DUAL LINE HOSE AND MANUFACTURING METHOD

FIELD

[0001] This invention relates generally to a dual line hose and its method of manufacture, and more particularly to two hoses secured together.

BACKGROUND

[0002] Dual line hoses are widely used in processes requiring two fluids to flow in parallel, whether in the same direction or in opposite directions. Conventional dual line plastic, unreinforced hoses may be extruded in one step with a connecting wall between them. For textile-reinforced hoses, two finished hoses may be overmolded with a layer of rubber and/or plastic which forms a connecting wrap and/or a wall between the two hoses. Such extrusion and overmolding processes typically require special tooling for each hose size or each combination of hose sizes, may be difficult to control, and may require multiple additional processing steps including curing, cooling, measuring for quality control, and the like. The difficulties associated with such extrusion and overmolding processes are often compounded for larger hose sizes.

[0003] There is a need for methods of making dual line hose with fewer process steps, more flexible tooling, and easier controls.

SUMMARY OF THE INVENTION

[0004] The present disclosure is directed to multi-line hoses, and systems and methods that provide a multi-line hose. One aspect of the present disclosure relates to a dual line hose that includes two individual, finished hoses arranged in parallel, and a textile braid layer surrounding the two hoses and securing the two hoses together. The two hoses may have the same size and/or construction. Other embodiments, the two hoses may have different sizes and/or different constructions. The textile braid may include strands of natural or synthetic yams, rubber, plastic, metal or fabric material. The textile braid may include a predetermined numbers of carriers, ends per carrier, angles applied, and packing density, chosen to create any of various styles of braids. At least one of the hoses may have an outer diameter at least about 1 inch. At least one of the hoses may have an inner diameter at least about 3/16 inch. The two hoses may each comprise a reinforcing layer covered by a base material. The two hoses may be arranged in contact with each other. The dual line hose may also include a friction layer interposed between the two hoses and the textile braid. At least one of the hoses may be a hydraulic hose.

[0005] Another aspect of the present disclosure is directed to a method of manufacturing a dual line hose. The method includes positioning two individual, finished hoses in parallel and adjacent each other, and braiding a textile braid layer around the two hoses to secure the two hoses together. The two individual, finished hoses may have the same size and/or construction. In other embodiments, the two individual, finished hoses may have different sizes and/or different constructions. Positioning the two hoses adjacent each other may include arranging the two hoses in contact with each other. Braiding the textile braid layer may include using a 24-carrier braider with 6 ends per carrier, 65-70° angle relative to a length dimension, and packing density of about 60%. The textile braid layer may include strands of rubber, plastic, metal or fabric material. The method may further include arranging a friction layer around the braid layer or arranging a friction layer around the two hoses prior to braiding the textile braid layer around the two hoses. The method may include printing information on the textile braid layer.

[0006] A further aspect of the present disclosure relates to a dual line hose that includes two individual, finished hoses arranged side-by-side and in contact with each other, and a textile braid layer surrounding the two hoses, the textile braid layer connecting the two hoses to each other. The dual line hose may include other features and functionality, such as those described above.

[0007] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings, which are incorporated in and form part of the specification in which like numerals designate like parts, illustrate embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:

[0009] FIG. l is a partially fragmented perspective view of an example dual line hose in accordance with the present disclosure;

[0010] FIG. 2 is an end view of the dual line hose shown in FIG. 1;

[0011] FIG. 3 is an end view of another example dual line hose in accordance with the present disclosure;

[0012] FIG. 4 is a schematic of an example system for use in forming the dual line hose shown in FIG. 1 ;

[0013] FIG. 5A is an end view of another example dual line hose in accordance with the present disclosure with a caterpuller arrangement;

[0014] FIG. 5B is an end view of the dual line hose shown in FIG. 5A with a capstan arrangement;

[0015] FIG. 6 is a schematic of an example system for use in forming the dual line hose shown in FIG. 5 A;

[0016] FIG. 7 is an end view of another example dual line hose in accordance with the present disclosure; [0017] FIG. 8 is a schematic of an example system for use in forming the dual line hose shown in FIG. 7;

[0018] FIG. 9 is a schematic of different sized hoses and related measurements used for determining a braid size for a dual line hose; and

[0019] FIG. 10 is a flow chart of an embodiment of a method in accordance with the present disclosure.

DETAILED DESCRIPTION

[0020] The dual line hoses of the present disclosure address many of the challenges associated with manufacturing conventional dual line plastic, unreinforced hoses as well as textile-reinforced hoses that are overmolded with a layer of rubber and/or plastic to form a connecting wrap and/or a wall between the two hoses. Typically, processes associated with forming dual line hoses, in particular dual line hydraulic hoses, are only practical for hoses with diameters up to 1/2 inch because of the considerable scrap and defect rates and undesirable cosmetic defects associated with forming dual line hoses using larger diameter hoses. Current technology runs two braided tubes through a cross head cover extruder and covers the dual line hose simultaneously. This process is sometimes referred to as an extruded cover process. Scrap and defects often exceed 25% in this process even for hoses of 1/2 inch or smaller, and the scrap cannot be reworked. Since the scrap rate for single hose production processes is usually less than 5%, it is difficult to justify making dual line hoses.

[0021] The new methods disclosed herein reduce the hose scrap considerably as compared to the pre-existing extruded cover process. For example, when using the new methods disclosed herein, if any problems arise during formation of the dual line hose, such as defects in the braid, the hoses can be separated from the braid and run back through the braider.

[0022] The new methods disclosed herein can be used with larger hose sizes than the 1/2 inch hose limits with the pre-existing extruded cover process. For example, hoses with 5/8 inch, 3/4 inch, 1 inch, and sizes greater than 1 inch can be combined using the new methods disclosed herein. The new methods disclosed herein also allow for many different hose size combinations, and the use of many different hose sizes using the same braiding and other dual line hose forming equipment.

[0023] One aspect of the present disclosure relates to a method of forming a dual line hose that includes running two finished hoses through a textile braider that forms an overbraid on the exterior of the two hoses. The hoses are arranged in parallel and may be in contact with each other as the overbraid is formed on the exterior of the hoses to form a dual line hose. In one example, the method includes forming a braided cover over two 5/8 inch hoses to create a dual line hose.

[0024] An example dual line hose 100 is shown in FIGS. 1 and 2 having first and second hoses 102, 104 and a braid layer 106. The first and second hoses 102, 104 are independent of each other and typically are considered finished or complete hoses that are ready for use. The braid layer 106 wraps around the exterior of the first and second hoses 102, 104. The first and second hoses 102, 104 are arranged in parallel with each other. In at least some arrangements, the first and second hoses 102, 104 may be in contact with each other. The braid layer 106 secures or connects the first and second hoses 102, 104 together to provide an assembly for the dual line hose 100.

[0025] Each of the first and second hoses 102, 104 include a base layer 110, a reinforcing layer 112, an outer diameter OD, and an inner diameter ID. The reinforcing layer 112 may include materials such as fabric, metals, polymers, or the like. Typically, the reinforcing layer 112 is embedded within the base layer 110. The base layer 110 may encapsulate the reinforcing layer 112 such as through an overmolding or extrusion process.

In some embodiments, the hoses 102, 104 may include additional layers. In other embodiments, the hoses 102, 104 may include a base layer 110 only and not include a reinforcing layer 112. Preferably, the first and second hoses 102, 104 are finished hoses that could be used independent of each other if not included in the dual line hose 100. The first and second hoses 102, 104 may be configured as any of a variety of hoses, cables, and/or wires, such as, for example, a hydraulic hose, a fluid transfer hose, a vacuum hose, a power cable, a load bearing cable, a fiber optic or other communication cable, electric wires or power cables. The dual line hose 100 may include umbilicals or other types of bundled structures. In addition, periodic structures, such as mounting brackets of various types, may be inserted and/or held onto the dual line hose 100 by the braided layer 106.

[0026] The first and second hoses 102, 104 may have the same outer diameter OD, such that ODi for first hose 102 and OD ₂ for second hose 104 are the same. The inner diameters (IDi, ID ₂ ) may also be the same such that IDi for first hose 102 and ID ₂ for second hose 104 are equal. Other arrangements are possible in which the outer diameters OD and/or the inner diameters ID are different. FIG. 3 illustrates another example dual line hose 200 in which the first hose 102 has a smaller outer diameter ODi and a smaller inner diameter IDi than the outer diameter OD ₂ and inner diameter ID ₂ of the second hose 104. Still further arrangements are possible in which the outer diameters ODi and OD ₂ are the same and the inner diameters IDi and ID ₂ are different, or the outer diameters ODi and OD ₂ are different and the inner diameters IDi and ID ₂ are the same.

[0027] The braid layer 106 may comprise a plurality of sets of strands such as a first set of strands 114 and a second set of strands 116. The braid layer 106 may include more than two sets of strands 114, 116. Each set of strands 114, 116 may include a single strand of material or may include multiple strands of material. Each set of strands may include the same number of strands or may include different numbers of strands.

[0028] The braid layer 106 may comprise any of a variety of different materials such as, for example, a textile material such as nylon, aramids, polyester, natural fibers, rayon, fiberglass, carbon fiber, a metal material such as, for example, stainless steel, brass, or copper wire, or combinations thereof. The braid layer 106 may provide a protective function for the first and second hoses 102, 104 as well as a retaining or connecting function that secures the first and second hoses 102, 104 together. The braid layer 106 may be referred to as a protecting layer, a wear resistant layer, a flexible connecting layer, a textile braid layer, textile layer, or other combinations of these terms or other descriptive terms.

[0029] The braid layer 106 may be formed using many different types or styles of braiding. For example, the braid layer 106 may be formed using different numbers of carriers, ends per carrier, angles applied, and packing density to create various styles of braids. One example includes a 24-carrier braider with 6 ends per carrier, 65-70° angle relative to a length dimension, and packing density of about 60%. The braid layer 106 may completely cover the first and second hoses 102, 104. In other embodiments, the braid layer 106 may include spaces or gaps between the sets of strands 114, 116 that provide exposure of portions of the first and second hoses 102, 104. Other example braiders include 18, 20, 24,

36, 48, 64 and 128 carriers. The braid layer 106 may include different yarn types, yam weights, % coverage density, colors, plaids, and stripes, and may have a blackout structure verses a see-through structure that permits visualization of underlying hose.

[0030] The braid layer 106 may have different colors, wherein different colors are associated with different sizes or other properties associated with the first and second hoses 102, 104. The braid layer 106 may have printing or other visual indicia provided thereon. The printing or other visual indicia may include branding information or other information related to the properties of the dual line hose 100 generally or properties of the first and second hoses 102, 104 and/or the braiding 106. For example, the braid layer 106 may include a color that matches the color of one or more of the underlying hoses or other bundled objects. One or more colors of the braid layer 106 may identify a pressure rating of one or more of the first and second hoses 102, 104.

[0031] The dual line hose 200 shown in FIG. 3 also includes a tension member 142 and a third hose 144 positioned internal the braid layer 106. The tension member 142 may include a wire, cable or other elongated member that is used to apply a tension force to the dual line hose 200. The third hose 144 may be configured to carry any of a plurality of different types of fluids. In one example, the third hose 144 is configured as a pneumatic hose that provides a flow of pressurized air.

[0032] The tension member 142 and third hose 144 may be used with any of the dual line hose embodiments disclosed herein. A plurality of tension members 142 and/or a plurality of third hoses 144 may be used with any of the embodiments disclosed herein. The tension member 142 and third hose 144 may be positioned internal the braid layer 106 or external the braid layer 106. In embodiments having multiple braid layers 106, the tension member 142 and third hose 144 may be separated from one or both of the first and second hoses 102, 104 by one of the braid layers 106.

[0033] Referring now to FIG. 4, an example system is illustrated for use in forming the dual line hose 100 shown in FIGS. 1 and 2. The system includes first and second decks 120, 122 that include guide blocks or rings 126, 128, respectively. The guide blocks 126, 128 are receptive of hoses 102, 104 being drawn from spools 136, 138, optionally within a cold box 134 or other controlled environment. Strands 114, 116 are fed to a braid point 132 downline of the guide block 128. The braid layer 106 is formed at the braid point 132 around the first and second hoses 102, 104 to create the dual line hose 100. The guide blocks 126, 128 may help maintain the first and second hoses 102, 104 in a particular orientation relative to each other while the braid layer 106 is applied to the exterior of the first and second hoses 102, 104. The orientation, spacing and positioning of the first and second hoses 102, 104 provided by the guide blocks 126, 128 and other features of the system shown in FIG. 4 may help reduce or eliminate relative twisting of first and second hoses 102, 104 of the dual line hose 100. The guide blocks 126, 128 may assist in reducing twist of the dual line hose 100. The guide blocks 126, 128 may also hold the first and second hoses 102, 104 in contact with each other in their parallel arrangement while the braid layer 106 is formed on the exterior of the first and second hoses 102, 104.

[0034] FIGS. 5 A and 5B illustrate another example dual line hose 300 that includes a friction layer 140 positioned between the exterior of the first and second hoses 102, 104 and the braid layer 106. FIG. 5A shows the dual line hose 300 in an arrangement for use with a caterpuller to assist with pulling the hoses through the system. FIG. 5B shows the first and second hoses 102, 104 in an arrangement for a capstan to assist with pulling the hoses through the system.

[0035] FIG. 6 illustrates a system for forming the dual line hose 300. The system shown in FIG. 6 includes decks 120, 122, 124. The friction layer 140 is applied to the exterior of the first and second hoses 102, 104 prior to the hoses entering a guide block 130 associated with the deck 124. Thereafter, the sets of strands 114, 116 are provided at a braid point 132 wherein the braid layer 106 is formed around the exterior of the friction layer 140. The friction layer 140 may reduce friction otherwise imposed between the braid layer 106 and the exterior surfaces of the first and second hoses 102, 104. Such friction may result in higher wear rates and damage to the hoses over time. The friction layer 140 may also apply a constricting force to assist in holding the first and second hoses 102, 104 in contact with each other. A further constricting force may be applied by the braid layer 106. The braid layer 106 may also provide a protective layer for the first and second hoses 102, 104 and/or the friction layer 140.

[0036] The friction layer 140 may comprise a low friction material, such as, for example, rubber, plastic, fabric, thermoplastic elastomer (TPE), thermoplastic vulcanizate (TPV), or other suitable textile. In one example, the friction layer 140 comprises heat tape, shrink wrap material, or the like. The friction layer 140 may reduce relative movement between the first and second hoses 102, 104 that may otherwise affect performance of the braid layer 106. The friction layer 140 may reduce incidents of fraying or unravelling of the braid layer 106.

[0037] FIG. 7 illustrates another dual line hose 400 that includes a friction layer 140 wrapped around an exterior of the braid layer 106. The friction layer 140 may protect the braid layer 106 from wear or environmental conditions. The friction layer 140 may comprise a high coefficient of friction material or low coefficient of friction layer. The friction layer 140 may be referred to as a gum layer, a tie layer, a material layer, or an adhesion layer. The friction layer 140 may be applied using roll, spiral, extrusion and other application methods. The friction layer 140, as described above, may include a heat tape, shrink wrap, or other material that applies a constricting force to the braid layer 106 and/or first and second hoses 102, 104. The friction layer 140 may comprise rubber, polymer materials, fabric, or an extruded material. The friction layer 140 may be liquid-tight or provide a liquid-proof covering for the braid layer 106 and/or hoses 102, 104.

[0038] FIG. 8 shows a system for forming the dual line hose 400. The friction layer 140 is shown being applied to the exterior of the braid layer 106 after the braid layer 106 has been formed around the first and second hoses 102, 104. The friction layer 140 may be applied to the braid layer 106 at an additional manufacturing step before a deck 125 and associated guide block 131. The guide block 131 may assist with applying the friction layer 140 to the braid layer 106. Other system configurations are possible to provide the assembly necessary to form the dual line hose 400. For example, an additional step may include application of heat used to activate a heat-shrink function of the friction layer 140.

[0039] Other embodiments are possible in which more than one braided layer 106 is applied to the exterior of the first and second hoses 102, 104. Furthermore, more than one friction layer 140 may be associated with any given dual line hose. For example, a first friction layer 140 may be interposed between the exterior of the first and second hoses 102, 104 and the braid layer 106, and a second friction layer 140 may be arranged on an exterior of the braid layer 106. Furthermore, a combination of multiple braid layers 106 and multiple friction layers 140 may be used on the exterior of the first and second hoses 102, 104.

[0040] FIG. 9 illustrates a set of hoses 102, 104 with dimensions used for calculation of a perimeter around the combined first and second hoses 102, 104. The perimeter value may be used for setting up equipment used to form the braid layer 106 described herein. Typically, the outer diameters ODi and OD ₂ of the hoses 102, 104 is known. The following parameters can also be determined:

• H = Core Height = ODi + OD2 FL = Flank Length

·

• P = Perimeter p

• OD _E Q = Equivalent Diameter = -

Minimum Friction Width = p OD _E Q + t&iction

• Recommended Friction Width = Minimum Friction Width + FL

• OD _E Q, F = Equivalent Diameter = OD _E Q + (2 t _friCtion )

[0041] FIG. 10 is a flow diagram showing steps of an example method 500 in accordance with the present disclosure. The method 500 may be directed to a method of manufacturing or forming a dual line hose. The method 500 includes, at block 505, positioning two individual, finished hoses in parallel and adjacent to each other. At block 510, the method 500 includes braiding a braid layer around the two hoses to secure the two hoses together. The braid layer may include textile materials. The method 500 may also include providing the hoses with the same size and construction. The method 500 may include providing the hoses with at least one of different sizes or different constructions. Positioning the two hoses adjacent to each other may include arranging the two hoses in contact with each other. The textile braid layer may include, for example, the braid layer 106 may be formed using different numbers of carriers, ends per carrier, angles applied, and packing density to create various styles of braids. The textile braid layer may comprise, for example, strands of natural synthetic yams, rubber, plastic, metal or fabric material. The method 500 may include arranging a friction layer around the braid layer. The method 500 may include applying a friction layer around the two hoses prior to braiding the textile braid layer around the two hoses. The method 500 may include printing information on the textile braid layer.

[0042] An example application for the dual line hoses disclosed herein is an extension boom with a pair of hydraulic lines that extend from one end of the boom to the other. The boom may include a track or tray that holds the hydraulic lines. The hydraulic lines may include one of the dual line hose embodiments disclosed herein. The dual line hose may slide along or move into and out of the tray as the boom extends and retracts. The dual line hose may include additional hoses, power cables, and the line that are captured with one or more braided layers, which bundling may help keep all of the lines consolidated and avoid kinking or tangling during operation of the boom.

[0043] Another example application is a kit that includes at least one dual line hose, such as any of the dual line hoses disclosed herein, and one or more accessories. The accessories may include power cables, tension wires, pneumatic lines, fiber optic lines, brackets or other fasteners, or the like.

[0044] The dual line hoses and related methods of manufacture disclosed herein may provide one or more of the following improvements/advantages over conventional solutions:

• The ability to reduce maximum size constraints for hose outer diameters (ODs).

• Reduced equipment size and related space requirements for hose diameters greater than 1/2 inch compared to extrusion equipment.

• The use of braiders to connect two or more hoses provides significantly greater size possibilities for the hoses with less cost and size constraints. • The use of braiders, which are commonly available globally for production, can be more easily implemented than other techniques for joining hoses together.

• The elimination of special extrusion tooling, measuring equipment, and product testing otherwise needed when using traditional hose joining techniques.

• The integration of additional sizes of hose and other lines ( e.g tension wires and/or cables) in the same package.

• The use of finished hose products that are held together with a braid layer results in reduced scrap and longer continuous lengths.

• The ability to adjust the packing tightness of the hoses using different types, styles and variables for the braid layer.

• Overall reduced scrap rates and increased production rates that translate into cost saving and increased profitability.

[0045] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. The invention disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein.