Related Application

[0001] This application is being filed on April 18, 2022, as a PCT International

Patent application and claims the benefit of and priority to Indian Provisional patent Application No. 202111017524, filed April 15, 2021, the entire disclosure of which is incorporated by reference herein in its entirety.

Background

[0002] High-pressure hoses have numerous applications particularly in the context of engine design. For example, high-pressure hoses can be used as fuel/oil delivery lines, as airbrake lines, as power steering lines, as coolant lines, or any other application within an engine where hydraulic fluid, air, water, fuel, or coolants are needed. Preferred high pressure, high temperature hoses suitable for the noted application includes those that meet a Society of Automotive Engineers standard, particularly the SAE 100R5 standard. Hoses that meet the SAE 100R5 standard have met performance characteristics that include: (a) a temperature operating range of -40 to 212 °F; (b) an inner diameter range of 3/16 to 3-1/16 inches; (c) a maximum operating range of 200 to 3000 psi (pounds per square inch); (d) a proof pressure range of 400 to 6000 psi; (e) a minimum burst pressure range of 800 to 12,000 psi; and (f) a minimum bend radius of 3 to 33 inches. The entirety of the SAE 100R5 standard is hereby incorporated by reference.

Summary

[0003] The Summary is not intended to describe each embodiment or every implementation. A more complete understanding will become apparent and appreciated by referring to the following detailed description and claims in conjunction with the accompanying drawings.

[0004] An aspect of the present disclosure is directed to a high-pressure hose.

The high-pressure hose includes an inner tube, a single wire braiding layer about the inner tube and a single yarn braiding layer about the single wire braiding layer. The combined inner tube, single wire braiding layer and single yarn braiding layer exceed the minimum performance characteristics of a Society of Automotive Engineers (SAE) standard comprising the SAE 100R5 standard. For example, the combined inner tube, the single wire braiding layer and single yam braiding layer meet or exceed each the following performance characteristics: a temperature operating range of -55 to 302 °F; an inner diameter range of 3/16 to 7/8 inches; a maximum operating range of 800 to 3,050 psi; a proof pressure range of 1,600 to 6,100 psi; and a minimum burst pressure range of 3,200 to 12,200 psi; and (f) a minimum bend radius of 1.5 to 3.54 inches.

[0005] In certain embodiments the high-pressure hose has an overall wall thickness and the inner tube has a wall thickness that comprises 55% to 65% of that overall wall thickness.

[0006] In certain embodiments, the single wire braiding layer is in direct contact with the inner tube. In certain embodiments, an insulation layer is intermediate the single wire braiding layer and the single yarn braiding layer. In certain embodiments the high-pressure hose further includes a flat crimp fitting coupled to the combined inner tube, single wire braiding layer and single yarn braiding layer.

[0007] In certain embodiments, the single wire braiding layer has a wire braid coverage in a range of 55% to 80% and/or wherein the single yarn braiding layer has a yarn coverage in a range of 115% to 140%.

[0008] In certain embodiments, the combined inner tube, single wire braiding layer and single yarn braiding layer have a service pressure in a range of 800 psi to 3050 psi and/or have a bend radius in a range of 38mm to 90 mm.

[0009] In certain embodiments the high-pressure hose comprises a fuel/oil hose, a hydraulic fuel hose, an air hose, a water hose, a coolant hose and/or a steering fluid hose.

[0010] A high-pressure hose comprising can include an inner tube having an internal diameter, a single wire braiding layer about the inner tube, and a single yam braiding layer about the single wire braiding layer. The high-pressure hose can be one of a first, second, third, fourth, fifth, or sixth size relating to an internal diameter of the inner tube, and wherein the high pressure hose has performance characteristics relating to a maximum operating pressure, a minimum burst pressure, and a minimum bend radius for a given size, as follows:

[0011] In some examples, the high-pressure hose has an overall wall thickness and wherein the inner tube has a wall thickness that comprises 55% to 65% of the overall wall thickness.

[0012] In some examples, the single wire braiding layer is in direct contact with the inner tube.

[0013] In some examples, an insulation layer is intermediate the single wire braiding layer and the single yam braiding layer.

[0014] In some examples, a flat crimp fitting is coupled to the combined inner tube, single wire braiding layer and single yarn braiding layer.

[0015] In some examples, the single wire braiding layer has a wire braid coverage in a range of 55% to 80%.

[0016] In some examples, the single yarn braiding layer has a yarn coverage in a range of 115% to 140%.

[0017] In some examples, the combined inner tube, single wire braiding layer and single yam braiding layer have a service pressure in a range of 800 psi to 3050 psi. [0018] In some examples, the combined inner tube, single wire braiding layer and single yam braiding layer have a bend radius in a range of 38mm to 90 mm.

[0019] In some examples, the high-pressure hose comprises a fuel/oil hose.

[0020] In some examples, the high-pressure hose comprises a hydraulic fluid hose. [0021] In some examples, the high-pressure hose comprises an air hose.

[0022] In some examples, the high-pressure hose comprises a water hose.

[0023] In some examples, the high-pressure hose comprises a coolant hose.

[0024] In some examples, the high-pressure hose comprises a power steering fluid hose.

[0025] In some examples, the high-pressure hose is the first size with an internal diameter of 0.19 inch and has a maximum operating pressure of about 3,050 psi, a minimum burst pressure of about 12,200 psi, and a minimum bend radius of about 1.5 inch, a vacuum service of about 94.8 in/Hg, and a weight about 0.11 pounds per foot.

[0026] In some examples, the high-pressure hose is the second size with an internal diameter of 0.31 inch and has a maximum operating pressure of about 2,300 psi, a minimum burst pressure of about 9,200 psi, and a minimum bend radius of about 1.97 inch, a vacuum service of about 94.8 in/Hg, and a weight about 0.14 pounds per foot.

[0027] In some examples, the high-pressure hose is the third size with an internal diameter of 0.41 inch and has a maximum operating pressure of about 2,050 psi, a minimum burst pressure of about 8,200 psi, and a minimum bend radius of about 2.28 inch, a vacuum service of about 94.8 in/Hg, and a weight about 0.17 pounds per foot.

[0028] In some examples, the high-pressure hose is the fourth size with an internal diameter of 0.5 inch and has a maximum operating pressure of about 1,750 psi, a minimum burst pressure of about 7,000 psi, and a minimum bend radius of about 2.75 inch, a vacuum service of about 94.8 in/Hg, and a weight about 0.21 pounds per foot. [0029] In some examples, the high-pressure hose is the fifth size with an internal diameter of 0.62 inch and has a maximum operating pressure of about 1,500 psi, a minimum burst pressure of about 6,000 psi, and a minimum bend radius of about 3.15 inch, a vacuum service of about 94.8 in/Hg, and a weight about 0.25 pounds per foot.

[0030] In some examples, the high-pressure hose is the sixth size with an internal diameter of 0.88 inch and has a maximum operating pressure of about 800 psi, a minimum burst pressure of about 3,200 psi, and a minimum bend radius of about 3.54 inch, a vacuum service of about 67.7 in/Hg, and a weight about 0.32 pounds per foot. Brief Description of the Drawings

[0031] FIGS. 1A-1C illustrate a prior art high pressure fuel and engine hose meeting the Society of Automotive Engineers (SAE) standard SAE 100R5 with FIG.

1 A providing a perspective view of the prior art high pressure fuel and engine hose with braiding and insulation layers revealed, FIG. IB providing a cross-sectional view of the braiding layers of the prior art high pressure fuel and engine hose, and FIG. 1C providing a perspective view of a barrel crimp fitting secured to the prior art high pressure fuel and engine hose.

[0032] FIG. 2 is a specification chart of an example prior art high pressure fuel and engine hose (i.e., the Aeroquip™ FC300 hose available from Eaton Hydraulics Group) in various size configurations.

[0033] FIGS. 3A-3C illustrate a high pressure fuel and engine hose according to the present disclosure that meets the SAE 100R5 standard with FIG. 3 A providing a perspective view of the high pressure fuel and engine hose with braiding and insulation layers revealed, FIG. 3B providing a cross-sectional view of the braiding layers of the high pressure fuel and engine hose, and FIG. 3C providing a perspective view of a flat crimp fitting securable to the high pressure fuel and engine hose of FIG. 3 A.

[0034] FIG. 4 is a specification chart of the high pressure fuel and engine hose of the present disclosure in various size configurations which correspond to the size configurations of FIG. 2.

Detailed Description

[0035] The present disclosure is directed to a high pressure engine and fuel hose that meets the SAE 100R5 standard while also providing a sleeker profile, reduced weight, increased flexibility, and a tighter bend radius than that provided by currently available high pressure engine and fuel hoses. Further, the high pressure engine and fuel hose of the present disclosure provides an improved cost of manufacturing and reduced carbon footprint over that provided by currently available high pressure engine and fuel hoses. [0036] Referring to FIGS. 1 A-1C, an example of a prior art high pressure engine and fuel hose 100 can be appreciated. The illustrated hose 100 can generally be termed a three-layer hose in that the hose 100 includes an elastomer inner tube 110 along with three layers of textile and wire braiding. A first braiding layer 120 is positioned about, and directly in contact with, the inner tube 110 and comprises a polyester yam braid. An insulation layer 122 separates the first braiding layer 120 from a second braiding layer 124 with the second braiding layer 124 comprising a reinforcement wire braid. Another insulation layer 126 separates the third braiding layer 128 from the second braiding layer 124 with a third braiding layer 128 comprising a polyester yam braid cover. The prior art high pressure engine and fuel hose 100 is terminated with a barrel crimp fitting 130 to achieve the SAE 100R5 standard.

[0037] In an example configuration, the prior art high pressure engine and fuel hose 100 comprises an Aeroquip™ FC300 hose, available from Eaton Hydraulics Group; the FC300 hose is known to meet the requirements of the SAE 100R5 standard. The FC300 hose has a tube thickness that ranges from 0.052 inches (FC300-04) to 0.100 inches (FC300-16), a first braiding layer 120 having a yarn braid coverage of 103% (FC300-04) to 20% (FC300-16), a second braiding layer 124 having a wire braid coverage of 65% (FC300-04) to 54% (FC300-16), and a third braiding layer 128 having a yam braid coverage of 116% (FC300-04) to 110 % (FC300-16). Note that FC300 is a part number while the number following the dash, e.g. -04 is a dash size. A dash size refers to an inner diameter (I.D.) of a hydraulic hose or fitting in 1/16 inch increments. For example, a -04 hose would indicate a hose with I.D. of 3/16 inches (5.0 mm - millimeter) and a -16 hose would indicate a hose with I.D. of 7/8 inch (22.0 mm).

[0038] FIG. 2 is a specification chart of the example prior art high pressure fuel and engine hose 100, i.e., the Aeroquip™ FC300 hose, in various size configurations. As illustrated, each hose configuration is identified by a part number and specifications for: (a) an inner diameter of the hose 100 ranging from 4.8 mm to 22.4 mm (0.19 inches to 0.88 inches); (b) an outer diameter of the hose ranging from 13.2 mm to 31.2 mm (0.52 inches to 1.27 inches); (c) a maximum operating pressure ranging from 210.0 bar to 56.0 bar (3000 psi to 800) psi; (d) a minimum burst pressure ranging from 840.0 bar to 224.0 bar (12000 psi to 3200 psi); (e) a minimum bend radius ranging from 76.2 mm to 187.5 mm (3.00 inches to 7.38inches); (f) a vacuum service ranging from 94.8 kPa to 67.7 kPa (28 in/Hg to 20 in/Hg); and (g) a hose weight ranging from 0.19 kg/m to 0.55 kg/m (0.13 lbs/ft to 0.55 lbs/ft). The performance characteristics of at least the maximum operating pressure, minimum burst pressure, and minimum bend radius listed in Fig. 2 can be characterized as indicating the SA 100R5 standard for each listed hose size.

[0039] Referring to FIGS. 3A-3C a high pressure engine and fuel hose 300 of the present disclosure can be appreciated. The illustrated high pressure engine and fuel hose 300 is designed to meet or exceed the SAE 100R5 standard performance characteristics through use of only two braiding layers in combination with a flat crimp fitting. It should be noted that while the high pressure engine and fuel hose 300 does exceed the SAE 100R5 standard performance characteristics it does so with dimensions that do not meet the SAE 100R5 standard.

[0040] As shown, the high pressure engine and fuel hose 300 includes an elastomer inner tube 310 along with first and second braiding layers. The first braiding layer 320 is positioned about, and directly in contact with, the inner tube 310. Notably, the first braiding layer 320 comprises a reinforcement wire braid as opposed to the first braiding layer 120 of the prior art hose 100 that is comprised of polyester yarns (e.g., the first braiding layer 120 of the prior art hose 100 is eliminated). An insulation layer 322 separates the first braiding layer 320 from a second braiding layer 324. The insulation layer 322, similar to the insulation layers 122, 126, comprises a rubber insulation compound having a tensile strength minimum of 1700 psi, a %EB min. of 160, a Modulus 100 is a min. of 800 psi and a hardness max. of 90. The second braiding layer 324 comprises a polyester yarn braid cover. The high pressure engine and fuel hose 300 is terminated with a flat crimp fitting 330 to achieve the performance characteristics of the SAE 100R5 standard.

[0041] In the design of the high pressure engine and fuel hose 300, the inner tube thickness is optimized and reduced from that of the prior art hose 100 (e.g., the FC300). For example, an inner tube thickness having a range of 0.062 in. to 0.080 is used. Further, the thickness of an inner tube wall is designed to comprise 55% to 65% of the total, overall hose wall thickness. [0042] FIG. 4 is a specification chart of the high pressure fuel and engine hose

300 of the present disclosure in various size configurations that correspond to the size configurations of FIG. 2. As illustrated, each hose configuration is identified by a part number and specifications for: (a) an inner diameter of the hose 300 ranging from 4.8 mm to 22.2 mm (0.19 inches to 0.88 inches); (b) an outer diameter of the hose ranging from 11.8 mm to 30.4 mm (0.46 inches to 1.20 inches); (c) a maximum operating pressure ranging from 210.0 bar to 56.0 bar (3050 psi to 800) psi; (d) a minimum burst pressure ranging from 840.0 bar to 224.0 bar (12200 psi to 3200 psi); (e) a minimum bend radius ranging from 38 mm to 90 mm (1.5 inches to 3.54 inches); (f) a vacuum service ranging from 94.8 kPa to 67.7 kPa (28 in/Hg to 20 in/Hg); and (g) a hose weight ranging from 0.17 kg/m to 0.47 kg/m (0.11 lbs/ft to 0.32 lbs/ft). Note the specification chart of FIG. 4 identifies the high pressure fuel and engine hose of the present disclosure with part numbers of FC250H/H250H along with a dash size. As noted earlier, a dash size refers to an inner diameter (I.D.) of a hydraulic hose or fitting that increases in 1/16 inch increments. For example, a -04 hose would indicate a hose with I.D. of 3/16 inches (5.0 mm), a -05 would indicates a hose with I.D. of 1/4 inches (6.3 mm) and so on to a -16 hose which indicates a hose with I.D. of 7/8 inch (22.0 mm).

[0043] The design of the of the high pressure engine and fuel hose 300 is further optimized by eliminating the prior art first braiding layer 120 from the hose enabling a reduced hydraulic diameter of the wire braiding layer 320 (hydraulic diameter is the wire braid outside diameter). Further, the percentage of wire braid coverage of the first braiding layer 320 is kept low, for example between 55% and 80% coverage, which assists in providing adhesion between the insulation layer 322 and the inner tube 310. In comparison to the prior art FC300 hose, the braid coverage of the first braiding layer 320 enables improved inner tube bonding, to the extent of 20% and 45%, between the inner tube 310 and the insulation layer 322.

[0044] The design of the high pressure engine and fuel hose 300 is further optimized by providing a polyester yarn coverage of the second braiding layer 324 in a range of 115% to 140% (percentage indicates number of yarns per square inch, e.g., a coverage of 115% has 115 yams per square inch). [0045] The optimized design considerations of the high pressure engine and fuel hose 300 produces a hose with a lighter weight, a compact design having a service pressure range of 800 psi to 3050 psi (56 bar to 210 bar), a bend radius of 38mm to 90mm (1.5 in. to 3.54 in.) and a hose wall thickness in the range of 2.8mm to 3.3mm (0.11 in. to 0.13 in). Further, the optimized design consideration of the high pressure engine and fuel hose 300 produces a hose that exceeds the SAE 100R5 impulse performance requirement at SAE 100R5 half-bend radius with flat crimp fitting 330 installed.

[0046] Overall, in comparison to the prior art FC300 hose, the hose outer diameter of the high pressure fuel and engine hose 300 is reduced by 10% which, in turn, provides improved flexibility at a reduced weight, improved performance and a hose design that is more easily routed in various applications. Example applications of the high pressure fuel and engine hose 300 include utilizing the high pressure engine and fuel hose 300 as a fuel/oil delivery line, an airbrake line, a power steering line, a coolant line, or any other high pressure fluid delivery application (fluids delivered can include, for example, hydraulic fluids, air, water, fuel, or coolants). Further, in comparison to the prior art FC300 hose, the flexibility of the high pressure fuel and engine hose 300 is improved by 25% and the weight of the high pressure fuel and engine hose 300 is reduced by 20%.

[0047] The description and illustration of one or more aspects of the invention provided in this application are not intended to limit or restrict the scope of the claims in any way. The aspects, examples, and details provided in this application are considered sufficient to convey possession and enable others to make and use the best mode of the claimed invention. The claims should not be construed as being limited to any aspect, example, or detail provided in this disclosure. Regardless of whether shown and described in combination or separately, the various features (both structural and methodological) are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate aspects falling within the spirit of the broader aspects of the general inventive concept and within the scope of the claims.