U.S. patent application number 11/146190 was filed with the patent office on 2005-12-01 for thin rubber hose and its production method.
Invention is credited to Baba, Hiroki, Fujii, Hiromi, Hirano, Yuji, Matano, Takafumi.
Application Number | 20050263937 11/146190 |
Document ID | / |
Family ID | 27344818 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050263937 |
Kind Code |
A1 |
Baba, Hiroki ; et
al. |
December 1, 2005 |
Thin rubber hose and its production method
Abstract
An impermeable rubber hose is thinned for the purpose of
reducing weight and costs. A rigid resin film is used as an
intermediate layer. When the resin film is gradually rolled up into
a cylindrical shape from a planar shape and fed to an extrusion
head and rubber is simultaneously extrusion-molded inside and
outside the cylindrical film, the film produces a break or a twist
to make extrusion molding difficult. It is an object of the present
invention to make simultaneous extrusion molding possible even in
such a condition. To attain the above object, a thermoplastic resin
film (5) which forms an intermediate layer (2) and of which the
melting point is lower than the vulcanizing temperature is formed
in a long belt-shape. Slits (7) are provided at fixed intervals on
the right and left long side sections (8, 8) of the film (5) in the
longitudinal direction. When the resin film (5) is fed into an
extrusion head (10) to be rolled up into a cylindrical shape,
because both the long side sections (8, 8) of the film (5) are
formed as weak sections by the slits (7), the film (5) adsorbs a
strain when bent and is bent in a circle, thereby allowing the
right and left long side sections (8, 8) to overlap at an
overlapping section (6). In this condition, rubber is
simultaneously extrusion-molded inside and outside the film and
then, vulcanized to weld the overlapping section (6), thereby
eliminating the slits (7).
Inventors: |
Baba, Hiroki; (Iruma-gun,
JP) ; Hirano, Yuji; (Iruma-gun, JP) ; Fujii,
Hiromi; (Iruma-gun, JP) ; Matano, Takafumi;
(Iruma-gun, JP) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
27344818 |
Appl. No.: |
11/146190 |
Filed: |
June 7, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11146190 |
Jun 7, 2005 |
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10148416 |
Jun 24, 2002 |
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6945279 |
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10148416 |
Jun 24, 2002 |
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PCT/JP01/05129 |
Jun 6, 2001 |
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Current U.S.
Class: |
264/171.12 ;
264/171.13; 264/171.26; 264/174.11 |
Current CPC
Class: |
Y10S 138/10 20130101;
F16L 11/06 20130101; F16L 2011/047 20130101; B29C 48/09 20190201;
F16L 11/04 20130101; B29C 48/06 20190201; B29C 48/153 20190201;
B29C 48/34 20190201 |
Class at
Publication: |
264/171.12 ;
264/171.13; 264/171.26; 264/174.11 |
International
Class: |
B29C 047/06 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 29, 2000 |
JP |
2000-301531 |
Sep 29, 2000 |
JP |
2000-301532 |
Sep 19, 2000 |
JP |
2000-301533 |
Claims
What is claimed is:
1. A method for producing by extrusion molding a thin rubber hose
having a resin film as an intermediate layer with an inner rubber
layer and an outer rubber layer laminated inside and outside the
resin film, the resin film consisting of a long belt-shaped film
having a weak section provided in advance on the long sides of the
film, wherein the resin film is rolled up into a cylindrical shape
so that the two long sides overlap, comprising the steps of:
feeding a long, belt-shaped resin film of which the long sides are
provided with a weak section in advance into an extrusion head to
be rolled up and bent into a cylindrical shape so that the two long
sides overlap; extruding rubber inside and outside the resin film
for integration and extrusion-molding a raw rubber hose of which
the intermediate layer is the resin film; and heating the raw
rubber hose to a predetermined temperature for vulcanization.
2. The method for producing the thin rubber hose according to claim
1, wherein the resin film is a thermoplastic resin and the
overlapping section is integrally welded simultaneously with
vulcanization.
3. The method for producing the thin rubber hose according to claim
1, wherein the weak section is composed of a plurality of slits cut
inwardly from the edge sections of the long sides, and the inward
end of each slit is inclined toward the feeding direction of the
resin film or is provided perpendicular to the longitudinal
direction of the resin film.
4. The method for producing the thin rubber hose according to claim
3, wherein the slits are respectively provided on both long sides
and provided in a positional relation in which they do not overlap
when the two long sides overlap.
5. The method for producing the thin rubber hose according to claim
3, wherein the slits are respectively provided on the two long
sides in a positional relation in which they overlap when the two
long sides overlap.
6. The method for producing the thin rubber hose according to claim
1, wherein the weak section is composed of a plurality of punched
holes.
7. The method for producing the thin rubber hose according to claim
1, wherein the weak section is formed by thinning one or both of
the long side sections which overlap.
8. The method for producing the thin rubber hose according to claim
1, wherein the rubber is mixed with a thermoplastic resin and after
vulcanizing the raw rubber hose, this hose is reheated to about the
melting temperature of the mixed thermoplastic resin to give a
predetermined shape.
9. The method for producing the thin rubber hose according to claim
7, wherein thinning is realized by a taper shape in which the
thickness is gradually reduced toward an end section.
10. A method for producing a thin rubber hose by extruding an inner
layer rubber and an outer layer rubber inside and outside an
intermediate layer made of a film of a substantially cylindrical
shape, comprising the steps of: rolling a belt-shaped film into a
substantially cylindrical shape to allow a pair of edge sections,
one on each side in the lateral direction of the film, to overlap
to form an overlapping section and feeding the film into an
extrusion head; and extruding the inner layer rubber and the outer
layer rubber inside and outside the film while decompressing and
drawing the overlapping section within the extrusion head.
11. The method for producing a thin rubber hose which has an
intermediate film layer according to claim 10, wherein the film is
fed into the extrusion head while being rolled up from a planar
shape to a substantially cylindrical shape at the inlet of the
extrusion head.
12. The method for producing a thin rubber hose which has an
intermediate film layer according to claim 10, wherein the film is
shaped into a substantially cylindrical shape in advance before fed
into the extrusion head.
13. The method for producing a thin rubber hose which has an
intermediate film layer according to claim 10, wherein the film is
composed of a thermoplastic resin or an inorganic material such as
metal, or a laminated structure combining them.
14. The method for producing a thin rubber hose which has an
intermediate film layer according to claim 10, wherein the film
bending load is 400 N or more when the film width is 100 mm and the
film thickness is 0.05 mm.
15. The method for producing a thin rubber hose according to claim
10, wherein each of the pair of edge sections overlapping at the
overlapping section is tapered so that they are thinned toward the
end in the lateral direction thereof.
16. A method for producing a thin rubber hose provided with an
intermediate layer by extruding an inner rubber layer and an outer
rubber layer inside and outside the intermediate layer of a
substantially cylindrical shape within an extrusion head,
comprising the steps of: forming a pipe serving as the intermediate
layer in advance; providing the pipe with a cut line in the axial
direction; feeding the pipe into the extrusion head, cutting the
pipe open; and rounding the pipe again within the extrusion head to
allow the cut line sections to directly or indirectly overlap,
thereby forming the cylindrical-shaped intermediate layer.
17. The method for producing a thin rubber hose provided with an
intermediate layer according to claim 16, wherein the bending load
of the intermediate layer is 400 N or more for a film of 100 mm
width and 0.05 mm thickness.
18. The method for producing a thin rubber hose provided with an
intermediate layer according to claim 16, wherein the inner rubber
layer and the outer rubber layer are extruded, decompressing and
drawing in the overlapping section.
19. The method for producing a thin rubber hose provided with an
intermediate layer according to claim 16, wherein the intermediate
layer is formed in a bellows-shape.
20. A method for producing by extrusion molding a thin rubber hose
having an inner rubber layer and an outer rubber layer laminated
respectively inside and outside a resin film serving as an
intermediate layer, the intermediate layer having a circular cross
section and forming an overlapping section by allowing a pair of
side sections, which divide the intermediate layer in the
circumferential direction, to overlap, wherein at least one of the
two sides forming the overlapping section on the surface side is
thinned to eliminate a step in the overlapping section on the
surface side, comprising the steps of: thinning at least one of two
long side sections of a long belt-shaped resin film; rounding the
resin film to be fed into an extrusion head so that the two long
sides of the resin film overlap to form an overlapping section
where no step is produced at least on the surface side; bending the
resin film into a cylindrical shape within the extrusion head; and
extruding rubber inside and outside the resin film.
21. A method for producing by extrusion molding a thin rubber hose
having an inner rubber layer and an outer rubber layer laminated
respectively inside and outside a resin film serving as an
intermediate layer, the intermediate layer having a circular cross
section and forming an overlapping section by allowing a pair of
side sections, which divide the intermediate layer in the
circumferential direction, to overlap, wherein at least one of the
two sides forming the overlapping section on the surface side is
thinned to eliminate a step in the overlapping section on the
surface side, comprising the steps of: rounding a long belt-shaped
resin film to allow the two long side sections to overlap; forming
the resin film into a cylindrical shape which has an overlapping
section where a step is produced at least on the surface side;
eliminating the step on the surface side by a subsequent process;
and extruding rubber inside and outside the cylindrical resin film.
Description
[0001] This application is a Divisional of co-pending application
Ser. No. 10/148,416 filed on Jun. 24, 2002 and for which priority
is claimed under 35 U.S.C. .sctn. 120. application Ser. No.
10/148,416 is the national phase of PCT International Application
No. PCT/JP01/05129 filed on Jun. 6, 2001 under 35 U.S.C. .sctn.
371. The entire contents of each of the above-identified
applications are hereby incorporated by reference. This application
also claims priority of Applications Nos. 2000-301531, 2000-301532
and 2000-301533 all filed in Japan on Sep. 29, 2000 under 35 U.S.C.
.sctn. 119.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for producing a
liquid or gas transportation hose, and more particularly to a
method for extrusion-molding rubber inside and outside an
intermediate layer which is formed by rolling up a film made of a
resin or the like into a cylindrical shape to allow both ends in
the bending direction to overlap.
DESCRIPTION OF THE PRIOR ART
[0003] An example of a rubber hose wherein rubber and a resin film
are laminated is disclosed in Japanese Unexamined Patent
Publication No. SHO 60-113882 in which an inner layer rubber, the
resin film serving as an intermediate layer, and an outer layer
rubber are extrusion-molded one by one. Also, in Japanese
Unexamined Patent Publication No. HEI 7-314610, there is a
description of a fluororesin film having excellent permeability
resistance being used alone as the intermediate layer and this
resin film is simultaneously extrusion-molded together with the
inner and outer rubber layers. For such simultaneous extrusion
molding, a method for feeding a long, belt-shaped resin film into
an extrusion head for rolling up into a cylindrical shape and for
extruding rubber inside and outside the resin film is also
known.
[0004] Further, Japanese Unexamined Patent Publication No. HEI
9-169061 discloses that in such a simultaneous extrusion molding,
reinforced fibers such as long belt-shaped knit are rounded into a
cylindrical shape to provide an intermediate layer, and inner and
outer rubber layers are simultaneously extrusion-molded, while
feeding the intermediate layer into an extrusion head.
[0005] When a liquid or gas transportation hose is thinned for the
purpose of reducing weight and costs, an inner layer collapses in a
process for weaving a reinforced intermediate layer and a process
for coating a subsequent outer layer rubber according to a hose
production method of conventional specifications and molding
becomes very difficult. Even in simultaneous extrusion molding in
which weaving of the reinforced intermediate layer is not
necessary, when the thickness of an overlapping section of the
reinforced intermediate layer is reduced, the strength deteriorates
and the thickness is limited to about 3.5 mm.
[0006] In the extrusion molding method, when the rubber hose is
produced using a resin and a metal film in the intermediate layer
for the purpose of thinning and improvement of permeability, an
intermediate layer film is inserted into an extrusion head in a
planar ribbon shape, i.e. a long belt shape. As a result, a strain
is generated in the intermediate layer film in a process in which
the film is finally wound from a conical shape to a cylindrical
shape. Accordingly, if the intermediate layer film is made of a
material which is soft and not flexible, a break or a twist is
produced in the intermediate film layer and the method becomes
limited, inasmuch as the film cannot be extrusion-molded into a
uniformly cylindrical shape.
[0007] It is therefore a first object of the present invention to
solve the above-mentioned problems, to increase the degrees of
freedom for bending during molding, to provide an impermeable thin
rubber hose which is thin and has excellent pressure resistance,
and to realize an efficient production method of the rubber
hose.
[0008] When a film made of resin etc. is rolled into a cylindrical
shape and fed into an extrusion head, allowing both ends in the
bending direction to overlap, wherein rubber is simultaneously
extruded inside and outside the film, an overlapping section of the
film is provided and if this overlapping section is vulcanized
while opening, there is the possibility that liquid or gas
contained within can permeate outside through this opening to the
detriment of the permeability resistance. To avoid this, the degree
of adhesion at the overlapping section must be increased so as not
to generate openings at each step to the completion of the
vulcanization. Causes of deterioration of the degree of adhesion by
emergence of openings at the overlapping section include:
[0009] 1) By using a high elastic modulus film with high rigidity,
softened inner and outer rubber layers directly after extrusion are
deformed to open by restoration of elasticity;
[0010] 2) Displacement of the overlapping section by bending of a
raw rubber hose when mounted on a mandrel for vulcanizing; and
[0011] 3) Generation of a gap in the overlapping section by welding
the overlapping section of which adhesion is incomplete.
[0012] The above-mentioned problem is readily caused when the film
is too hard to bend. When the bending load (hereinafter simply
referred to as "film bending load) of the film in measurements
converted from bending modulus of the film material in the
cross-section of which the width is 100 mm and the thickness is
0.05 mm is 400 N or more, it was difficult so far to perform
extrusion-molding in a condition in which the film is rolled to
allow the end sections to overlap. It was also difficult to perform
subsequent operations such as mounting of the hose on the
mandrel.
[0013] Accordingly, if a thin film with superb flexibility is
adopted, this kind of opening possibility can be eliminated.
However, it is difficult to satisfy the permeability resistance and
a tear in the film is readily generated when used during molding or
under high pressure. Accordingly, a film thickness of at least 0.05
mm or more is generally necessary to satisfy the demands of
permeability resistance and pressure resistance.
[0014] However, when the film of such a thickness is a
thermoplastic resin, because the resin strongly exhibits the
properties of elasticity and rigidity as an inherent property, it
is difficult to roll the film into a cylindrical shape so that it
serves as an intermediate layer. Even though the rolled
intermediate layer is formed, the strength of the outer layer
rubber is less than the elasticity of the film at the stage of raw
rubber hose before vulcanizing, the overlapping section easily
opens due to the elasticity of the film. When the raw rubber hose
is mounted on the mandrel for vulcanizing, the overlapping section
readily opens because the stress also acts from the inner surface
of the hose. This phenomenon also applies to an inorganic film such
as metal. Accordingly, it is extremely difficult to mold vulcanized
rubber hose by rolling up the film, which has a fixed thickness and
a fixed hardness necessary to satisfy the permeability resistance
and pressure resistance performance, to form an overlapping
section, thereby performing simultaneous extrusion-molding.
[0015] Further, when the film is extrusion-molded in a condition in
which volatile foreign material such as water is adhering to the
surface of the film, the volatile content expands during a heating
process such as vulcanizing. As a result, a foaming phenomenon is
generated when the rubber and the film adhere or the overlapping
section of the film is welded. Accordingly, there is some
possibility that the product performance will deteriorate. It is
therefore an second object of the present invention to solve the
problems described above and to provide a film which can be rolled
up to form an overlapping section, wherein the film serving as an
intermediate layer can be simultaneously extrusion-molded.
[0016] And it is a third object of the present invention to make
simultaneous extrusion molding possible using an intermediate layer
made of a high elastic material.
[0017] In the case where the long belt-shaped resin film is rounded
in a cylindrical shape, an overlapping section is formed at a part
of the circumferential section in the longitudinal direction. As a
result, a bar-shaped step resulting from the overlapping section is
formed on the surface of a rubber hose. Accordingly, when the
rubber hose is mounted on the other member and secured by a spring
clip, the fastening force becomes inconstant and as a result, an
improved method of securing is required to improve the sealing
properties or non-ejection properties. Particularly, if a rubber
hose is thinned for the purpose of lightening and miniaturization,
this bar-shaped step becomes larger. Also, if the resin film is
thickened to improve the barrier properties for permeation of gas
or liquid, the step becomes larger. It is therefore a fourth object
of the present invention to provide an improved thin rubber hose in
which, even though an overlapping section is formed on an
intermediate layer, this does not affect the surface of the rubber
hose.
DISCLOSURE OF THE INVENTION
[0018] To attain the above first object, according to the present
application, a rubber hose having a resin film as an intermediate
layer with an inner rubber layer and an outer rubber layer
laminated inside and outside the resin film is provided,
characterized in that the resin film is composed of a long,
belt-shaped film, wherein a weak section is provided in advance on
the long sides of the film and the resin film is rolled up into a
cylindrical shape so that the two long sides overlap. In this case,
the resin film can be a laminated metal film or reinforced fiber
layer structure.
[0019] According to the present invention, a method of producing a
thin rubber hose by extrusion molding comprises the steps of
feeding a long, belt-shaped resin film which is provided with a
weak section on the long sides in advance, to be rolled up and bent
into a cylindrical shape so that the two long sides overlap,
extruding rubber inside and outside the resin film for integration
and extrude-molding a raw rubber hose of which the intermediate
layer is the resin film, and heating the raw rubber hose up to a
predetermined temperature for vulcanization.
[0020] In this case, the resin film is a thermoplastic resin,
wherein the overlapping section can be vulcanized, and
simultaneously, integrally welded. Further, the weak section can be
formed by providing a plurality of slits or a plurality of punched
holes, or by thinning one or both of the long side sections which
overlap. It is also possible to provide this thinned section in a
tapered shape.
[0021] The rubber is mixed with a thermoplastic resin, wherein
after vulcanizing the raw rubber hose, this hose can be reheated to
the melting temperature of the mixed thermoplastic resin so that a
predetermined shape can be provided. As methods for extrusion
molding the inner and outer rubber layers, there are a construction
method for simultaneously extruding the inner layer rubber and the
outer layer rubber inside and outside the resin film, and a
construction method for extruding a laminated inner layer rubber
film first and then extruding the outer layer rubber on the
laminated inner layer rubber film. Either method can be
adopted.
[0022] According to a thin rubber hose and its production method
according to the present invention, when a resin film is rolled up
in a cylindrical shape within an extrusion head or the like,
because a weak section is provided in advance on the long sides, a
strain in the resin film generated in the rolling-up process is
adsorbed by deformation of the weak section. Because even a rigid
resin film can be easily bent in the cylindrical shape,
simultaneous extrusion molding is possible in a uniform shape. In
addition, the degrees of freedom for bending at the time of
vulcanizing molding can be increased. Further, sections other than
an overlapping section of the film also closely contact the inner
and outer layer rubbers by reduced pressure adsorption and this
close contact can be maintained until completion of a vulcanizing
process whereby the shape is finally determined. Accordingly,
production of a thin hose that has been difficult until now is also
possible. Further, it is possible to efficiently produce an
impermeable rubber hose that is thin and has excellent pressure
resistance.
[0023] To attain the above second and third objects, a method for
producing a thin rubber hose which has an intermediate film layer
according to the present invention is provided, in which an inner
layer rubber and an outer layer rubber are extruded inside and
outside the intermediate layer made of film of a substantially
cylindrical shape to mold the rubber hose, the method comprising
the steps of rolling the belt-shaped film into a cylindrical shape
to allow a pair of edge sections, one on each side in the lateral
direction, to overlap so that an overlapping section is formed,
feeding the film into an extrusion head, and extruding the inner
layer rubber and the outer layer rubber inside and outside the film
while decompressing and drawing the overlapping section into the
extrusion head.
[0024] In this case, there are two methods for feeding the film
into the extrusion head: First, the film is rolled from a planar
shape to a substantially cylindrical shape at the inlet of the
extrusion head to be fed into the extrusion head (hereinafter
referred to as "bending treatment within the extrusion head"). The
second is that the film is shaped into a substantially cylindrical
shape in advance in front of the inlet of the extrusion head and is
then fed into the extrusion head (hereinafter referred to as
"bending treatment outside the extrusion head"). Further, a
construction technique for simultaneously extruding the inner layer
rubber and the outer layer rubber inside and outside the film, and
a construction technique for extruding the laminated layer of the
inner layer rubber and the film, and then extruding the outer layer
rubber onto the film can also be adopted.
[0025] The film can be composed of a thermoplastic resin or an
inorganic material such as a metal, or a laminated structure
combining them. The bending load of the film of which the width is
100 mm and the thickness is 0.05 mm can be 400 N or more.
[0026] The two edge sections overlapping at the overlapping section
can be tapered so that they are thinned toward the ends in the
lateral direction.
[0027] In extrusion molding, the overlapping section can be caused
to adhere by decompressing the overlapping section of the film that
was rolled up into a circular shape. In the extruding molding for
forming the overlapping section on the film, adhesion can be
maintained so as to not allow the overlapping section to open
within the extrusion head. Accordingly, even such an intermediate
layer material that opens unless decompressed, simultaneous
extrusion molding is possible. Since adhesion of the overlapping
section can be continued until vulcanizing is completed after
extrusion molding, adhesion of the overlapping section can be
continued even within a raw rubber hose that is soft at an
unvulcanized stage. Even when the raw rubber hose is mounted on the
mandrel while being bent, it is possible to cause the overlapping
section to not open while maintaining adhesion. It is also possible
to prevent generation of a gap at the overlapping section by
welding the overlapping section in an adhering condition.
[0028] Accordingly, even though the film bending load is 400 N or
more for the film of which the width is 100 mm and the thickness is
0.05 mm, which is difficult in a conventional technique, it is
possible to continue operations without any problems from extrusion
molding to subsequent vulcanizing process by decompressing the
overlapping section. In addition, since parts other than the
overlapping section adhere to the inner and outer layer rubber by
pressure reduction and adsorption, and this adhesion can be
maintained until completion of the vulcanizing process whereby the
shape is finally determined, it is possible to produce a thin hose
that has been difficult until now.
[0029] Accordingly, it is possible to realize a method with
excellent mass productivity, even though a film with a thickness
that can satisfy the demands of reinforcement of heat resistance
and pressure resistance, and improvement of reinforcement and
permeability resistance can be provided. Particularly, a film of a
high elastic modulus that has been impossible to mold in a
conventional technique can be used. Further, since both the resin
and inorganic material can be used as the film material, it is
possible to freely choose the material according to the purpose and
performance required.
[0030] In this case, if the planar shaped film is processed by
bending treatment within the extrusion head, it is possible to make
the extrusion molding more efficient. Further, if the film is
formed into a cylindrical shape in advance by bending treatment
outside the extrusion head, processing becomes easier than with the
bending treatment within the extrusion head and a film with higher
rigidity can be used.
[0031] If each of a pair of edge sections overlapping at the
overlapping section is tapered so that they are thinned toward each
end, steps can be eliminated or reduced. Accordingly, when the
rubber hose is mounted on the other member and secured using a
spring clip, compacting (fastening) force becomes constant and as a
result, positive fastening can be realized to improve the sealing
properties and non-ejection properties. Even though the edge
sections are thinly tapered, adhesion can be maintained by
decompression.
[0032] To attain the above-mentioned third object, a method for
producing a thin rubber hose provided with an intermediate layer
according to the present invention is provided, in which an inner
rubber layer and an outer rubber layer are extruded inside and
outside the intermediate layer of a substantially cylindrical shape
within an extrusion head, comprises the steps of forming a pipe
serving as the intermediate layer in advance, providing the pipe
with a cut line in the axial direction, feeding the pipe into the
extrusion head while cutting the pipe open, and rounding the pipe
again within the extrusion head to allow the cut line sections
(i.e. end sections facing the cut line) to directly or indirectly
overlap, thereby forming the cylindrical intermediate layer.
[0033] In this case, the intermediate layer can be composed of a
thermoplastic resin, an inorganic material such as a metal, or a
laminated structure combining these. Further, a bending load of the
intermediate layer can be 400 N or more for a film of which a width
of 100 mm and a thickness of 0.05 mm. The inner rubber layer and
the outer rubber layer can also be extruded decompressing and
drawing the overlapping section. There are two extruding methods:
One is a construction technique for simultaneously extruding the
inner rubber layer and the outer rubber layer inside and outside
the pipe, and the other is a construction technique whereby the
inner rubber layer and the pipe are first laminated and extruded,
then the outer rubber layer is extruded onto the pipe. Either
technique can be adopted. Further, the intermediate layer can be
formed in a bellows-shape, be helically wound, or be provided with
an embossment.
[0034] According to the present invention, a pipe serving as an
intermediate layer is formed in advance. This pipe is provided with
a cut line in the axial direction and fed into an extrusion head,
cutting the pipe open. The pipe is rounded again within the
extrusion head to allow the cut line section to directly or
indirectly overlap, thereby forming the intermediate layer of a
cylindrical shape. Thus, even a highly elastic material of which
the bending load in a width of 100 mm and a thickness of 0.05 mm
which is difficult in a conventional technique is 400 N or more can
be rounded into a cylindrical shape and fed into the extrusion
head. Accordingly, a method can be realized which has excellent
productivity and which can use the intermediate layer of which the
thickness can satisfy the demands of reinforcement, such as for
pressure resistance and improvement of permeability resistance.
Further, since either of the thermoplastic resin and the inorganic
material or the laminated body of these can be used for the
intermediate layer material, it is possible to freely choose any of
them according to the aiming performance.
[0035] If the overlapping section is decompressed at the time of
extrusion molding, it is possible to allow the overlapping section
to adhere. Accordingly, adherence can be maintained so that the
overlapping section does not open within the extrusion head, and
simultaneous extrusion molding becomes possible without opening the
overlapping section even in the case of high elastic material.
Further, adherence of the overlapping section within the raw rubber
hose can be maintained even at the unvulcanizing stage after
extrusion molding. Even when the rubber hose is bent to be mounted
on the mandrel in the subsequent vulcanizing process, it is
possible to allow the overlapping section to continuously adhere so
as not to open the overlapping section. Accordingly, by
decompressing the overlapping section, operations from extrusion
molding to completion of the subsequent vulcanizing process can be
performed without any problem using the intermediate layer of high
elasticity. Sections other than the overlapping section of the pipe
are caused to adhere to the inner and outer rubber layers by
decompression and drawing and this adherence is maintained until
the completion of the vulcanizing process whereby a final shape is
determined. Thus, it is also possible to produce a thin hose that
would be difficult by a conventional technique. If the intermediate
layer is provided with a bellows shape or is helically wound, or is
provided with embossment, bending during mounting of the hose on
the mandrel is easy and it is possible to make opening of the
overlapping section more difficult.
[0036] To attain the above-mentioned fourth object, according to
the present invention, a thin rubber hose comprising an inner
rubber layer and an outer rubber layer laminated respectively
inside and outside a resin film serving as an intermediate layer,
characterized in that the intermediate layer has a circular
cross-section and forms an overlapping section by allowing a pair
of sides which divide the intermediate layer in the circumferential
direction to overlap, wherein at least one of the two sides forming
the overlapping section on the surface side is thinned to eliminate
a step in the overlapping section on the outside. In this case, the
thinned section can be tapered to reduce the thickness of the side
toward one end in the circumferential direction.
[0037] Further, a method for producing a thin rubber hose by
extrusion molding comprises the steps of thinning at least one of
two long side sections of a long belt-shaped resin film, rounding
the resin film to be fed into an extrusion head so that the two
long sides of the resin film overlap to form an overlapping section
where no step is produced at least on the surface side of the two
sides, bending the resin film in a cylindrical shape within the
extrusion head, and extruding rubber inside and outside the resin
film.
[0038] It is also possible to round a long belt-shapes resin film
to allow the two long side sections to overlap, form a cylindrical
shape which has an overlapping section where a step is produced at
least on the surface side of the two sides, eliminate the step on
the surface side by a subsequent process, and extrude rubber inside
and outside the cylindrical resin film.
[0039] According to the present invention, when the resin film is
rounded in a cylindrical shape or after the resin film is rounded,
it is possible to produce no step at least on the surface of the
overlapping section. Accordingly, when a rubber layer is laminated
inside and outside the cylindrically shaped resin film to produce a
thin rubber hose, no step is produced resulting from the
overlapping section on the thin rubber hose surface.
[0040] Accordingly, when the thin rubber hose is mounted on the
other member and secured by a spring clip, the fastening force
becomes constant to improve the sealing properties, wherein it is
possible to make it difficult for the rubber hose to become
detached from the other member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a perspective view of a hose product partially cut
away according to a first embodiment (FIGS. 1 through 6);
[0042] FIG. 2 is a cross-sectional view taken along line 2-2 of
FIG. 1;
[0043] FIG. 3 is a view schematically showing an extrusion molding
process;
[0044] FIG. 4 is a view showing a planar shape of a resin film;
[0045] FIG. 5 is a view explaining mounting of a hose on a mandrel
in a vulcanizing process;
[0046] FIG. 6 is a partially expanded cross-sectional view showing
a mandrel mounting condition;
[0047] FIG. 7 is a perspective view of an intermediate layer
according to a second embodiment (FIGS. 7 and 8);
[0048] FIG. 8 is a view showing a resin film in the extended
shape;
[0049] FIG. 9 is a view showing an entire molding device of a
second embodiment;
[0050] FIG. 10 is an enlarged cross-sectional view of an essential
part within an extrusion head;
[0051] FIG. 11 is a cross-sectional view taken along the line 11-11
of FIG. 9;
[0052] FIG. 12 is a detailed cross-sectional view of the extrusion
head;
[0053] FIG. 13 is view showing a structure of an overlapping
section according to a third embodiment;
[0054] FIG. 14 is a view showing a joint structure of an
overlapping section according to a fourth embodiment;
[0055] FIG. 15 is an end view of an intermediate layer according to
a fifth embodiment (FIGS. 15 and 16);
[0056] FIG. 16 is an extended perspective view of a resin film;
[0057] FIG. 17 is a view showing a structure of a lamination film
according to an sixth embodiment;
[0058] FIG. 18 is a view showing a joint structure of an
overlapping section according to a seventh embodiment;
[0059] FIG. 19 is a view showing a vulcanizing process according to
a eighth embodiment;
[0060] FIG. 20 is a view showing a cross head construction
technique of a ninth embodiment;
[0061] FIG. 21 is a view showing the helical winding of a film
according to the above-mentioned construction technique;
[0062] FIG. 22 is a partially enlarged cross-sectional view of the
helical winding;
[0063] FIG. 23 is a view schematically showing a molding device of
a tenth embodiment;
[0064] FIG. 24 is a perspective view schematically showing an
extrusion molding method according to the tenth embodiment;
[0065] FIG. 25 is a cross-sectional view corresponding to the line
25-25 of FIG. 23;
[0066] FIG. 26 is a view showing a joint structure of an
overlapping section according to an eleventh embodiment;
[0067] FIG. 27 is a perspective view of a completed thin hose
partially cut away according to a twelfth embodiment (FIGS. 27
through 30);
[0068] FIG. 28 is a cross-sectional view taken along the line 28-28
of FIG. 27;
[0069] FIG. 29 is a cross-sectional view showing a condition in
which a resin film is rounded;
[0070] FIG. 30 is a perspective view showing the planar shape of
the resin film;
[0071] FIG. 31 is an end view of an intermediate layer according to
a thirteenth embodiment (FIGS. 31 and 32);
[0072] FIG. 32 is a partial cross-sectional view of an extrusion
head according to the thirteenth embodiment; and
[0073] FIG. 33 is a view showing a fourteenth embodiment for
eliminating a step in a overlapping section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0074] Preferred embodiments of the present invention will now be
described with reference to the accompanying drawings. As shown in
FIGS. 1 and 2, a rubber hose 1 according to the present invention
is provided with an inner rubber layer 3 inside an intermediate
layer 2 made of a resin film and an outer rubber layer 4 outside
the intermediate layer 2. The rubber hose 1 is obtained by
extrusion-molding these three layers at the same time.
[0075] The total thickness of the rubber hose 1 including the
intermediate layer 2, the inner layer rubber layer 3, and the outer
layer rubber layer 4 is about 1.5.about.3.5 mm. This is a
remarkably thin hose compared with a conventional one. In the
present invention, a thin hose means one in such a thickness range.
It is desirable that the total thickness of the intermediate layer
2 be in a range between 0.01 mm and 1.00 mm.
[0076] The resin film 5 forming the intermediate layer 2 is rolled
up into a cylindrical form to provide a partially overlapping
section 6. The overlapping section 6 is provided in the
longitudinal direction with a plurality of slits 7 at predetermined
intervals.
[0077] The resin film 5 forming the intermediate layer 2 is a
thermoplastic resin of which the melting point is between
50.degree. C. and 300.degree. C. For example, THV500 and THV610G
(trade names of ternary fluororesin manufactured by Sumitomo 3M
Co., Ltd.) or nylon-12 are used. A material for such a resin film
can be chosen from a resin such as LDPE (low density polyethylene),
LLDPE (linear low density polyethylene), HDPE (high density
polyethylene), PP (polypropylene), PET (polyethylene
terephthalate), PBT (polybutylene terephthalate), PA6 (polyamide
6), PA66 (polyamide 66), PA11 (polyamide 11), PA12 (polyamide 12),
PPS (polyphenylene sulfide), PVDC (polyvinylidene chloride), PVC
(polyvinyl chloride), PVA (polyvinyl alcohol), ethylene-vinyl
alcohol copolymer, or fluororesin (monopolymer, bipolymer, and
terpolymer) according to use in view of strength, pressure
resistance, permeability resistance, melting point, heat
resistance, flexibility resistance, price or the like. A film can
be manufactured by either of an inflation film molding method or a
T-die molding method, so that multi-layer extrusion is possible for
each molding method. Further, it is possible to laminate separately
extruded films for molding at a later process.
[0078] A rubber material forming the inner rubber layer 3 and the
outer rubber layer 4 can be chosen from NBR (nytril butadiene
rubber), SBR (styrene butadiene rubber), FKM (fluorine-contained
rubber), BR (butadiene rubber), CR (chloroprene rubber), IIR
(isobutylene isoprene rubber), CSM (chlorosulfonated polyethylene
rubber), ECO (epichlorohydrine rubber), EPDM
(ethylene-propylene-diene rubber), or silicon rubber based on
demand characteristics from the viewpoints of permeability
resistance, strength, heat resistance, weather resistance, chemical
resistance, oil resistance, cold resistance, hardness, specific
gravity, or price. The inner and outer layers can be manufactured
as a structure of up to three layers by combining the same or
separate materials.
[0079] FIG. 3 is a view for schematically explaining simultaneous
extrusion molding in which an intermediate layer forming section 11
of an extrusion head 10 is separately shown for the sake of
convenience. In this figure, a resin film 5 formed in a long,
belt-shape is continuously fed into the intermediate layer forming
section 11 along a feeding direction A. In this case, the resin
film 5 gradually changes its shape from the original planar shape B
to a conical shape C and then a cylindrical shape D when fed into
the intermediate layer forming section 11.
[0080] Namely, the right and left, long side sections 8, 8 relative
to the feeding direction A are overlapped within the intermediate
layer forming section 11 to form an overlapping section 6. The
right and left long side sections 8, 8 are rolled up in a circular
section to form a cylindrical shape D, but first they form a
conically shaped section C as an intermediate form for shifting
from the planar shape B to the cylindrical shape D in the vicinity
of the inlet of the intermediate layer forming section 11. At the
conically shaped section C, both the long side sections 8, 8 of the
resin film 5 are bent in the direction in which they come close to
gradually form the overlapping section 6.
[0081] When the resin film 5 forms the cylindrical shape D within
the intermediate layer forming section 11, an inner layer rubber
and an outer layer rubber are extruded inside and outside the
cylindrical shape D by the extrusion head 10, wherein a hollow raw
rubber hose 12 obtained by integrally forming these three layers is
simultaneous extrusion-molded and exits the extrusion head 11. This
raw rubber hose 12 is cut to a predetermined dimension and becomes
a completed rubber hose product 1 through a vulcanizing process
described later.
[0082] FIG. 4 shows part of the resin film 5 which is in the planar
shape B. Slits 7 are provided by cutting the edge section of the
right and left, long side sections 8, 8 in a range, entering
inwardly, forming a width of an overlapping dimension (a) from each
edge section of both long side sections on the right and left side.
This overlapping dimension (a) has a width equivalent to or smaller
than that of the overlapping section 6. The structure of the long
sided sections 8, 8 forming the slits 7 is one specific example of
a weak section structure.
[0083] The slits 7 are formed in such a manner that the inward end
section is inclined forward toward the feeding direction A.
However, the angle of inclination is optional, but it can be
provided in a range of up to 90.degree., i.e. in a range up to the
perpendicular to the feeding direction A, which is substantially
parallel to a short side 9. The slits 7 are also formed in the
longitudinal direction at regular intervals. If the interval is b,
the slits are alternately arranged to be offset by (1/2) b on the
right and left sides and, in the overlapping section 6, the right
and left slits 7, 7 are arranged to not overlap.
[0084] However, the slits can be arranged to overlap at the
overlapping section 6. In this case, it is effective for the
overlapping section 6 to be completely welded at a vulcanizing
temperature. Since the slits are situated in the same position on
the right and left sides, the raw rubber hose 12 can be easily bent
when inserted into a mandrel for the vulcanizing process. It is
also possible to provide the slits with a different angle and
length on the right and left sides. The slits 7 with various
structures can be continuously formed when the resin film 5 is
molded.
[0085] Further, when a length obtained by adding one third (1/3) of
the circumferential length (for example, when the inner diameter of
a rubber hose is 36.5 mm and the thickness thereof is 3 mm, the
added length is 41 mm) of the intermediate layer 2 to the
circumferential length is set as the maximum width (i.e. short side
measurement) of the resin film 5, it is desirable that slits 7 of a
maximum length of 40 mm be provided at equal intervals in the
longitudinal direction of the resin film 5 on both sides or one
side of the long side sections 8, 8 of the resin film 5.
[0086] FIGS. 5 and 6 show a vulcanizing process for a raw rubber
hose 1a obtained by such simultaneous extrusion molding. Namely,
the raw rubber hose 1a cut to a predetermined dimension is mounted
on a mandrel 19 which has a selectively bent shape as a
three-dimensional shape and is vulcanized at a predetermined
temperature for a predetermined time. In this manner, a rubber hose
product 1 with a bent shape corresponding to the mandrel 19 is
obtained.
[0087] In this case, as shown in FIG. 6, if the mandrel 19 is
provided near the base section 19a of the mandrel 19 with a taper
section 19b expanding outward toward the lower section, the end
section of the raw rubber hose 1a is also formed with an expanded
section 1b of a tapered shape which is similar to the taper section
19b of the mandrel 19. In this manner, it is possible to easily
manufacture an expanded hose, to be connected to the rubber hose,
of which the outer diameter is different from the inner diameter of
the rubber hose.
[0088] Operation of the present invention will now be described. In
FIG. 3, since the long sided sections 8, 8 are provided with slits
7, these sections 8, 8 form weak sections. Accordingly, when a
resin film 5 is fed into an intermediate layer forming section 11
along the feeding direction A, the resin film 5 is deformed to have
a conic section C which is an intermediate form for shifting from a
planar shape B to a cylindrical shape D. Any strain in the resin
film 5 generated in this case can be absorbed by a change of
opening conditions of the slits 7.
[0089] Accordingly, even though the resin film 5 is made
comparatively thick and rigid without flexibility and extensibility
for the purpose of improving permeability and pressure resistance,
a break or a twist is not generated in the course of the conic
section C, wherein a uniform cylindrical shape can be provided
within the intermediate layer forming section following the conic
section C. As a result, since a uniform cylindrical shape can be
maintained even during the simultaneous extrusion molding in an
extrusion head 10, it is possible to form a thin hose.
[0090] Even in the case of woven fabric reinforced cloth which is
superior to the resin film in flexibility and extensibility and of
which the cloth end section in the overlapping section is
originally difficult to break during extrusion molding, there is
some possibility that the cloth end section will break if the
overlapping width is too great. In the case of the resin film which
is inferior to the woven fabric reinforced cloth in flexibility and
extensibility, it is considered that a break will be easily
generated in the course of bending into a cylindrical shape from a
planar shape. However, by providing a weak section such as slits on
the long side sections 8, 8, the resin film can be easily bent and
such a break is easily prevented.
[0091] Further, within the intermediate layer forming section 11,
the long side sections 8, 8 on the right and left sides form an
overlapping section 6, wherein the slits 7 on the right and left
sides do not overlap and are alternately situated in the
longitudinal direction. Accordingly, although the slits 7 are
provided, it is possible to prevent permeation through the slits 7
and to maintain good impermeability that is an object of the
present invention.
[0092] In a condition of the raw rubber hose 1a obtained by such a
simultaneous extrusion molding method, at the overlapping section 6
of the resin film 5 forming the intermediate layer 2, the long side
sections 8, 8 which overlap are not integrally provided by welding
or the like. Accordingly, some displacement is possible between the
overlapped sections.
[0093] However, since the intermediate layer 2 is integrally
embedded between an inner rubber layer 3 and an outer rubber layer
4, it is possible to maintain the overlapping section 6 even though
there is deformation due to some displacement or the like. The
overlapping measurement (a) (see FIG. 4) is also set to such a
degree that the overlapping section 6 can be maintained.
[0094] When the raw rubber hose 1a is vulcanized as shown in FIG.
5, the raw rubber hose 1a can be mounted on the mandrel 19
following the bent shape of the latter since the overlapping
section 6 is designed to have a flexible structure for permitting
the deformation such as displacement.
[0095] Next, when the raw rubber hose 1a mounted on the mandrel 19
is vulcanized at a predetermined temperature, the inner layer
rubber layer 3 and the outer layer rubber layer 4 are vulcanized
and fixed to a bent shape. Since the resin film 5 of the
intermediate layer 2 is also melted at the vulcanizing temperature
and then hardened, the upper and lower long side sections 8, 8 are
integrally welded at the overlapping section 6. In this case, since
the slits 7 have disappeared to form a single resin layer,
impermeability improves further.
[0096] Also, since the slits 7, 7 provided on both the long side
sections 8, 8 are alternately formed not to overlap at the
overlapping section 6, the slits 7 on one side of the long side
sections 8, 8 overlap the sections where no slits are provided on
the other side at the overlapping section 6. As a result, no
internal solution permeates through the slits 7.
[0097] However, the slits 7, 7 provided on both the long side
sections 8, 8 can be provided in such a position that they overlap
at the overlapping section 6. In this case, the resin film 5 can be
easily bent into a cylindrical shape compared with the case where
the slits are alternately provided. Even though the slits 7, 7
provided on both the long side sections 8, 8 overlap at the
overlapping section 6, the slits 7, 7 are melted and welded when
vulcanized and finally disappear. As a result, no internal solution
permeates through the slit sections.
[0098] As shown in FIG. 6, an expanded section 19b can also be
easily formed by a flexible structure at the overlapping section 6.
If the raw rubber hose is semi-cured (semi-vulcanized) soon after
extrusion to increase the rubber hardness, the raw rubber hose can
be easily inserted into the mandrel. The raw rubber hose can also
be vulcanized on the mandrel.
[0099] Further, if the resin film 5 is formed to have a
multilayered structure of two to five layers and the melting point
of the resin film of at least an innermost layer or an outermost
layer is lower than the vulcanizing temperature of the raw rubber
hose 12, it is possible to weld the overlapping section 6 and slits
7 of the resin film 5 in the vulcanizing process. When a resin of
which the permeability resistance is superior, but the melting
point is low, is used, the resin with a low melting point can also
be used by laminating a resin of which the heat resistance is
superior to both sides of the resin of low melting point.
[0100] Close contact between the intermediate layer 2 and the inner
layer rubber 3 and outer layer rubber 4 at the overlapping section
6 and at sections other than the overlapping section 6 is
maintained until completion of molding under pressure reduced
during extrusion. Accordingly, it is possible to manufacture a thin
hose such as has been difficult until now. For example, when the
film 5 is 0.2 mm thick, it is possible to set the thickness of the
inner layer rubber 3 at 0.8 mm, the thickness of the outer layer
rubber 4 at 1.0 mm and the entire thickness at 2.0 mm. Further, the
entire thickness of the inner layer rubber 3, the intermediate
layer 2 and the outer layer rubber 4 can be about 3 to 500 times as
thick as the entire thickness of the intermediate layer 2. However,
it is desirable that the entire thickness of the inner layer rubber
3, the intermediate layer 2, and the outer layer rubber 4 be about
20 times as thick as the entire thickness of the intermediate layer
2 for the purpose of obtaining a thin hose.
[0101] As is obvious from FIGS. 7 and 8, punched holes 7a are
formed at fixed intervals in the longitudinal direction at a
section (i.e. an overlapping section) where the long side sections
8, 8 overlap. The punched holes 20 are alternately provided not to
overlap on the right and left sides.
[0102] Since it is possible to make the long side sections 8, 8
weak flexible sections in such a manner, the same function as the
slits can be expected. The punching holes 7a can also be
continuously formed when the resin film 5 is molded.
[0103] As other examples of the weak section, there are
irregularities shown in FIGS. 13 and 14, a step-like thin section
shown in FIG. 29, a tapered thin section shown in FIG. 31 and the
like. These examples will be described hereinafter.
[0104] The principle of a method for molding the rubber hose by the
bending treatment within an extrusion head is explained by FIG. 9.
First, a belt-shaped film 5 is continuously fed to an
extrusion-molding machine 10 from a raw film roll 17, wherein the
film 5 is rolled up into a cylindrical shape to be fed to an
intermediate passage 12 of an extrusion head 11. The intermediate
passage 12 is a passage for feeding the film 5 and is provided
between an intermediate layer forming section 13 which is part of
the extrusion head 11. An inner passage 14 for an inner layer is
provided inside the intermediate layer forming section 13 and an
outer passage 15 for an outer layer is provided outside the
intermediate layer forming section 13. Raw rubber is fed to each
passage to form inner and outer layers. These three passages are
joined at the junction 16a in the vicinity of the inlet of a
collective passage 16. The raw rubber passes through the collective
passage 16 and is extruded from there as a rubber hose 1 in which
three layers are integrally formed.
[0105] By connecting a vacuum pump 18 serving as a pressure
reduction device to the intermediate passage 12, the intermediate
passage 12 is reduced to a predetermined level of pressure lower
than atmospheric pressure. The pressure reduction extends to the
collective passage 16 through the intermediate passage 12.
Accordingly, the inner and outer layers 3, 4 are integrally
laminated on the intermediate layer 2 by increasing their degree of
adhesion to the intermediate layer 2. Two vacuum pumps 18 are shown
in the figure for the sake of convenience, but the actual
intermediate passage 12 is a single ring-shaped passage to which
one vacuum pump 18 is connected.
[0106] The rubber hose 1 in a condition directly after extrusion
molding is performed as an unvulcanized or semi-vulcanized raw
rubber hose 1a to be vulcanized later. The extruded raw rubber hose
1a is cut to a predetermined dimension and vulcanized by a method
shown in FIG. 6.
[0107] FIG. 10 is an enlarged cross-sectional view for partially
explaining an overlapping section 6 in the vicinity of the junction
16a of FIG. 9. FIG. 11 is a cross-sectional view taken along line
11-11 of FIG. 9 to show the condition of the intermediate layer 2
within the intermediate layer forming section 13. As shown in these
figures, the intermediate layer forming section 13 is tapered
toward the junction 16a and an opening width of an intermediate
passage 12 on the outlet side facing the junction 16a is about the
thickness of the overlapping section 6.
[0108] Accordingly, on the outlet side of the intermediate passage
12, the upper and lower films 5, 5 forming the overlapping section
6 are caused to come into close contact by the intermediate layer
forming section 13. Since the intermediate passage 12 is
decompressed in the pressure reduction direction schematically
shown by arrows on a colored background of FIG. 10, pressure
between the upper and lower films 5, 5 is also reduced at the
overlapping section 6 to provide strong adhesion therebetween. As a
result, foreign materials such as volatile matter in the
overlapping section 6 are drawn out and removed. Accordingly, it is
possible to prevent generation of a phenomenon whereby the volatile
matter content expands to form bubbles at the time of heating in
the subsequent vulcanizing process.
[0109] Further, as shown in FIG. 11, a small space 29 is formed
between a section of the film 5 other than the overlapping section
6 and a section of the intermediate passage 12 on the exit side.
Accordingly, pressure on the junction 16a shown in FIG. 10 can also
be reduced at the same time by a vacuum pump 18 connected through
the space 29 to the intermediate passage 12.
[0110] The film 5 is fed into the junction 16a in a condition in
which a section of the upper and lower films 5, 5 at the
overlapping section 6 is decompressed and caused to adhere, wherein
the inner layer rubber 3 and the outer layer rubber 4 are
integrally formed. Accordingly, even with such a hard film 5
whereby the overlapping section 6 does not adhere, it is possible
to positively allow the overlapping section 6 to adhere for
simultaneous extrusion molding. Since bending treatment within the
extrusion head is possible, highly efficient mass-production can be
realized.
[0111] In this case, as is obvious from FIG. 10, a high vacuum
condition is maintained up to the junction 16a. Accordingly, it is
possible to eliminate gas such as air, or foreign materials such as
volatile matter content, and to allow the inner layer rubber 3 and
the outer layer rubber 4 to be integrally formed with the
intermediate layer 2 with a high degree of adhesion. It is also
possible to prevent generation of a phenomenon whereby the volatile
material content expands to form bubbles during heating in the
subsequent vulcanizing process. Further, since the high vacuum is
maintained up to the conjunction 16a, the outer layer rubber 4 and
the inner layer rubber 3 also receive the force in the direction in
which they come close and it is possible to integrally form them
together with high adherence strength.
[0112] A raw rubber hose 1a extrusion-molded in such a manner is
cut to the necessary length after cooling and stored until
vulcanization. Adhesion between the intermediate layer 2, the inner
layer rubber 3 and the outer layer rubber 4 at the overlapping
section 6, and at the section other than the overlapping section 6,
is maintained under the reduced pressure when extruded. No
treatment is given to the hose end surface after cutting, but since
the rubber of the inner and outer layer apply bearing stress to the
film contacting surface, no phenomenon whereby the atmosphere or a
water content permeates into the overlap of the film occurs. The
adhering condition at the overlapping section can be maintained
even during storage of the raw rubber hose.
[0113] As shown in FIG. 6, adhesion of the overlapping section 6
under decompression is maintained until vulcanizing is completed.
It is therefore possible to prevent displacement or opening of the
overlapped section between contacting surfaces. Further, when the
overlapping section 6 is welded at the vulcanizing temperature by
vulcanizing after mounting on the mandrel 18, no gap is produced at
the overlapping section 6 because adhesion is maintained. Since the
overlapping section 6 is completely integrated from that point,
permeability resistance and pressure resistance can be favorably
maintained.
[0114] Accordingly, even though a hard film is used which can
satisfy predetermined demands such as high permeability resistance
and pressure resistance which are required, for example, in a fuel
hose, simultaneous extrusion molding can not only satisfy
permeability resistance, pressure resistance or the like, but also
provide a method that has excellent mass-productivity.
[0115] Table shows the relationship between the film bending load
and the condition of the overlapping section in the process from
extrusion molding to vulcanizing, wherein a .largecircle. is marked
when the overlapping section did not open and an X is marked when
it opened. A comparative example 1 shows a case where bending
treatment within the extrusion head was performed without pressure
reduction. An embodiment 1 is a case where the bending treatment
within the extrusion head was performed when pressure was reduced
to the negative pressure of 98658 Pa (namely 740 mmHg) below the
atmospheric pressure. As is obvious from this Table, in the
comparative example 1, when the film bending load is 400 N or more,
the result was X (not suitable), but in the embodiment 1,
processing between 5000 N and 10000 N is possible. This means that
a hard film having high bending modulus, i.e. the strong elasticity
and rigidity, in other words, a hard film that can attain high
permeability resistance and pressure resistance, can be used.
[0116] An embodiment 2 in FIG. 1 is an example using the bending
treatment outside the extrusion head where the film 5 is shaped to
be bent in a lateral direction in advance by a means other than the
extrusion head in front of the inlet of the extrusion head 11.
Comparison with the embodiment 2 will be described hereinafter.
1TABLE Comparative Film bending load (*) example Embodiment 1
Embodiment 2 250 N 400 N X 5000 N X 10000 N X X 20000 N X X : No
opening formed at overlapping section; X: Opening formed at
overlapping section. (*): Film bending load is a measure converted
from bending modulus of the film material in the cross section of
which the width is 100 mm and the thickness is 0.05 mm. Molding
Conditions Comparative example: Bending treatment within extrusion
head, molded at atmospheric pressure. Embodiment 1: Bending
treatment within extrusion head, molded at 98658 Pa (740 mm Hg)
below the atmospheric pressure. Embodiment 2: Bending treatment
outside extrusion head, molded at: 98658 Pa (740 mm Hg) below the
atmospheric pressure.
[0117] FIG. 12 is a cross-sectional view showing one specific
example of the extrusion head 11. As is obvious from this figure,
the front end of the extrusion head 11 is provided with a core 20
and a die 21 surrounding the periphery of the core 20. Provided
between the outer circumference of the core 20 and the inner
circumference of the die 21 is a circular slit 22 for extruding the
rubber hose 1. The circular slit 22 is concentrically provided with
the outer circumference of the core 20 and the inner circumference
of the die 21.
[0118] The outer circumferential surface of the core 20 and the
inner circumferential surface of the die 21 are respectively
provided with linear cross-sectional sections 23, 24 parallel to
the extrusion axis C. Each rear section of the linear
cross-sectional sections 23, 24 continuously extends to an
ascending slope 25 which inclines to expand outwardly relative to
the extruding direction A and a descending slope 26 which inclines
inwardly.
[0119] Provided within a space formed to expand backward between
the ascending slope 25 and the descending slope 26 are a
substantially cylindrical outer cylindrical section 27 of which the
top is tapered off and an inner cylindrical section 28 of which the
top is tapered in the expanding direction and which is provided
concentrically inside the outer cylindrical section 27. The outer
cylindrical section 27 and inner cylindrical section 28 form an
intermediate layer forming section 13. The outer cylindrical
section 27 is provided with an outer peripheral slope 30 and an
inner peripheral slope 31. The outer peripheral slope 30 is
arranged to face the descending slope 26 leaving a space
therebetween, and an outer passage 15 of which the top is tapered
off relative to the extruding direction A is formed between the
outer peripheral slope 30 and the descending slope 26.
[0120] The inner cylindrical section 28 is provided with an outer
peripheral surface 32 of a straight cross-section and an inner
peripheral slope 33. The outer peripheral surface 32 forms an
intermediate passage 12 of which the top is tapered off relative to
the extrusion direction A between itself and the inner peripheral
slope 31 of the outer cylindrical section 27. The inner peripheral
slope 33 is arranged to face the ascending slope 25 leaving a space
therebetween and forms an inner passage 14 of which the top is
tapered off relative to the extrusion direction A.
[0121] Reference numeral 34 in the figure is a back joint which
forms a part of the inner passage 14 and concentrically holds the
outer cylindrical section 27 and the inner cylindrical section 28.
The back joint 34 also supports the core 20 through an axial center
section rod 35. Reference numeral 36 is a casing for supporting the
die 21.
[0122] FIG. 13 is a third embodiment relating to a structure of the
overlaping section. In FIG. 13A, lattice-shaped grooves 40 are
provided on at least the overlapping section which are freely
bendable. Irregularities such as embossment may be provided in
place of the grooves 40. In FIG. 13B, wave-shaped irregularity
consisting of recesses 41 and convex sections 42 extending in the
vertical direction (in the longitudinal direction parallel to the
long side sections) are provided. With this construction, the resin
film 5 is easily bent at the recesses 41.
[0123] FIG. 14 shows a fourth embodiment relating to an overlapping
section 6, in which rough surfaced sections 45 consisting of a
minute recessed section or convex section, or of irregular sections
are formed at an overlapping section of both end sections on the
long sides using a surface roughening method. Since friction at the
overlapping section 6 is increased by the rough surfaced sections
45, displacement is not easily caused. As the surface roughening
method, there are a suitable mechanical method such as
shot-blasting, a method for roughening a surface by chemical
treatment and the like. The rough surfaced section is also allowed
to be the weak section.
[0124] FIG. 15 is an end view of a resin film 5 which is formed in
a cylindrical shape according to a fifth embodiment and FIG. 16 is
an extended perspective view of the resin film 5. As is obvious
from these figures, a metal film 50 is laminated to the resin film
5 to provide a laminated structure, wherein the metal film 50 is
arranged to face inside. Both films are bonded at an overlapping
section 6 by a suitable adhesive. However, if the metal film 50 is
integrally embedded in the resin film 5, it is possible to
integrally form the overlapping section 6 by welding.
[0125] Such a laminated structure can be provided in various
manners, in which the resin film 5 can be a multilayered structure
of from two layers to a maximum of about five layers. As a result
of the multilayered structuring, characteristics of different
resins can not only be compensated for, but also generation of
pinholes in the resin film production process can be reduced. The
entire thickness of the multilayered structure exhibits the same
performance as a single layer film and can be further thinned.
[0126] The resin film 5 of such a multilayered structure includes
for example, a resin single layer such as a fluororesin
(monopolymer, bipolymer, and terpolymer), PVDC, PVC, PVA, PPS, PET,
PBT, PA6, PA66, PA11, PA12, PP, HDPE, LLDPE, LDPE, or an
ethylene-vinyl alcohol copolymer, or a resin laminated body
consisting of two to five layers made of different materials; a
single body of metal sheet alone such as aluminum or a laminated
body consisting of two to six layers made of the above resin and an
aluminum sheet. In addition, there is another laminated body in
which a laminated body consisting of two to six layers in which
aluminum, alumina, or silica has been deposited on the above resin
single layer or the laminated body is treated as a film
intermediate layer, wherein a fiber-reinforced layer such as
aramid-fiber, PA6, PA66, PET, PBT, PPS or PVA is added to the inner
layer hose side of the film intermediate layer.
[0127] In this laminated body, it is desirable that at least an
innermost or outermost resin layer be constructed using a resin of
which the melting point is lower than the vulcanizing temperature
and the entire thickness of the intermediate layer 2 be in a range
of 0.01 mm to 1.00 mm.
[0128] Reinforced cloth can be added to the intermediate layer for
improvement of pressure resistance and can be chosen from
aramid-fiber, PA6, PA66, PET, PPS, PVA, or the like depending on
use. A main role of the reinforced cloth is to maintain the
pressure resistance, but it is desirable that fibers with excellent
performance relating to strength, heat resistance, flexing
resistance, absorptivity, resistance, or hydrolytic resistance be
used.
[0129] There are various weaving structures for fibers such as
raschel knitting, plain weave or the like. Wherein, a weaving
structure is desirable which is thin and has the
pressure-resistance performance and of which change of outer
diameter are small. When the resin or metal film and the
fiber-reinforced layer are laminated, it is desirable that they be
laminated in advance for use. When the resin or metal film and the
fiber-reinforced layer are extruded without lamination, molding
failure or breaking of the film layer due to displacement between
the film and the reinforced cloth is easily generated. The
lamination structure of a laminated body of the resin or metal film
and the fiber-reinforced layer consists of two layers to a maximum
of about six layers.
[0130] If the thickness of a rubber layer is simply reduced for the
purpose of thinning of the hose, the amount of permeation increases
in a form inversely proportional to the reduction. Factors such as
rubber material and kind of internal solution, thickness of
material and gas permeability of material, atmosphere temperature,
internal pressure and the like affect the permeation of the
contents. Material factors for affecting the gas permeability
include polarity, degree of crystallinity, orientation, crystal
structure and the like. A resin is generally better than rubber for
gas permeability for the same thickness, except fluorocarbon
rubber. To make the best use of the gas permeability resistance of
the film, it is desirable that the entire thickness of a film
laminated body and/or a laminated body of the film and the
fiber-reinforced cloth be 0.01 mm.about.1.00 mm. If the thickness
is larger than 1.00 mm, even though the slits are provided, it is
difficult to mold the film in a cylindrical shape during extrusion.
This also affects flexing properties of the hose and conflicts with
thinning of the hose.
[0131] When a rubber layer of hose with a reinforced cloth is
thinned, compressive strength, pressure resistance and durability
tend to deteriorate and it is obvious that not only the reinforced
cloth, but also tensile strength and elastic modulus of the rubber
layer itself have a great influence on the strength of the hose.
When the rubber thickness of a hose with the reinforced layer is
reduced, the amount of deformation when stress is applied
increases. Accordingly, in such a condition in which repeated
stress is applied, pressure resistance, durability and strength
deteriorate. When the rubber layer is thinned, sealing properties
also deteriorate.
[0132] Permeability of a rubber hose with the reinforced cloth in
the intermediate layer substantially depends on the material and
thickness of the rubber layer and a degree of contribution by the
reinforced cloth to permeability is low. Permeation is a phenomenon
of penetration and diffusion of the contents in the rubber layer in
a micro-level field, wherein the contents easily pass through a gap
in the reinforced cloth composed of yarn. On the other hand, when
the resin film is added to the reinforced cloth, the film functions
as a barrier layer in a micro-level and as a result, permeability
remarkably improves. Further, if the resin film is laminated with
an inorganic material such as aluminum or ceramic or deposited film
is used, complete impermeability of inner solution or inner gas is
realized.
[0133] A thermoplastic resin film is stretched and oriented in all
directions in the manufacturing process, but has creep
characteristics. Accordingly, if a stress load is continuously
applied for a long time, there is some possibility that deformation
is caused. If orientation is intensified, tensile strength in the
orientation direction increases, but, on the contrary, tear
resistance and pinhole resistance deteriorate. It is therefore
necessary to use a resin that has excellent pressure resistance and
heat resistance in a predetermined thickness in the intermediate
film layer. However, by adding one fiber-reinforced layer, it is
possible to improve the pressure resistance, thinning the film
layer. Because the reinforced cloth has a weaving structure
obtained by twisting a single yarn which is strongly stretched and
oriented in the longitudinal direction, the stress in a
predetermined range can be retained by stretching deformation of
the weaving structure itself and any stress greater than the
predetermined range can be retained by the tensile strength of the
yarn itself.
[0134] FIG. 17 shows an sixth embodiment adopting a laminated film,
in which resin films 51, 52, of which the orientation direction and
the stretching direction meet at right angles, are laminated. In
this manner, the laminated film can be easily bent to form a
cylindrical shape or bent in the longitudinal direction after
forming the cylindrical shape, wherein sufficient strength can be
secured.
[0135] FIG. 18 shows a seventh embodiment relating to the joint of
an overlapping section 6, in which an adhesive agent layer 53,
which has excellent fuel oil resistance characteristics, is
inserted between the overlapping sections. In this manner, better
sealing can be provided against permeation of the fuel oil by the
adhesive agent layer 53. If the adhesive agent layer 53 is a hot
melt type, this is convenient because adhesion is made at the same
time as joining the overlapping section 6 by heat welding.
[0136] To improve workability after extrusion molding in the case
where the film of high bending modulus is used, it is possible to
use a mixture of 2.about.30 parts by weight of a thermoplastic
resin to 100 parts by weight of a rubber material. Resins for
mixing can be chosen from PP, PBT, polymethyl pentene, PS or the
like.
[0137] In this manner, if the resin in the rubber material is
non-compatible with the rubber, the resin remains contained in the
rubber even after vulcanizing. Since the resin in the vulcanized
rubber has the property of thermoplasticity, it exhibits plasticity
if the temperature is greater than the softening point. On the
other hand, the vulcanized rubber, once vulcanized, does not lose
the property of rubber elasticity. Now, by mixing the rubber with
the thermoplastic resin, if the vulcanized rubber is heated again
to the softening point after vulcanizing to deform and then cooled,
it can retain its shape after deformation. Deformation can be
eliminated if heated again. Specifically, the rubber is
semi-vulcanized directly after extrusion to increase the rubber
hardness so that it can be easily mounted on the mandrel. The
rubber is fully vulcanized after mounting on the mandrel.
[0138] Thus, it is possible to improve the problems of rubber hose
productivity by reducing various problems such as creases or twists
at the bent R section, collapse of the end surface, or adherence of
work glove marks on the hose surface generated when the hose is
mounted on the mandrel.
[0139] FIG. 19 shows a eighth embodiment in which the composition
of the rubber has been changed. An inner rubber layer and an outer
rubber layer according to the present embodiment are mixed with a
thermoplastic resin. An intermediate layer described in the
previous embodiments is selectively used. In such a material
composition, a raw rubber hose 1a is extruded and then vulcanized.
The vulcanized hose is mounted on a mandrel 19 and heated close to
the melting temperature of the thermoplastic resin and then
cooled.
[0140] Thanks to softening of the thermoplastic resin, the hose
follows the shape of the mandrel 19 by and is bent to that shape.
This bent shape is set through the subsequent cooling. In this
manner, even though vulcanization is preceded, the subsequent
shaping is possible. Since the overlapping section can be
stabilized by vulcanization, even though the hose is freely bent at
the mounting stage on the mandrel 19, it is possible to maintain
the intermediate layer in the cylindrical shape.
[0141] As a composition example, the mixture of 2.about.30 parts by
weight of the thermoplastic resin such as PP, PBT, Polymethyl
pentene or PS (polystyrene) to 100 parts by weight of rubber
material is possible. By using this mixture, it is possible to
further improve workability and performance of the rubber hose.
[0142] If the thermoplastic resin in the rubber material is
non-compatible with the rubber, the resin content remains contained
in the rubber even after vulcanization. Since the resin in the
vulcanized rubber has the property of thermoplasticity, it exhibits
plasticity if the temperature is greater than the softening point.
Accordingly, the vulcanized rubber, once vulcanized, does not lose
the property of rubber elasticity permanently. However, if the
vulcanized rubber is heated again to re-deform after vulcanization
and then cooled, it can retain the shape after re-deformation.
Re-deformation can be eliminated if heated again.
[0143] A rubber hose according to the present invention can also be
molded by a crosshead construction method. A ninth embodiment
relating to the cross-head method will now be described. In FIG.
20, an inner layer extruder 60 and an outer layer extruder 61 are
connected to a head 62 from the perpendicular direction. A supply
section 63 of a resin film 5 is provided at the intermediate
section of the head 62 which is connected to the inner layer
extruder 60 and the outer layer extruder 61.
[0144] The head 62 is constructed as shown in an expanded view, in
which the inner layer extruder 60 extrudes an inner layer rubber 3
from an inner layer rubber passage 65 to the periphery of an inner
core 64. The resin film 5 of a tape shape which is supplied from
the film supply section 63 is helically wound around the inner
layer rubber 3 (see FIG. 21). The outer layer extruder 61 extrudes
an outer layer rubber 4 from an outer layer rubber passage 66 on
the inner layer rubber 3 for lamination. In this manner, a
desirable hose 1a is obtained.
[0145] Thus, the film 5 can be helically wound around the rubber
using the cross-head construction method. As shown in FIG. 22, the
resin film 5 forms an overlapping section 6 around the inner layer
rubber 3 in the longitudinal direction. By vacuum-sucking the
overlapping section 6 through the film supply section 63,
adsorption is performed and close contact can be maintained. FIG.
21 shows the condition in which the resin film 5 is wound around
the inner layer rubber 3 and FIG. 22 is a partially expanded
cross-sectional view showing the winding operation
[0146] Next, a tenth embodiment relating to the bending treatment
outside the extrusion head will be described.
[0147] As shown in FIGS. 23 and 24, the intermediate layer 2 is
formed as a pipe 70 which has been obtained in advance by
extrusion-molding a high elastic material as outlined below by
separate equipment. The pipe 70 is cut by a cutter 71 in the axial
direction to provide a slit-shaped cut line 72 to be opened
laterally. Opposing ends 78, 78 of the cut line 72 are opened to
provide a C-shaped cross-section. The pipe 70 is continuously fed
into an extruder 10 in such a condition, wherein the pipe 70 is
rounded again into a cylindrical shape to allow the opposing ends
78, 78 to overlap to form an overlapping section 6. The pipe 70 is
then fed into an intermediate passage 12 of an extrusion head 11
while forming the overlapping section 9. The pipe 70 and the
intermediate layer 2 are the same, but a section before extrusion
molding is especially referred to as the pipe 70. The extruder 10
shown in FIG. 23 has a same structure as one in the above-mentioned
embodiment.
[0148] FIG. 25 is a cross-sectional view corresponding to the line
25-25 of FIG. 23. The inner cylindrical section 80 is integrally
provided, at part of the outer peripheral section, with a larger
diameter section 81 which projects outward in the radial direction.
The outer peripheral surface of the larger diameter section 81
closely contacts the inner peripheral slope 83 of the outer
cylindrical section 82 and can be concentrically supported on the
inner side of the outer cylindrical section 82, wherein the
intermediate passage 12 has a C-shaped cross-section. Part of the
outer peripheral section of the outer cylindrical section 82 is
also integrally provided with a larger diameter section 84 which
projects outward in the radial direction. The outer peripheral
surface of the larger diameter section 84 closely contacts an inner
peripheral slope of an outer ring 85, wherein an outer passage 15
has a semi-circular arch shape. Reference numeral 86 in FIG. 25 is
a back joint which forms part of the inner passage 14 and
concentrically holds the outer cylindrical section 82 and the inner
cylindrical section 80. The back joint 86 also supports the core 20
(see FIG. 12) through an axial center road 86.
[0149] A production method for a hose made of various materials as
outlined above will now be described in detail. FIG. 24 is a view
for schematically explaining simultaneous extrusion molding
according to the present invention in which an intermediate layer
forming section 11 of an extrusion head 10 is separately shown for
the sake of convenience. In this figure, a pipe 70 previously
extrusion molded to have a circular cross-section is continuously
fed into the intermediate layer forming section 11 along a feeding
direction A while being cut by a cutter 71 to provide a cut line
7.
[0150] In this case, in front of the intermediate layer forming
section 11, the opposing cut sides 78, 78 of the pipe 70 are opened
to provide a substantially C-shaped cross-section as in the
intermediate passage 12 of a C-shaped cross-section shown in FIG.
25. Thus, the pipe 70 can be inserted into the intermediate passage
12 even though the inner cylindrical section 80 has the larger
diameter section 81. After passing through this larger diameter
section 81, the pipe 70 is rounded again into a circular
cross-section within the intermediate layer forming section 11 to
allow the opposing ends 78, 78 to overlap to provide the
overlapping section 6. Since the pipe 70 tends to maintain the
circular cross-section from its inherent structure, it readily
forms the overlapping section 6 and makes it difficult to open.
[0151] In this manner, after the pipe 70 is first cut open, the
pipe 70 is rounded again into a substantially circular
cross-section within the intermediate layer forming section 11.
Then, the inner rubber layer 3 and the outer rubber layer 4 are
extruded inside and outside the pipe 70 and a hollow rubber hose 1
obtained by integrally molding these three layers is simultaneously
extrusion-molded and then extruded from the extrusion head 10.
[0152] Since the intermediate layer is formed as the pipe 70 which
tends to be restored to its original shape within the intermediate
passage 12, it is possible to readily form the overlapping section
6. A small space 29 is formed between a section of the pipe 70
other than the overlapping section 6 and a section of the
intermediate passage 12 on the exit side (see FIG. 11).
Accordingly, the pressure up to the junction 16a shown in FIG. 23
can be reduced in a single operation by a vacuum pump 18 connected
through the space 29 to intermediate passage 12.
[0153] The pipe 70 serving as the intermediate layer is fed into
the junction 16a in a condition in which a section of the upper and
lower opposing sides 78, 78 at the overlapping section 6 is
decompressed and caused to adhere, wherein the inner rubber layer 3
and the outer rubber layer 4 are integrally molded. Accordingly,
even with a pipe 70 of such a hardness that the overlapping section
6 is not caused to adhere, it is possible to positively allow the
overlapping section 6 to adhere for simultaneous extrusion molding.
In addition, highly efficient mass-production can be realized.
[0154] In this case, as is obvious from FIG. 23, a high vacuum
condition is maintained up to the junction 16a. Accordingly, it is
possible to eliminate gas such as air, or foreign materials such as
volatile matter, and to allow the inter rubber layer 3 and the
outer rubber layer 4 to be integrally molded with the intermediate
layer 2 with a high degree of adhesion. It is also possible to
prevent generation of a phenomenon whereby the volatile matter
expands to form bubbles during heating in the subsequent
vulcanizing process. Further, since the high vacuum is maintained
up to the junction 16a, the outer rubber layer 4 and the inner
rubber layer 3 also receive the force in the direction in which
they come close and it is possible to integrally mold them together
with high adhesion strength.
[0155] As is described above, by molding the intermediate layer 2
into the pipe 70 in advance, even the highly elastic material can
be rounded and fed into the extrusion head 10. As shown in FIG. 25,
even though the intermediate passage 12 of the extrusion head 10 is
constructed to have a C-shaped cross-section, the pipe 70 can be
fed into the extrusion head by cutting the pipe 70 open in the
C-shaped cross-section.
[0156] In this manner, it is possible to use the film with a high
bending modulus. Namely, in the embodiment 2 in Table 1, an
embodiment is shown in which such a bending treatment outside the
extrusion head is adopted, wherein pressure has been reduced to
98658 Pa (740 mmHg) below atmospheric pressure. As is obvious from
this Table, processing up to 20000 N of the film bending load is
possible and the film of high bending modulus can be used. When
pressure is largely reduced as shown in the embodiment, it is
possible to eliminate gas such as air or foreign materials as
volatile matter and it is difficult for the volatile matter to
expand to form bubbles during vulcanizing or the like.
[0157] Moreover, in the case of bending treatment within the
extrusion head, even though the extrusion head 11 is decompressed,
the limit of the adhesion effect of the film is between 5000 N and
10000 N at the most. However, if bending treatment outside the
extrusion head is performed and pressure is reduced, this means
that it is possible to process up to 20000 N. If the film is shaped
into the cylindrical shape in advance, processing is easier than
with the bending treatment within the extrusion head. Since the
film of a high bending modulus after extrusion acts to maintain the
cylindrical shape, this also helps improve workability.
[0158] When such a high bending modulus film is used, it is
desirable that flexing be improved during mounting of the rubber on
the mandrel and in the hose product. For such a purpose, when the
film is shaped into the cylindrical shape, by providing
irregularities extending in the circumferential direction, it is
effective to make the entire section or part thereof a
bellows-shape.
[0159] After forming the film in the cylindrical shape in advance,
the film can be processed also by blow molding or the like to form
a circular irregularity on the circumference in the circumferential
direction. If the irregularity is continuously provided in the
longitudinal direction to provide a bellow shape, it is also
possible to freely bend the film in the longitudinal direction.
[0160] FIG. 26 shows a eleventh embodiment relating to an
overlapping section formed by the bending treatment outside the
extrusion head. According to one example shown in FIG. 26 (A), the
opposed sections 78, 78 do not overlap directly and both ends
thereof are arranged to face one another with a gap 79 between. A
separate seal piece 77 is positioned to bridge the gap 79 and is
integrally welded to both the long side sections. In this manner,
it is possible to provide an intermediate layer with a larger
diameter than the pipe 70 whereby the opposed sections 78, 78
cannot be overlapped. The degrees of freedom in the diameter
dimension become large. Even when the opposed sections 78, 78 are
overlapped in advance, or when the section does not sufficiently
overlap and the gap 79 is partly generated, it is prevented for gas
or liquid to penetrate from the gap 79, since the gap 79 is sealed
by a seal piece 77.
[0161] According to another example shown in FIG. 26 (B), the
opposed sections 78, 78 are caused to directly overlap to provide
an overlapping section 6. A separate seal piece 77 is positioned
over the overlapping section 6 and the seal piece 51 and the
section 6 are integrally welded together. In this manner, even when
the slit or the like is formed on the lapping portion 6, it is
possible to keep impermeability and to further strengthen the joint
of the opposed sections 78, 78 at the overlapping section 6.
Forming of the overlapping section using the seal piece 77 is also
available for the bending treatment within the extrusion head. In
the case, the opposed sections 78, 78 are made as the long side
sections 8, 8.
[0162] Preferred embodiments of the present invention relating to a
step-less structure will now be described with reference to the
accompanying drawings. FIG. 27 through FIG. 30 are drawings
relating to the twelfth embodiment.
[0163] As shown in FIGS. 27 and 28, the rubber hose 1 is provided
with an intermediate layer 2, an inner rubber layer 3 and an outer
rubber layer 2. The total thickness of the rubber hose including
the intermediate layer 2, the inner rubber layer 3 and the outer
rubber layer 4 is about 1.5.about.3.5 mm. This is an extremely thin
hose compared with a conventional one.
[0164] Either the bending treatment within the extrusion head or
the bending treatment outside the extrusion head can form the
intermediate layer 2. The bending treatment within the extrusion
head will now be described. The resin film 5 forming the
intermediate layer 2 is rounded into a cylindrical form to provide
a partially overlapping section 6. The overlapping section 6 is
provided with a thinned section 90 in the longitudinal
direction.
[0165] This simultaneous extrusion molding can be done by the
above-described method. The cross head structure is also available.
A following explanation relates to the simultaneous extrusion
molding.
[0166] FIG. 29 is a cross-sectional view of the intermediate layer
2 formed in cylindrical shape and FIG. 30 is a partially extended
perspective view of the resin film 5 in a condition of a planar
shape. As is obvious from these figures, the long side sections 8,
8 are respectively provided with a thinned section 90 consisting of
thin steps that are inversely provided. This thinned section 90 is
formed to stretch over the full length of the resin film 5 in the
width of the overlapping measurement (a) and continuously formed at
the same time as molding of the resin film 5. Slits 7 are provided
along the long side section 8 in a range, entering inwardly,
forming a width of an overlapping dimension (a) from each edge
section of both long side sections 8, 8 on the right and left side.
This overlapping dimension (a) has a width equivalent to or smaller
than that of the overlapping section 6. The structure of the long
side sections 8, 8 forming the thinned section 90 is one specific
example of a weak section structure.
[0167] The right and left thinned sections 90 are set to overlap at
the overlapping section 6. When a length obtained by adding one
third (1/3) of the circumferential length of the intermediate layer
2 to the circumferential length is set as the maximum width (i.e.
short side measurement) of the resin film 5 (for example, when the
inner diameter of a rubber hose is 36.5 mm and the thickness
thereof is 3 mm, the added measurement is 41 mm), it is desirable
that the thinned sections 7 of a maximum length of 40 mm be
provided over an equal width in the longitudinal direction of the
resin film 5 on both sides or one side of the long side sections 8,
8 of the resin film 5.
[0168] In FIG. 30, when the thickness of the resin film 5 in a
central section (a section between the long side sections 8, 8) in
the lateral direction is T, one of the thinned sections 7 has a
thickness t 1. The thickness of the other thinned section 7 is t 2
where t 2=T-t 1. In this manner, both the thinned sections 90, 90
overlap at an overlapping section 6 so that the total thickness
becomes the thickness T of the resin film 5 at the central section.
Accordingly, the entire thickness is constant and no step is formed
on the circumferential section of the intermediate layer 2.
[0169] Operation of the present embodiment will now be explained.
In FIG. 30, since the long side sections 8, 8 are provided with
thinned sections 90, these sections 8, 8 form weak sections.
Accordingly, when the resin film 5 is bending-treated within the
extrusion head, it is easily bent and a uniform cylindrical shape
can be provided. As a result, since a uniform cylindrical shape can
be maintained even during the simultaneous extrusion molding in an
extrusion head 10, it is possible to form a thin hose.
[0170] Accordingly, as no bar-shaped step resulting from the
overlapping section 6 is provided on the inner surface or outer
surface of the thin rubber hose 1 after extrusion molding, the
fastening force becomes constant when the rubber hose 1 is mounted
on the other member and secured by a spring clip, and the sealing
properties are improved. Thus, it is possible to make it difficult
for the rubber hose 1 to separate from the other member. If the
bar-shaped step is formed on the surface (i.e. outer surface) of
the rubber hose 1, the fastening force of the spring clip becomes
inconstant and thus an improved method of mounting is required to
improve the sealing properties and non-separation properties.
Accordingly, the thin hose is realized without spoiling mounting
performance.
[0171] Even in the case of woven fabric reinforced cloth which is
superior to the resin film in flexibility and extensibility and of
which the cloth end section in the overlapping section is
originally difficult to break during extrusion molding, there is
some possibility that the cloth end section will break if the
overlapping width is too great. In the case of the resin film that
is inferior to the woven fabric reinforced cloth in flexibility and
extensibility, it is considered that a break will be easily
generated in the course of bending into a cylindrical shape from a
planar shape. However, by providing a thinned section 90, 90 on the
long side sections 8, 8, the resin film can be easily bent and such
a break is easily prevented. If the thinned sections 90, 90 are
provided with slits or the like, it is possible to make them
weaker.
[0172] In a condition of the raw rubber hose obtained by such
simultaneous extrusion molding, at the overlapping section 6 of the
resin film 5 forming the intermediate layer 2, the long side
sections 8, 8 which overlap are not integrally secured by welding
or the like. Accordingly, some displacement is possible between the
overlapped sections.
[0173] However, since the intermediate layer 2 is integrally
embedded between an inner rubber layer 3 and an outer rubber layer
4, it is possible to maintain the overlapping section 6 even though
there is deformation due to a certain amount of displacement or the
like. The overlapping measurement (a) (see FIG. 5) is also set to
such a degree that the overlapping section 6 can be maintained.
[0174] When the raw rubber hose 12 is vulcanized, it can be mounted
on the mandrel conforming to the bent shape of the latter since the
overlapping section 6 is designed to have a flexible structure for
permitting deformation such as displacement.
[0175] Next, when the raw rubber hose 12 mounted on the mandrel is
vulcanized at a predetermined temperature, the inner rubber layer 3
and the outer rubber layer 4 are vulcanized and set in a bent
shape. Since the resin film 5 of the intermediate layer 2 is also
melted at the vulcanizing temperature and then hardened, the upper
and lower long side sections 8, 8 are integrally welded at the
overlapping section 6. In this case, since the thinned sections 90
have disappeared to form a single resin layer, impermeability
improves further.
[0176] Further, if the resin film 5 is formed to have a
multilayered structure of two to five layers and the melting point
of the resin film of at least an innermost layer or an outermost
layer is lower than the vulcanizing temperature of the raw rubber
hose, it is possible to weld the overlapping section 6 and the
thinned sections 90 of the resin film 5 in the vulcanizing process.
When a resin of which the permeability resistance is superior but
the melting point is low is used, a resin with a low melting point
can also be used by laminating a resin, of which the heat
resistance is superior, to both sides of the resin with a low
melting point.
[0177] FIGS. 31 and 32 relate to a thirteen embodiment, wherein
FIG. 31 is an explanatory view in the case where a resin film 5 is
bent into a cylindrical shape and FIG. 32 is partial
cross-sectional view of an extrusion head 10. A structure of the
extrusion head 10 shown in FIG. 32 is as same as one shown in FIG.
11. In FIG. 31, the upper section of the figure shows the resin
film in an extended shape where the long side sections 8, 8 are
provided with inversely faced tapered surfaces 91, 91, thereby
forming the thinned sections 90, 90. The tapered surfaces 91, 91
are formed in an inclined shape so that the thinned sections 90, 90
are gradually thinned toward one end in the lateral direction of
the long side sections 8, 8.
[0178] As shown in the lower section of the figure, when the resin
film 5 is rounded in the lateral direction to allow the long side
sections 8, 8 to overlap, the taper surfaces 91, 91 overlap to
provide an overlapping section 6. When the thickness of the resin
film 5 in a central section (a section between the long side
sections 8, 8) in the lateral direction is T, the thickness of the
overlapping section 6 is almost equivalent to T. As a result, it is
possible to dispense with any step on the overlapping section
6.
[0179] The taper surfaces 91, 91 can be provided on the surface of
the long side sections 8, 8 opposing one another or on the surface
on the same side. The taper surfaces 91, 91 can also be provided to
form a wedge in the cross-section from both surfaces. Further, the
tapered sections 91, 91 can be formed to stretch the full length of
the resin film 5 in the longitudinal direction in the width of the
overlapping measurement (a) and can be continuously formed at the
same time as molding of the resin film 5 or formed in the
subsequent process.
[0180] It is desirable that the length of the taper surfaces 91, 91
in each lateral direction be longer by a predetermined measurement
(e.g. about 10 mm) than the length (a) of the overlapping section
6. In this manner, even though the length of the overlapping
section 6 has changed minutely at the time of actual extrusion
molding, it is possible to sufficiently secure the thickness as the
intermediate layer 2 to maintain a necessary level of permeability
resistance. Even though the overlapping section 6 has been
displaced a little in the lateral direction, it is possible to
substantially make the entire thickness of the overlapping section
6 constant so that a bar-shaped step resulting from the overlapping
section 6 is not produced on the inner surface or outer surface of
the thin rubber hose 1.
[0181] In particular, in the intermediate layer 2 with a thickness
of 0.05 mm or more, when a step corresponding to the thickness of
the film is produced at the overlapping section 6, even though the
overlapping section 6 is covered by the inner and outer rubber
layers, the step tends to remain on the inner surface of the inner
layer or the outer surface of the outer layer. The greater the
thickness of the film and the greater the elasticity, the more
prominent the step, and the thinner the inner and outer rubber
layers, the more prominent the step. However, by making the long
side sections 8, 8 thinner and tapered, it is possible to
substantially remove such a step. It is also possible to provide
slits on the thinned section to make it weaker for easy
bending.
[0182] To form the resin film 5 in a cylindrical shape, as shown in
FIG. 32, an intermediate layer passage 12 is provided between an
outer die 27 and an inner die 28 within an extrusion head 10. The
resin film 5 is rounded and inserted into the intermediate layer
passage 12. The intermediate layer passage 12 is a ring-shaped
space and the opening width is almost the same as the thickness of
the overlapping section 6.
[0183] The upper and lower long side sections 8, 8 forming the
overlapping section 6 partially contact the inside of the
intermediate layer passage 12. However, space 29 is formed between
a part of the overlapping section 6 and parts other than the
overlapping section 6 and the intermediate layer passage 12. When
operation of a vacuum pump 26 connected through the space 29 to the
intermediate layer passage 12 reduces the pressure of the
intermediate layer passage 12, the pressure of the space between
the upper and lower long side sections 8, 8 is also reduced at the
overlapping section 6. As a result, the upper and lower long side
sections 8, 8 are caused to closely contact each other.
[0184] In this condition, an inner rubber layer 3 and an outer
rubber layer 4 are extruded inside and outside the resin film 5 for
integration. Accordingly, even though the resin film 5 is too hard
to allow close contact with the overlapping section 6, it is
possible to allow reliable contact with the overlapping section and
to perform simultaneous extrusion molding. It is also possible to
efficiently mass-produce a rubber hose. In addition, since foreign
materials such as volatile matter in the overlapping section 6 are
extracted and removed, it is possible to prevent a phenomenon
whereby the volatile matter expands to form bubbles during heating
in the subsequent vulcanizing process.
[0185] A stepless structure is provided, in which the long side
sections 8, 8 are thinned in the tapered shape as shown in the
present embodiment or the long side sections 8, 8 are thinned in
the step shape as shown in FIG. 30, so that the thickness of the
overlapping section 6 is the same as or equivalent to that of the
non-overlapping sections, thereby providing the overlapping section
6 without any step or with a small step. This stepless structure
can not only be applied to the molding method according to the
previous embodiment in which the long belt-shaped film 5 is rounded
to be inserted into the extrusion head, thereby forming the
cylindrical shape, but also to a production method in which the
film is rounded into the cylindrical shape in advance in front of
the extrusion head or the film is extrusion-molded first as a pipe
member, and then slits are formed on the pipe member in the
longitudinal direction for opening the pipe member (referred to as
"preforming treatment").
[0186] FIG. 33 is a fourteenth embodiment further showing another
example for eliminating the step in the overlapping section 6. In
this example, the overlapping section 6 of a general structure
provided with a step D is formed in a cylindrical shape (see FIG.
23A). The step D is then melted by means of ultrasonic welding or
the like to eliminate at least the step formed on the outer surface
side (see FIG. 23B). In this manner, since the same degree of
accuracy in overlapping is not required as in the case where a side
of the resin film 5 is thinned in advance before overlapping,
production becomes easier.
[0187] When a rubber hose according to the present invention is
molded either by a cross head structure method, by a helically
winding or by a overlapping section, which is parallel to the axis
line, forming method, the overlapping portion can be made to be the
step-less structure. In a case in which the bending treatment
outside the extrusion head is adopted, the thinned portion can be
formed during the resin pipe is supplied to the extrusion head
while pressure is reduced after the pipe is formed in advance in a
cylindrical shape and cut out along the longitudinal direction. It
is possible to form a cut out portion in a thinned portion
simultaneously with the extrusion of the pipe and the thin portion
is formed simultaneously with cutting out.
INDUSTRIAL APPLICABILITY
[0188] Production method of a thin rubber hose according to the
present invention is suitable for thinning a impermeability rubber
hose for the purpose of light-weighting and cost reduction and for
extrusion molding of gas or liquid transportation hose using a
resin or metal film as an intermediate layer for improving
permeability performance.
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