Stitched Double Layer Composite Hose and Manufacturing Method Thereof

Abstract

A stitched double layer composite hose and a manufacturing method thereof are provided. The stitched double layer composite hose includes a middle fabric pipe layer (1), an inner surface composite colloid material layer (2) and an outer surface composite colloid material layer (3). The structure of the fabric pipe layer is weft-stitched double-layer unit structure. The double-layer unit structure includes an outer layer, an inner layer and stitched wefts. The inner layer includes inner layer warps and inner layer wefts; the outer layer includes outer layer warps and outer layer wefts. The stitched wefts interweave with the outer layer warps and the inner layer warps for conjoining the inner layer and the outer layer together. The fabric pipe layer weaved according to this invention solves problems of the stitched double layer composite hose in the fabric pipe layer of traditional casing, with such advantages as high flexibility, less weaving point, less loss of yarn strength and less degree of torsion. The fabric pipe layer, with special coating equipment and special coating process, can be directly processed into a stitched double layer composite hose satisfying market needs with large caliber, high dielectric strength and higher flexibility. The production process is simple, featured with extremely high utility value and worthy of promotion for production.

Claims

1. A stitched double layer composite hose, comprising a fabric pipe layer, an inner surface composite colloid material layer and an outer surface composite colloid material layer, wherein: a structure of the fabric pipe layer is weft-stitched double-layer unit structure; the double-layer unit structure comprises an outer layer, an inner layer and stitched wefts, and the inner layer comprises inner layer warps and inner layer wefts; the outer layer comprises outer layer warps and outer layer wefts; the stitched wefts interweaves with the outer layer warps and the inner layer warps, for conjoining the inner layer and the outer layer together.

2. A manufacturing method of the stitched double layer composite hose according to claim 1, comprising steps of: weaving the fabric pipe layer, which comprises steps of: first, determining total amount of warps in a fabric pipe layer according to an amount of the warps in a single complete cycle unit and an amount of cycles of complete cycle units; then, setting total amount of the warps, at a same time, weaving the inner layer and the outer layer of the fabric pipe layer respectively, and interweaving the inner layer and the outer layer through the stitched wefts, for conjoining the inner layer and the outer layer together to form the fabric pipe layer; and colloid compositing, which comprises steps of: co-extruding rubber compound/thermoplastic elastomer on inner and outer surfaces of the fabric pipe layer once, or lining the rubber compound/thermoplastic elastomer on the inner surface and color painting on the outer surface.

3. The manufacturing method according to claim 2, wherein a weaving structure of the fabric pipe layer is a double twill structure or a double plain structure, and the total amount of the warps in the fabric pipe layer is determined in following manners: when the weaving structure is in double twill stitching, the weaving structure is weaved using n complete cycle units, the amount of the warps in each complete cycle unit is 6, and the total amount of the warps in the fabric pipe layer is 6n+4; when the weaving structure is in double plain stitching, the weaving structure is weaved using n complete cycle units, the amount of the warps in each complete cycle unit is 4, and the total amount of the warps in the fabric pipe layer is 4n+2.

4. The manufacturing method according to claim 3, wherein the complete cycle unit applies a following weaving method comprising steps of: driving wefts by synchronous circling motions of set amount of shuttles on a weaving machine, making the wefts shuttling through layered warps to weave, cooperating with set amount of noseplates in a same weaving cycle for leasing, making shuttle lead wefts through the layered warps to connect inner and outer textiles, thus completing the weaving of the fabric pipe layer.

5. The manufacturing method according to claim 4, wherein there are three shuttles.

6. The manufacturing method according to claim 5, wherein when the complete cycle unit is in double twill stitching, the weaving method is as follows, wherein: the noseplate cooperating with a first shuttle has following three leasing movements successively: one up one down one up three down, two down one up one down one up one down, one up three down one up one down (, , ) and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with a second shuttle has the following three leasing movements successively: three up one down one up one down, one up one down three up one down, one up one down one up one down two up (, , ) and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with a third shuttle has the following three leasing movements successively: two up two down one up one down, one up one down two up two down, two down one up one down two up (, , ), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double twill weft stitching the fabric pipe layer of the hose.

7. The manufacturing method according to claim 5, wherein when the complete cycle unit is in double plain stitching, the weaving method is as follows, wherein: the specially made noseplate cooperating with the first shuttle has following two leasing movements successively: one up three down, two up(down) one up one down (, ), and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with the second shuttle has following two leasing movements successively: three up one down, one up one down two up (, ), and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with the third shuttle has following two leasing movements successively: two up two down, two down two up (, ), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double plain weft stitching the fabric pipe layer of the hose.

8. (canceled)

9. The manufacturing method according to claim 2, wherein the rubber compound/thermoplastic elastomer is a high polymer elastomer compound, and the color painting is a high polymer elastomer color paste.

10. The manufacturing method according to claim 2, wherein the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU.

11. The manufacturing method according to claim 9, wherein the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU.

12. The manufacturing method according to claim 2, wherein the warps and wefts are made of any high-strength fiber thread.

13. The manufacturing method according to claim 3, wherein the warps and wefts are made of any high-strength fiber thread.

14. The manufacturing method according to claim 4, wherein the warps and wefts are made of any high-strength fiber thread.

15. The manufacturing method according to claim 5, wherein the warps and wefts are made of any high-strength fiber thread.

16. The manufacturing method according to claim 6, wherein the warps and wefts are made of any high-strength fiber thread.

17. The manufacturing method according to claim 7, wherein the warps and wefts are made of any high-strength fiber thread.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Other features, objects, and advantages of the invention will become more apparent from reading the description of non-limiting embodiments detailed with reference to the following figures:

[0032] FIG. 1 is a structure diagram of the invention;

[0033] FIG. 2 is a stitching structure diagram of the fabric pipe layer in a double twill stitching structure;

[0034] FIG. 3 is a stitching structure diagram of the fabric pipe layer in a double plain stitching structure;

[0035] FIG. 4 is an outside surface physical image of the outer layer of the fabric pipe layer in the double twill stitching structure;

[0036] FIG. 5 is an inside surface physical image of the outer layer of the fabric pipe layer in the double twill stitching structure;

[0037] FIG. 6 is an outside surface physical image of the inner layer of the fabric pipe layer in the double twill stitching structure;

[0038] FIG. 7 is an inside surface physical image of the inner layer of the fabric pipe layer in the double twill stitching structure;

[0039] FIG. 8 is an overall physical image of the inner and outer layers of the fabric pipe layer in the double twill stitching structure.

[0040] In the figures: 1. fabric pipe layer; 2. inner surface composite colloid material layer; 3. outer surface composite colloid material layer; 4. twill weaving's first shuttle and second circle; 5. twill weaving's first shuttle and third circle; 6. twill weaving's first shuttle and first circle; 7. twill weaving's third shuttle and second circle; 8. twill weaving's third shuttle and third circle; 9. twill weaving's second shuttle and first circle; 10. twill weaving's third shuttle and first circle; 11. twill weaving's second shuttle and second circle; 12. twill weaving's second shuttle and third circle; a. warps; b. wefts; c. outer layer of twill weaving layer; d. inner and outer layers stitched wefts; e. inner layer of twill weaving layer; A, C, D are wefts on the first shuttle of twill weaving, twill weaving with the single-layer formed by outer layer warps; F, G, I are wefts on the second shuttle, twill weaving with the single-layer formed by inner layer warps; B, E, H are wefts on the third shuttle, making the connection formed by inner and outer layers stitching a whole; 13. plain weaving's first shuttle and second circle; 14. plain weaving's first shuttle and first circle; 15. plain weaving's second shuttle and first circle; 16. plain weaving's second shuttle and second circle; 17. plain weaving's third shuttle and second circle; 18. plain weaving's third shuttle and first circle; 19, 20 are the warps on the first shuttle of plain weaving; 21, 22 are the warps on the second shuttle of plain weaving; J, L are wefts on the first shuttle, plain weaving with the single-layer formed by outer layer warps; M, 0 are wefts on the second shuttle, plain weaving with the single-layer formed by inner layer warps; K, N are wefts on the third shuttle, making the connection formed by inner and outer layers stitching a whole.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0041] The invention is elaborated below with specific embodiments. The following embodiments will help provide further understanding of the invention for those skilled in the art, and not in any way limit the invention. It shall be noted that several variants and improvements can be made without departing from concept of the invention for those of ordinary skill in the art. All these fall within the scope of protection of the invention.

[0042] As shown in FIG. 1, this invention provides a double layer composite hose, comprising a fabric pipe layer 1, an inner surface composite colloid material layer 2, and an outer surface composite colloid material layer 3, wherein:

[0043] when a structure of the fabric pipe layer 1 is a double-layer twill unit structure, six warps form a complete cycle unit, the double-layer twill unit structure comprises an inner layer, an outer layer and independent stitched wefts; the independent stitched wefts interweave with outer layer warps and inner layer warps, for conjoining an inner layer twill textile and an outer layer twill textile together;

[0044] when the structure of the fabric pipe layer 1 is a double-layer plain unit structure, four warps form a complete cycle unit, the double-layer plain unit structure comprises an inner layer, an outer layer and independent stitched wefts, and the inner layer comprises inner layer warps and inner layer wefts, the outer layer comprises outer layer warps and outer layer wefts, and the independent stitched wefts interweave with the outer layer warps and the inner layer warps, for conjoining an inner layer plain textile and an outer layer plain textile together.

[0045] As shown in FIG. 2, it is a diagram showing the complete cycle unit structure of the fabric pipe layer 1, and the complete cycle unit structure is a double-layer twill stitching structure, in the figure: 4 is twill weaving's first shuttle and second circle; 5 is twill weaving's first shuttle and third circle; 6 is twill weaving's first shuttle and first circle; 7 is twill weaving's third shuttle and second circle; 8 is twill weaving's third shuttle and third circle; 9 is twill weaving's second shuttle and first circle; 10 is twill weaving's third shuttle and first circle; 11 is twill weaving's second shuttle and second circle; 12 is twill weaving's second shuttle and third circle; a are warps; b are wefts; c is an outer layer of twill weaving layer; d are stitched wefts of inner and outer layers; e is an inner layer of twill weaving layer; A, C, D are single-layer twill weavings formed by wefts on the first shuttle and the outer layer warps; F, G, I are single-layer twill weaving formed by wefts on the second shuttle and the inner layer warps; B, E, H are wefts on the third shuttle, for stitching the inner and outer layers as a whole.

[0046] As shown in FIG. 3, it is a diagram showing the complete cycle unit structure of the fabric pipe layer 1, and the complete cycle unit structure is a double-layer plain stitching structure, in the figure: 13 is plain weaving's first shuttle and the second circle; 14. plain weaving's first shuttle and first circle; 15. plain weaving's second shuttle and first circle; 16. plain weaving's second shuttle and second circle; 17. plain weaving's third shuttle and second circle; 18. plain weaving's third shuttle and first circle; 19, 20 are the warps on the first shuttle of plain weaving; 21, 22 are the warps on the second shuttle of plain weaving; J, L are single-layer plain weaving formed by wefts on the first shuttle and the outer layer warps; M, O are single-layer plain weaving formed by wefts on the second shuttle and the inner layer warps; K, N are wefts on the third shuttle, stitching inner and outer layers as a whole.

[0047] This invention also refers to a manufacturing method of a stitched double layer composite hose, comprising the following steps of:

[0048] weaving a fabric pipe layer, which comprises steps of: first, determining total amount of warps in a fabric pipe layer according to an amount of warps in a single complete cycle unit and an amount of cycles of complete cycle units; then, setting total amount of warps, at a same time, weaving an inner layer and an outer layer of the fabric pipe layer respectively, and interweaving the inner layer and the outer layer through stitched wefts, for conjoining the inner layer and the outer layer together to form the fabric pipe layer; and

[0049] colloid compositing, which comprises steps of: co-extruding rubber compound/thermoplastic elastomer on inner and outer surfaces of the fabric pipe layer once, or lining the rubber compound/thermoplastic elastomer on the inner surface and color painting on the outer surface.

[0050] As a preferred embodiment, a weaving structure of the fabric pipe layer is a double twill structure or a double plain structure, and the total amount of warps in the fabric pipe layer is determined in following manners:

[0051] When the weaving structure is in double twill stitching, the weaving structure is weaved using n complete cycle units, the amount of warps in each complete cycle unit is 6, and the total amount of the warps in the fabric pipe layer is 6n+4. That is: for the double-layer twill stitching weaving, the total amount of the warps under control (the total amount of threading reeds) minus 4 must be a multiple of 6;

[0052] When the weaving structure is in double plain stitching, the weaving structure is weaved using n complete cycle units, the amount of the warps in each complete cycle unit is 4, and the total amount of the warps in the fabric pipe layer is 4n+2. That is: for the double-layer plain stitching weaving, the total amount of the warps under control (the total amount of threading reeds) minus 2 must be a multiple of 4, and the warps are arranged according to regularity in a weaving cycle; and the amount of the warps in each unit of the warps (also known as one reed) can be odd number or even number.

[0053] The complete cycle unit applies the following weaving method, which comprises steps of: driving wefts by synchronous circling motions of set amount of shuttles on a weaving machine, making the wefts shuttling through layered warps to weave, cooperating with set amount of noseplates in a same weaving cycle for leasing, making shuttle lead wefts through the layered warps to connect inner and outer textiles, thus completing the weaving of the fabric pipe layer.

[0054] When the complete cycle unit is in double twill stitching, the weaving method is as follows: the noseplate cooperating with a first shuttle has the following three leasing movements successively: one up one down one up three down, two down one up one down one up one down, one up three down one up one down (, , ) and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with a second shuttle has the following three leasing movements successively: three up one down one up one down, one up one down three up one down, one up one down one up one down two up (, , ) and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with a third shuttle has the following three leasing movements successively: two up two down one up one down, one up one down two up two down, two down one up one down two up (, , ), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double twill weft stitching the fabric pipe layer of the hose.

[0055] When the complete cycle unit is in double plain stitching, the weaving method is as follows: the noseplate cooperating with the first shuttle has the following two leasing movements successively: one up three down, two up (down) one up one down (, ), and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with the second shuttle has the following two leasing movements successively: three up one down, one up one down two up (, ) and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with the third shuttle has the following two leasing movements successively: two up two down, two down two up (, ), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double plain weft stitching the fabric pipe layer of the hose.

[0056] The warps and wefts are made of any high-strength fiber thread.

[0057] As a preferred embodiment, the rubber compound/thermoplastic elastomer is a high polymer elastomer compound, and the color painting is a high polymer elastomer color paste.

[0058] As a preferred embodiment, the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU.

[0059] As shown in FIGS. 4-7, they are an outside surface physical image of the outer layer of fabric pipe layer in stitching double-layer twill, an inside surface physical image of the outer layer of fabric pipe layer in stitching double-layer twill, an outside surface physical image of the inner layer of fabric pipe layer in stitching double-layer twill and an inside surface physical image of the inner layer of fabric pipe layer in stitching double-layer twill respectively.

[0060] As shown in FIG. 8, it is an overall physical image of inner and outer layers of the middle in stitching double-layer twill, and it is molded product structure. In addition, the outer layer of twill weaving layer c and the inner layer of twill weaving layer e are connected by the inner and outer layers stitched wefts d.

[0061] The following describes two embodiments of this invention, and details are shown as follows:

Embodiment 1

[0062] This embodiment is a double-layer twill composite hose, comprising a fabric pipe layer of stitching double twill structure, inner surface and outer surface composite colloid material layer of the fabric pipe layer. The structure of the fabric pipe layer is a double-layer twill unit structure stitched by stitched wefts, six warps form a complete cycle unit, the double-layer twill unit structure comprises an inner layer, an outer layer and independent stitched wefts, and the independent stitched wefts interweave with outer layer warps and inner layer warps, for conjoining an inner layer twill textile and an outer layer twill textile together.

[0063] In this embodiment, the manufacturing method of the stitched double layer composite hose comprises the following steps of:

[0064] Step 1, weaving a fabric pipe layer, wherein:

[0065] in this embodiment, an amount of warps in a complete cycle units is 6, and an amount of cycles in the complete cycle unit is 106, so a total amount of the warps in the fabric pipe layer can be calculated to be 640;

[0066] weave an outer layer by a first shuttle alone, weave an inner layer by a second shuttle alone, and weave stitched wefts by a third shuttle, the third shuttle's stitched wefts interweave with outer layer warps and inner layer warps, for conjoining the inner layer and the outer layer together; and

[0067] Step 2, colloid compositing, which comprises steps of:

[0068] co-extruding rubber compound/thermoplastic elastomer on inner and outer surfaces of the fabric pipe layer once, or lining the rubber compound/thermoplastic elastomer on the inner surface and color painting on the outer surface, wherein: the rubber compound/thermoplastic elastomer is a high polymer elastomer compound, the color painting is a high polymer elastomer color paste, the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU.

Embodiment 2

[0069] This embodiment is a double-layer plain composite hose, comprising a fabric pipe layer of stitched double plain structure, inner surface and outer surface composite colloid material layer of the fabric pipe layer, and the structure of the fabric pipe layer is a double-layer plain unit structure stitched by stitched wefts, and four warps form a complete cycle unit, and the double-layer plain unit structure comprises an inner layer, an outer layer and independent stitched wefts, and the inner layer comprises inner layer warps and inner layer wefts, the outer layer comprises outer layer warps and outer layer wefts, and the independent stitched wefts interweave with the outer layer warps and the inner layer warps, for conjoining an inner layer plain textile and an outer layer plain textile together.

[0070] In this embodiment, the manufacturing method of the stitched double layer composite hose comprises the following steps of:

[0071] Step 1, weaving a fabric pipe layer, wherein:

[0072] in this embodiment, an amount of warps in a complete cycle units is 4, and an amount of cycles in the complete cycle unit is 159, so a total amount of the warps in a fabric pipe layer can be calculated to be 638;

[0073] weave an outer layer by a first shuttle alone, weave an inner layer by a second shuttle alone, and weave stitched wefts by a third shuttle, the third shuttle's stitched wefts interweave with outer layer warps and inner layer warps, for conjoining the inner layer and the outer layer together; and

[0074] Step 2, colloid compositing, which comprises steps of:

[0075] co-extruding rubber compound/thermoplastic elastomer on inner and outer surfaces of the fabric pipe layer once, or lining the rubber compound/thermoplastic elastomer on the inner surface and color painting on the outer surface, wherein: the rubber compound/thermoplastic elastomer is a high polymer elastomer compound, and the color painting is a high polymer elastomer color paste, the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU.

[0076] Specific embodiments of the invention are described above. It shall be understood that the invention is not limited to the above specific embodiments, and those skilled in the art can make different variants and modifications within the scope of the claims, and it shall not affect the substance of the invention.