For high-pressure hoses in rubber hose products, pressure resistance is a core indicator for evaluating their quality and application range, and the braiding process of the reinforcing layer is a key factor determining pressure resistance. As the core skeleton of the high-pressure hose, the reinforcing layer is constructed by weaving high-strength fibers or metal wires into a mesh structure using a specific braiding method, providing the hose with the necessary tensile strength and pressure resistance. The influence of the braiding process on pressure resistance is mainly reflected in multiple aspects, including braiding structure, fiber arrangement, interlayer bonding, and stress distribution.
The type of braiding structure directly affects the mechanical properties of the reinforcing layer. Common braiding methods include plain weave, twill weave, and spiral weave. Plain weave has a tight structure and many fiber crossing points, which can evenly distribute the stress generated by internal pressure, but its flexibility is relatively low. Twill weave, by adjusting the fiber crossing angle, improves the hose's bending performance while maintaining a certain strength. Spiral weave, through the spiral arrangement of fibers, allows the reinforcing layer to better adapt to the axial expansion and contraction of the hose under internal pressure, reducing stress concentration. The choice of different braiding structures must be weighed based on the specific application scenario and pressure resistance requirements of the hose.
The fiber arrangement is equally crucial to the pressure resistance of the reinforcing layer. During weaving, the fiber orientation, density, and tension control all affect the overall performance of the reinforcing layer. A tighter fiber arrangement results in higher tensile strength, but excessive density can reduce hose flexibility, affecting installation and use. Therefore, a proper fiber arrangement requires finding a balance between strength and flexibility. Furthermore, the uniformity of fiber tension is also a key factor. Improper tension control during weaving can lead to uneven stress distribution between fibers, making localized areas prone to stress concentration points, thus reducing the hose's pressure resistance limit.
The bonding strength between the reinforcing layer and the inner and outer rubber layers is another important factor affecting the pressure resistance of high-pressure hoses. The braided reinforcing layer needs to be tightly bonded to the inner and outer rubber layers through a middle rubber layer to form an integrated composite structure. The formulation and process of the middle rubber layer directly affect the interlayer bonding force. Insufficient adhesion between the middle rubber layer and the fibers, or improper vulcanization process control, can lead to delamination between the reinforcing layer and the rubber layer, significantly reducing the hose's pressure resistance. Therefore, optimizing the middle rubber layer formulation and improving the vulcanization process are key to achieving a reliable bond between the reinforcing layer and the rubber layer. The influence of braiding technology on the stress distribution of the reinforcing layer is a core mechanism determining the pressure resistance of high-pressure hoses. Under internal pressure, the reinforcing layer must withstand the dual effects of axial tensile force and circumferential stress. A reasonable braiding process can ensure a uniform stress distribution within the reinforcing layer, avoiding localized stress concentration. For example, by adjusting the braiding angle and fiber density, a more uniform stress field can be formed in the reinforcing layer under internal pressure, thereby improving the overall pressure resistance of the hose. Furthermore, optimizing the braiding process can reduce the deformation of the reinforcing layer under high pressure, maintaining the geometric stability of the hose and further extending its service life.
The application scenarios of high-pressure hoses impose differentiated requirements on the braiding process. In high-pressure, high-frequency impact environments such as mining and construction machinery, hoses need to withstand higher dynamic pressure and fatigue loads. In these cases, the reinforcing layer needs to use higher-strength fibers or metal wires, and its pressure resistance needs to be improved through multi-layer braiding or winding processes. In the chemical and food industries, hoses, in addition to meeting pressure resistance requirements, also need to possess good corrosion resistance and hygiene properties. Therefore, the braiding process needs to be specifically optimized based on material characteristics to meet the comprehensive performance requirements of different scenarios.
The precision control of the braiding process has a decisive impact on the pressure resistance of high-pressure hoses. In modern high-pressure hose production, the application of high-speed braiding machines and automated control technology has significantly improved the precision and consistency of the braiding process. By precisely controlling key parameters such as braiding angle, fiber tension, and interlayer bonding, it can be ensured that the reinforcing layer of each hose meets the design requirements for pressure resistance. In addition, advanced testing technologies such as non-destructive testing and pressure testing also provide strong guarantees for the quality control of the braiding process, further improving the reliability and safety of high-pressure hoses.
