and CZ into the filtered rubber compound in proportion, sheeting out to obtain a rubber material, cooling and standby for application. The rubber in the present embodiment is natural rubber.

(7) (2) preparing the reinforcing layer: mixing the ultrahigh molecular weight polyethylene and the polyester filament in a certain ratio, wherein a mixing ratio of the ultrahigh molecular weight polyethylene to polyester filament is 1:1, wherein the ultrahigh molecular weight polyethylene and the polyester filament are made into warps and wefts respectively, braiding into a tubular reinforcing layer using a circular loom;

(8) (3) producing a finished product: putting the reinforcing layer on a core of the coextrusion mold, putting the rubber material in step (1) into an extruder, wherein a temperature of the extruder is set at 45 C., starting the extruder, wherein a squeezing speed of the extruder is 10 rpm, and then starting the dragger so that the reinforcing layer squeezing out of the coextrusion mold with a base. The rubber material penetrates the reinforcing layer and forms the inner layer along with the base when passing through the coextrusion mold, at the same time, attaching to the surface of the reinforcement layer to become the outer layer. The dragger drags the outer layer to a cooling device in a speed of 2 m/min, and then reaches the vulcanization line to be vulcanized;

(9) (4) vulcanizing: applying clamps on two ends of the semi-product of step (3) on the ultralong vulcanization line, steaming on one end, wherein a vapor pressure of the vulcanization is 0.1 MPa with a time of 10 minutes to obtain the finished product;

(10) (5) pressure testing: dragging the product to a dedicated pressure test machine, applying clamps on the two ends, injecting water, testing the product under a pressure of 1.5 times of the design pressure to check whether leakage or not.

Embodiment 2

(11) An ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose including an outer rubber layer, a reinforcing layer, and an inner rubber layer. A thickness of the outer rubber layer is 3 mm, a thickness of the reinforcing layer is 3 mm, a thickness of the inner rubber layer is 2.5 mm. The outer rubber layer and the inner rubber layer are obtained by co-extruding to the reinforcing layer via a coextrusion equipment.

(12) The manufacturing method of an ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose, including the following steps:

(13) (1) rubber mixing: a technical formulation of the rubber are as follows by mass fraction: 100 parts of rubber, 7 parts of zinc oxide, 1.5 parts of stearic acid, 1.5 parts of microcrystalline wax, 3.5 parts of pvc stabilizer, 1.5 parts of antioxidant, 16 parts of white carbon black, 7.5 parts of titanium dioxide, 2 parts of resorcinol, 2.3 parts of accelerant hexamethylenetetramine, 3.5 parts of resin, 2.3 parts of accelerant CZ, 0.6 parts of accelerant TMTM, 2.2 parts of sulfur, 20 parts of dioctyl phthalate, and the pigment is replenished as needed; putting the above materials, except the sulfur, accelerant TMTM and accelerant CZ, into an internal mixer, wherein the mixing time is greater than or equal to 7 minutes, the discharging temperature is 110 C., and mixing on the open mill for 3 times, then entering into the rubber filter for straining, adding accelerants TMTM and CZ into the filtered rubber compound in proportion, sheeting out to obtain a rubber material, cooling and standby for application. The rubber in the present embodiment is synthetic rubber.

(14) (2) preparing the reinforcing layer: making the ultrahigh molecular weight polyethylene fiber into warps and wefts respectively, braiding into a tubular reinforcing layer using a circular loom;

(15) (3) producing a finished product: putting the reinforcing layer on a core of the coextrusion mold, putting the rubber material in step (1) into an extruder, wherein a temperature of the extruder is set at 65 C., starting the extruder, wherein a squeezing speed of the extruder is 30 rpm, and then starting the dragger so that the reinforcing layer squeezing out of the coextrusion mold with a base. The rubber material penetrates the reinforcing layer and forms the inner layer along with the base when passing through the coextrusion mold, at the same time, attaching to the surface of the reinforcement layer to become the outer layer. The dragger drags the outer layer to a cooling device in a speed of 3.5 m/min, and then reaches the vulcanization line to be vulcanized;

(16) (4) vulcanizing: applying clamps on two ends of the semi-product of step (3) on the ultralong vulcanization line, steaming on one end, wherein a vapor pressure of the vulcanization is 0.2 MPa with a time of 300 minutes to obtain the finished product;

(17) (5) pressure testing: dragging the product to a dedicated pressure test machine, applying clamps on the two ends, injecting water, testing the product under a pressure of 1.7 times of the design pressure to check whether leakage or not.

Embodiment 3

(18) An ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose including an outer rubber layer, a reinforcing layer, and an inner rubber layer. A thickness of the outer rubber layer is 6 mm, a thickness of the reinforcing layer is 5.0 mm, a thickness of the inner rubber layer is 5.0 mm. The outer rubber layer and the inner rubber layer are obtained by co-extruding to the reinforcing layer via a coextrusion equipment.

(19) The manufacturing method of an ultra-high molecular weight polyethylene enhanced high-flow delivery high pressure hose, including the following steps:

(20) (1) rubber mixing: a technical formulation of the rubber are as follows by mass fraction: 110 parts of rubber, 10 parts of zinc oxide, 2 parts of stearic acid, 2 parts of microcrystalline wax, 5 parts of pvc stabilizer, 2 parts of antioxidant, 20 parts of white carbon black, 10 parts of titanium dioxide, 3 parts of resorcinol, 3 parts of accelerant hexamethylenetetramine, 5 parts of resin, 3 parts of accelerant CZ, 0.8 parts of accelerant TMTM, 2.5 parts of sulfur, 30 parts of dioctyl phthalate, and the pigment is replenished as needed; putting the above materials, except the sulfur, accelerant TMTM and accelerant CZ, into an internal mixer, wherein the mixing time is greater than or equal to 7 minutes, the discharging temperature is 120 C., and mixing on the open mill for 3 times, then entering into the rubber filter for straining, adding accelerants TMTM and CZ into the filtered rubber compound in proportion, sheeting out to obtain a rubber material, cooling and standby for application.

(21) (2) preparing the reinforcing layer: making the ultrahigh molecular weight polyethylene fiber into warps and wefts respectively, braiding into a tubular reinforcing layer using a circular loom;

(22) (3) producing a finished product: putting the reinforcing layer on a core of the coextrusion mold, putting the rubber material in step (1) into an extruder, wherein a temperature of the extruder is set at 85 C., starting the extruder, wherein a squeezing speed of the extruder is 50 rpm, and then starting the dragger so that the reinforcing layer squeezing out of the coextrusion mold with a base. The rubber material penetrates the reinforcing layer and forms the inner layer along with the base when passing through the coextrusion mold, at the same time, attaching to the surface of the reinforcement layer to become the outer layer. The dragger drags the outer layer to a cooling device in a speed of 5 m/min, and then reaches the vulcanization line to be vulcanized;

(23) (4) vulcanizing: applying clamps on two ends of the semi-product of step (3) on the ultralong vulcanization line, steaming on one end, wherein a vapor pressure of the vulcanization is 0.3 MPa with a time of 600 minutes to obtain the finished product;

(24) (5) pressure testing: dragging the product to a dedicated pressure test machine, applying clamps on the two ends, injecting water, testing the product under a pressure of 2 times of the design pressure to check whether leakage or not.