A HELICALLY FABRICATED FLEXIBLE HOSE

Abstract: A helically fabricated flexible hose having at least two parallel helical support members (10, 11; 30, 31 and 32), inner and outer plastics strips (11; 30: 20; 44) wrapped helically about the support members, and at least one pair of helical electrical conductors (16, 17, 18, 19; 38, 39, 40, 41, 42, 43) disposed on opposite sides of one of the support members and slidably positioned between the inner and outer plastics strips. Each of the helical electrical conductors comprises a conductive element and a plastics dielectric coating disposed around the conductive element. The plastics dielectric coatings are not bonded to the inner and outer plastics strips so that they may slide between them.

Description: This invention related to a helically fabricated flexible hose. U.S. Patent 4,224,463 and its corresponding U.K. Patent 2,034,859 describe a helically fabricated flexible hose wherein first and second parallel helical wires are disposed in double lead fashion with successive convolutions alternating. An inner plastics strip is wrapped helically about the wires and is wider than the double lead of each wire, so that it has forward and rearward edge portions overlapping over convolutions of the first of the wires. An outer plastics strip is wrapped helically about the inner plastics strip and is wider than the double lead of each wire with forward and rearward edge portions overlapping over convolutions of the second of the wires. In a preferred form a plastics dielectric coating is disposed about each wire and a plurality of reinforcing cords are located about the inner strip and inside the outer strip, the plastics coatings and the two strips all being bonded together. It is characteristic of this structure that each wire convolution is covered by three wall plies, two from one strip and one from the other, with only two wall plies between the wire convolutions, thus imparting markedly better abrasion resistance at the raised convolutions where the greatest wear occurs. Unlike the single lead double-wire hoses proposed previously, the hose described above is of uniform double lead double wire form, so that the amount of wire per unit length of hose is at a minimum. Each wire helix flexes independently of the other and the structure therefore possesses exceptional flexibility allowing it to drape readily with close bend radius, all of which is important for vacuum cleaner hose. In accordance with the present invention, there is now provided a helically fabricated flexible hose having at least two parallel helical support members disposed in multiple lead fashion with each being axially spaced from the other or others. An inner plastics strip is wrapped helically about the support members and has forward and rearward edge portions overlapping the convolutions of one of the support members. An outer plastics strip is wrapped helically about the inner plastics strip and has forward and rearward edge portions overlapping the convolutions of another of the support members. At least one pair of helical electrical conductors is disposed on opposite sides of one of the helical support members and slidably positioned between the inner and outer plastics strips. The helical conductors are preferably stranded, for example of a plurality of copper strands disposed within a dielectric plastics coating to provide further electrical insulation in addition to the non-conductive inner and outer plastics strips. These plastics dielectric coatings of the helical conductors are not bonded to the inner and outer plastics strips so that they may slide between them. It is characteristic of this structure that each helical support member flexes independently of the other, and the structure therefore possesses exceptional flexibility allowing it to drape readily with close bend radius, all of which is important, as stated above, for vacuum cleaner hoses. Each of the helical conductors flexes with the helical support member with which it is associated, and is protected by its helical configuration from longitudinal stresses and by its positioning adjacent to the helical support member from kinking and excessive flexing. Because they are able to slide in the space they occupy between the inner and outer plastics strips, the helical conductors are not subjected to the stretching and tearing forces which would be transferred from the inner and outer strips if they were bonded to the helical support members. The invention will now be described in greater detail by way of example only with reference to the accompanying drawings, in which: Fig. 1 is a side elevation, partly broken away, of a dual support wire hose of the invention; Fig. 2 is an enlarged section of the wall of the hose of Fig. 1; Fig. 3 is a side elevation, partly broken away, of a triple support wire hose of the invention; Fig. 4 is an enlarged section of the wall of the hose of Fig. 3; and Fig. 5 is an enlarged partial section of Fig. 4. All of the various components of the hoses according to the invention are most advantageously assembled on the continuously advancing double belt mandrel of the type described in U.S. Patents 3,155,559 and 4,213,811. Such mandrels are of a diameter ranging from 1.25" to 1.50" (approximately 32 to 38 mm) and form hose of corresponding inside dimensions. With reference to the first preferred embodiment of the invention shown in Figs. 1 and 2, the elements initially applied to the mandrel are first and second helical support members 10 and 11. Each support member is preferably formed of wire having a steel core and a copper coating in typical diameters from .048" to .062" (approximately 1.2 to 1.6 mm). The copper content of such wires is usually between 10 and 35 percent by weight. The function of the pair of wires 10 and 11 in the finished product is to provide both a flexible self-supporting skeleton for the hose and a pair of electrical conductors which can carry current between the ends of the hose. Each of the wires 10 and 11 is preferably coated with a concentric layer of vinyl plastics 12 and 13, respectively, the thickness of which is in the order of .032" (approximately 0.8 mm). It is the purpose of this plastics coating to provide a bondable surface about which the body of the hose is formed and also to provide electrical insulation. Each of the wires 10 and 11 has a helical pitch of approximately 0.435" (approximately 11 mm). It should be noted, however, that the invention is applicable to the hose in which the wires 10 and 11 are not current-carrying, and in such cases the current or currents to be carried from one end of the hose to the other would flow through the one or more pairs of helical conductors which straddle the helical support members 10 and/or 11. In such a modified embodiment, the helical support members 10 and 11 would be formed of plastics material, for example. The next element disposed about the pair of helical wires 10 and 11 is an inner plastics strip 14 formed of vinyl, or vinyl blended with other polymers, which is applied with heat or a solvent or both so that it bonds to the coatings 12 and 13. It is wrapped about the wires on the mandrel under tension and at an elevated temperature directly from an extrusion head, so that the inner strip 14 stretches snugly over and between the convolutions of the wires 10 and 11. The extrusion die may appropriately be cross-sectioned to provide a preformed shape to the strip which conforms to the pair of wires and the mandrel surface. The die design may also impart feathered or tapered edges to the strip so that the overlapping edges fair smoothly into one another. In thickness the inner strip 14 is in the range from 0.014" to 0.020" (approximately 0.35 to 0.5 mm). The width of the inner plastics strip is slightly greater than the double lead of the pair of wires 10 and 11. As shown in Fig. 2, the rearward edge of the strip 14 thereby overlies the second wire 11, the central portion of the strip 14 overlies the next adjoining convolution of the first wire 10, and the forward edge of the strip 14 overlies the following convolution of the second wire 11. In this manner, the rearward edge of the strip 14 is in direct contact with and bonds to the coating 13 of wire 11, and the forward edge of the strip 14 is in direct contact with and bonds to the rearward edge of the strip 14 on the next convolution of that same wire 11. After application of the inner strip 14, a plurality of longitudinal cores 15 is preferably applied to the structure. The cords may be of polyester approximately 1100 denier in size. They are uniformly spaced around the circumference of the hose and are typically from nine to thirty-six in number, depending upon the size of hose. They may be precisely parallel to the axis of the mandrel, and thus of the finished hose also, or they may be applied at an angle to the mandrel axis. In any event, they are at least substantially longitudinal with respect to the hose structure because it is their purpose to lend longitudinal strength to the hose and to prevent it from being stretched to the point of damaging the plastics wall of the hose. The longitudinal cords 15 permit the use of softer wall materials having more plasticity, thus providing better flexibility in the finished product with equal or better strength. In order to provide a current path in addition to that formed by coated wires 10 and 11, a pair of helical conductors 16 and 17 is formed as an integral part of the hose by being sandwiched between the inner strip 14 and an outer strip 20 described below, on opposite sides of coated wire 10. The helical conductors 16 and 17 are preferably stranded copper conductors enclosed within a dielectric sheath. Such stranded copper conductors would preferably include relatively small numbers of copper strands, for example 5 to 10 strands of 30-gauge, as shown in Fig. 5. Stranded conductors have been found to be less costly than braided conductors and less susceptible to breaking than solid conductors, although these forms of conductors could also be used. The dielectric sheaths surrounding the stranded copper conductors, though preferred as an extra margin of electrical insulation and mechanical protection, may be eliminated because of the positioning of the helical conductors 16 and 17 between the inner and outer dielectric plastics strips 14 and 20. Each dielectric sheath is not bonded to the strips 14 and 20 so that it may slide with respect to those strips. Bonding is prevented by simply not applying either heat or solvent to the dielectric sheaths of the helical conductors 16 and 17. A second pair of helical conductors 18 and 19 may be similarly positioned on opposite sides of coated wire 11 to provide an additional current path through the hose. The current paths formed by the helical conductor pairs 16, 17 and 18, 19 may be used for such purposes as carrying motor control signals, current for indicator lamps, and the like. Hose weight and flexibility are not adversely affected by the inclusion of the helical conductor pairs 16, 17 and 18, 19 since they occupy the location of helical reinforcing cords in known forms of flexible hose. If a particular end use calls for only a single pair of helical conductors, the second pair of helical conductors shown in Figs. 1 and 2 would preferably be replaced by a pair of helical reinforcing cords, since the helical conductor pairs 16, 17 and 18, 19 also perform the function of retaining the longitudinal reinforcing cords 15 in place. The last element applied to the mandrel in forming the hose is an outer vinyl plastics strip 20 which is preferably of the same width and thickness as the inner plastics strip 14. It overlaps itself over the first wire 10, forward edge portion overlying rearward edge portion, while the central portion overlies the second wire 11. By the use of heat or solvents or both, the outer strip is bonded to the inner strip with the longitudinal cords 15 embedded between them and the helical conductors 16, 17, 18 and 19 slidably positioned therebetween. The inner and outer strips 14 and 20 may be of dissimilar materials, the inner being selected, for example, for chemical resistance and the outer for abrasion resistance or aesthetic quality. In the second preferred embodiment of the invention shown in Figs. 3 and 4, the hose construction and the manner of forming it are generally as described above for the first preferred embodiment, except for the inclusion of a third helical support member. The three helical support members 30, 31 and 32 have a greater helical pitch than their two counterparts in the first embodiment, for example about 0.450" (approximately 11 mm), and may be conductive or non-conductive; if conductive, they are preferably coated with concentric layers of vinyl plastics 33, 34 and 35, respectively. An inner plastics strip 36 is helically wrapped about the three helical support members 30, 31 and 32, the width of strip 36 being slightly greater than the triple lead of the helical support members so as to overlap itself over the first helical support member 30. Thus, as shown in Fig. 4, the rearward edge of strip 36 overlies the first support member 30; the central portion of strip 36 overlies the second and third support members 31 and 32; and the forward edge of strip 36 overlies the following convolution of the first support member 30. As in the first embodiment, the strip 36 is in contact with and bonded to the coatings 33, 34 and 35. A plurality of longitudinal reinforcing cords 37 are next applied, as in the first embodiment. Pairs of helical conductors 38 and 39, 40 and 41, 42 and 43 are then wrapped helically about the partially-formed hose structure so as to straddle the helical support members 30, 31 and 32, respectively. Depending upon the end use of the hose, one or two of the helical conductor pairs 38 and 39, 40 and 41, 42 and 43 may be replaced with helical reinforcing cords. The last element applied is an outer plastics strip 44 which overlaps itself over the second helical support member 31, and has its central portion overlying the first and third helical support members 30 and 32. In the form of this second embodiment in which the helical support members 30, 31 and 32 are conductive, they can provide positive, negative and ground (earth) leads for electrical apparatus at both ends of the hose. The several variations in construction referred to in the description of the first embodiment may also be made in this second embodiment. As a consequence of these many features, a current-carrying hose construction is provided which is of maximum versatility, flexibility, abrasion resistance, optimum longitudinal and radial strength, and minimal wire weight and voltage resistance.

Claims: A helically fabricated flexible hose comprising: (a) at least two parallel, helical axially spaced support members, (10, 11; 30, 31, 32) disposed with successive convolutions alternating; (b) an inner plastics strip (14; 36) wrapped helically about the support members with forward and rearward edge portions of the inner plastics strip overlapping the convolutions of one (11; 30) of the support members; (c) an outer plastics strip (20; 44) wrapped helically about the inner plastics strip with forward and rearward edge portions of the the outer plastics strip overlapping convolutions of another (10; 31) of the support members; and (d) at least one pair of helical electrical conductors (16, 17, 18, 19; 38, 39, 40, 41, 42, 43) disposed on opposite sides of one of the support members and slidably positioned between the inner and outer plastics strips. A helically fabricated flexible hose according to claim 1 comprising first and second parallel helical support members (10, 11) disposed in double lead fashion with successive convolutions alternating. A helically fabricated flexible hose according to claim 1 comprising first, second and third parallel helical support members (30, 31, 32) disposed in triple lead fashion with successive convolutions alternating. A hose according to claim 2 or claim 3, wherein only one helical support member has a pair of helical electrical conductors disposed on opposite sides thereof and slidably positioned between the inner and outer plastics strips, and the other parallel helical support member(s) (each) has a pair of helical reinforcing cords disposed on opposite sides thereof and embedded between the inner and outer pllastics strips. A hose according to claim 2, wherein each of the first and second helical support members has a pair of helical electrical conductors disposed on opposite sides thereof and slidably positioned between the inner and outer plastics strips. A hose according to claim 3, wherein two of the helical support members each has a pair of helical electrical conductors disposed on opposite sides thereof and slidably positioned between the inner and outer plastics strips, and the other helical support member has a pair of helical reinforcing cords disposed on opposite sides thereof and embedded between the inner and outer plastics strips. A hose according to claim 3, wherein each of the three parallel helical support members has a pair of helical electrical conductors disposed on opposite sides thereof and slidably positioned between the inner and outer plastics strips. A hose according to any one of claims 1 to 7, wherein each of the helical electrical conductors is stranded. A hose according to claim 8, wherein each of the stranded helical electrical conductors comprises a plurality of copper strands disposed within a dielectric plastics coating. A hose according to any one of claims 2 to 9, wherein the first and second helical support members are electrically conductive, and each has a dielectric plastics coating (12, 13). A hose according to any one of claims 3 to 9, wherein the first, second and third helical support members are electrically conductive and each has a dielectric plastics coating (33, 34, 35). A hose according to any one of claims 1 to 11, further comprising a plurality of longitudinal reinforcing cords (15; 37) disposed between said inner plastics strip and helical electrical conductors and helical reinforcing cords, when present.

Inventors: CHOINIERE, ALCIDE W., DUNN, GEORGE T., JR.
Applicants: FLEXIBLE TECHNOLOGIES, INC.
Application year: 1987
Main classification: F16L11
IPC codes: F16L11, A47L9