Stitched Double Layer Composite Hose and Manufacturing Method Thereof

Abstract

A stitched double layer composite hose and a manufacturing method thereof are provided. The stitched double layer composite hose includes a middle fabric pipe layer ( 1 ), an inner surface composite colloid material layer ( 2 ) and an outer surface composite colloid material layer ( 3 ). The structure of the fabric pipe layer is weft-stitched double-layer unit structure. The double-layer unit structure includes an outer layer, an inner layer and stitched wefts. The inner layer includes inner layer warps and inner layer wefts; the outer layer includes outer layer warps and outer layer wefts. The stitched wefts interweave with the outer layer warps and the inner layer warps for conjoining the inner layer and the outer layer together. The fabric pipe layer weaved according to this invention solves problems of the stitched double layer composite hose in the fabric pipe layer of traditional casing, with such advantages as high flexibility, less weaving point, less loss of yarn strength and less degree of torsion. The fabric pipe layer, with special coating equipment and special coating process, can be directly processed into a stitched double layer composite hose satisfying market needs with large caliber, high dielectric strength and higher flexibility. The production process is simple, featured with extremely high utility value and worthy of promotion for production.

1 . A stitched double layer composite hose, comprising a fabric pipe layer, an inner surface composite colloid material layer and an outer surface composite colloid material layer, wherein: a structure of the fabric pipe layer is weft-stitched double-layer unit structure; the double-layer unit structure comprises an outer layer, an inner layer and stitched wefts, and the inner layer comprises inner layer warps and inner layer wefts; the outer layer comprises outer layer warps and outer layer wefts; the stitched wefts interweaves with the outer layer warps and the inner layer warps, for conjoining the inner layer and the outer layer together. 
     
     
         2 . A manufacturing method of the stitched double layer composite hose according to  claim 1 , comprising steps of:
 weaving the fabric pipe layer, which comprises steps of: first, determining total amount of warps in a fabric pipe layer according to an amount of the warps in a single complete cycle unit and an amount of cycles of complete cycle units; then, setting total amount of the warps, at a same time, weaving the inner layer and the outer layer of the fabric pipe layer respectively, and interweaving the inner layer and the outer layer through the stitched wefts, for conjoining the inner layer and the outer layer together to form the fabric pipe layer; and   colloid compositing, which comprises steps of: co-extruding rubber compound/thermoplastic elastomer on inner and outer surfaces of the fabric pipe layer once, or lining the rubber compound/thermoplastic elastomer on the inner surface and color painting on the outer surface.   
     
     
         3 . The manufacturing method according to  claim 2 , wherein a weaving structure of the fabric pipe layer is a double twill structure or a double plain structure, and the total amount of the warps in the fabric pipe layer is determined in following manners:
 when the weaving structure is in double twill stitching, the weaving structure is weaved using n complete cycle units, the amount of the warps in each complete cycle unit is 6, and the total amount of the warps in the fabric pipe layer is 6n+4;   when the weaving structure is in double plain stitching, the weaving structure is weaved using n complete cycle units, the amount of the warps in each complete cycle unit is 4, and the total amount of the warps in the fabric pipe layer is 4n+2.   
     
     
         4 . The manufacturing method according to  claim 3 , wherein the complete cycle unit applies a following weaving method comprising steps of: driving wefts by synchronous circling motions of set amount of shuttles on a weaving machine, making the wefts shuttling through layered warps to weave, cooperating with set amount of noseplates in a same weaving cycle for leasing, making shuttle lead wefts through the layered warps to connect inner and outer textiles, thus completing the weaving of the fabric pipe layer. 
     
     
         5 . The manufacturing method according to  claim 4 , wherein there are three shuttles. 
     
     
         6 . The manufacturing method according to  claim 5 , wherein when the complete cycle unit is in double twill stitching, the weaving method is as follows, wherein: the noseplate cooperating with a first shuttle has following three leasing movements successively: one up one down one up three down, two down one up one down one up one down, one up three down one up one down (↑↓↑↓↓↓, ↓↓↑↓↑↓, ↑↓↓↓↑↓) and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with a second shuttle has the following three leasing movements successively: three up one down one up one down, one up one down three up one down, one up one down one up one down two up (↑↑↑↓↑↓, ↑↓↑↑↑↓, ↑↓↑↓↑↑) and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with a third shuttle has the following three leasing movements successively: two up two down one up one down, one up one down two up two down, two down one up one down two up (↑↑↓↓↑↓, ↑↓↑↑↓↓, ↓↓↑↓↑↑), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double twill weft stitching the fabric pipe layer of the hose. 
     
     
         7 . The manufacturing method according to  claim 5 , wherein when the complete cycle unit is in double plain stitching, the weaving method is as follows, wherein: the specially made noseplate cooperating with the first shuttle has following two leasing movements successively: one up three down, two up(down) one up one down (↑↓↓↓, ↓↓↑↓↑↓), and the shuttle leads wefts through layered warps to carry out the outer layer weaving; the noseplate cooperating with the second shuttle has following two leasing movements successively: three up one down, one up one down two up (↑↑↑↓, ↑↓↑↑), and the shuttle leads wefts through layered warps to carry out the inner layer weaving; the noseplate cooperating with the third shuttle has following two leasing movements successively: two up two down, two down two up (↑↑↓↓, ↓↓↑↑), and the third shuttle leads wefts through layered warps to carry out the connection of inner and outer textiles, thereby achieving the weaving of double plain weft stitching the fabric pipe layer of the hose. 
     
     
         8 . (canceled) 
     
     
         9 . The manufacturing method according to  claim 2 , wherein the rubber compound/thermoplastic elastomer is a high polymer elastomer compound, and the color painting is a high polymer elastomer color paste. 
     
     
         10 . The manufacturing method according to  claim 2 , wherein the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU. 
     
     
         11 . The manufacturing method according to  claim 9 , wherein the rubber compound/thermoplastic elastomer is made of TPU, and the color painting is made of water-based TPU. 
     
     
         12 . The manufacturing method according to  claim 2 , wherein the warps and wefts are made of any high-strength fiber thread. 
     
     
         13 . The manufacturing method according to  claim 3 , wherein the warps and wefts are made of any high-strength fiber thread. 
     
     
         14 . The manufacturing method according to  claim 4 , wherein the warps and wefts are made of any high-strength fiber thread. 
     
     
         15 . The manufacturing method according to  claim 5 , wherein the warps and wefts are made of any high-strength fiber thread. 
     
     
         16 . The manufacturing method according to  claim 6 , wherein the warps and wefts are made of any high-strength fiber thread. 
     
     
         17 . The manufacturing method according to  claim 7 , wherein the warps and wefts are made of any high-strength fiber thread.