Thermoplastic hoses are common in both mobile and industrial equipment, which they’re widely utilized in medium-to-high pressure hydraulic applications. Related products are often specified for handling gas and other gases, transporting chemicals, and in water-cleaning and paint-spray operations.Like its rubber counterpart, thermoplastic hydraulic hose typically has an tube , one or more layers of reinforcement, and a protective covering . Where they differ, because the name implies, is within the materials of construction.The specific polymers and type of design depend on numerous factors like pressure capability, compatibility with the fluids to be handled, temperature operating range, abrasion resistance, and thus the power to confront to attack from chemicals, solvents, cleaning fluids, saltwater, ozone and UV radiation
Thermoplastic hose deconstructed
The majority of hoses were made from rubber but today, a thermoplastic hose may live longer than conventional rubber products for several reasons.Rubber hose can crack from coldness embrittlement; therefore, it’s getting to not work well in freezers and weather .Thermoplastics are designed to handle low temperatures.
Rubber may fatigue from the constant flexing motion experienced in many applications.Thermoplastic hose can have a fiber reinforcement bonded between the hose and thus the jacket designed to handle constant flexing, even at higher pressures.In addition, these hoses offer good chemical/corrosion resistance and should be formed for straightforward routing or bonded together to form one unit from multiple hoses
The core is designed with cleanliness and safety as primary concerns. The core is resistant to erosion and maintains trouble free and long term cleanliness of the hydraulic system, with a mandrel free construction that eliminates lubricant contamination. With fibre reinforced thermoplastic hoses, cutting does not cause contamination as these do not require to be cut by a saw. Some Thermoplastic hoses are also non-conductive for ensuring the safety of the equipment operator from an electric shock.
Hoses are extremely vulnerable to external damage once the jacket has been compromised. It must protect the support of the system and thus the braided reinforcement. If it’s cracked it allows the braid to be exposed to the environment, chemicals and abrasives that are harmful to its integrity. Unlike rubber, a thermoplastic jacket won’t determinate, which can cause jacket failure and wire fatigue.Most thermoplastic hoses feature a UV and ozone resistant cover which resists cracking and UV damage, thus extending the service lifetime of the hose. it also produces specialty jackets, offering increased resistance to the weather and flexing, a selection of colors and laylines are often customized, enabling customers to color-code their systems and provide specific information on the hose itself.
Small inner diameter:
Unlike rubber hoses thermoplastic hoses manufacture, doesn’t require a mandrel for support of the core tube, hence these are often made from a really small inner diameter as small as 1.3mm. this might be crucial where only the fluid to be transferred is extremely small.Because thermoplastic hose/tube manufacturing doesn’t require a mandrel for support of the core tube, hoses are often made to extremely small inner diameters like 1.3mm/(051″). Since rubber hoses require a mandrel, the inner diameter of rubber hoses typically stops at 4.8mm (3/16″). this is often often often often important in applications where only little amount of fluid must be transferred
Compact outer layer:
Compared to rubber hoses, thermoplastic hoses require the utilization of lesser material thanks to the inherent strength of the materials and hence the outer diameter are often 20% smaller than those of rubber hoses. This quality is extremely beneficial in applications where the space is restricted and a number of other hoses got to slot in a relatively small area, for e.g. in mobile equipment.The inherent strength of the thermoplastic materials wont to make hose allows the utilization of less material in comparison to rubber hose. The outer diameter of thermoplastic hose from Parflex and Polyflex are often 20% smaller than outer diameters on comparable rubber hose. This feature is extremely important on equipment where space is restricted and lots of hoses must fit into a little area.
Really long lengths:
The very process of manufacturing of thermoplastic hose ensures long and continuous lengths of hoses because of the self-supporting inner core tube without the need of a mandrel and thus the fabric is cured on the road itself. this means fewer leak points, less wastage, and minimized changeover of reels at production.The manufacturing process of thermoplastic hose allows for long continuous lengths because of the material being “cured” on the road and a self-supporting core tube. Rubber hoses requires a secondary curing process and a mandrel to hold the core tube dimensions. The Parflex and Polyflex divisions have made continuous lengths of 3200m within the past – important for off shore oil applications like marine . For hose assembly locations, the long lengths mean less scrap, minimized leak points and fewer reel changeovers during production.
Thermoplastic hoses, due to the material and construction, are up to 40% lighter than comparable rubber hoses. low pressure rubber lines can be replaced with thermoplastic tubing that is 70% lighter.
Formed Thermoplastic hose:
Some Thermoplastic hoses are often thermally formed into specific shapes to suit unique customer application requirements, allowing cleaner routing, reduced scrap and quicker installations. Formed hose is rigid but flexible, and may be stored in small boxes instead of wooden crates, reducing shipping costs and increasing floor space. Formed hose also maintains and preserve its shape once formed and may be routed throughout small, hard-to-reach areas, resulting in fewer connecting points and eliminating the necessity for hose-tube combinations.For some custom applications, thermoplastic hoses are thermally formed into tailor made shapes to cater to unique client requests for specific shaped hoses, that fit snugly enabling compact routing, quicker installation and low wastage. Rigid yet flexible, these custom formed hoses are often stored in small boxes and hence reduce space for storing and shipping costs. Once formed these hoses retains its shape and may be routed through compact difficult-to-reach areas, with fewer connecting points getting obviate hose-tube combinations
Instead of using multiple hoses, one bonded hose element are often used, with several advantages-lower costs, quicker installations, and lower weight of the bonded hose. Other benefits are elimination of tangling in multiple hose environment and abrasion caused by rubbing of hoses against one another . Bonded hoses are more manageable and overall strength of the hose element is additionally increased reducing hose failure in challenging environments, particularly in mobile machinery equipment like lift trucks, cranes etc. Bonded hoses could also be permanent, strippable or skip bond and individual hose elements are often separated if needed for routing purposes.
Use Thermoplastic Hose
Hose products got to handle high temperatures and environmental stress to stop premature hose failure and safety risks. Thermoplastic hose offers a good sort of added value over their rubber counterparts. Thermoplastic hose is made with a high level of contact strength between the layers of core, braid and jacket. This contact is generated because thermoplastic materials are often re-melted during the assembly process allowing both a chemical and mechanical bond.
Thermoplastic Hose Construction
Polyester synthetic fibers are a critical aspect of thermoplastic hose construction. Even with repeated bending motion, the fibers won’t weaken or crack like wire braided rubber hose.Thermoplastic hose is in a position to face up to high-pressure while being 40 to 60% lighter than rubber hose (e.g. 100R8 hose can weigh 40% but a comparable 100R2 hose). Because it’s abrasion, UV and ozone resistant, thermoplastic hose is extremely long-lasting during a sort of environmental conditions that might typically cause rubber hose to degrade. All layers are naturally bonded together to supply maximum flexibility and kink resistance.Thermoplastic hydraulic hose is meant with safety and cleanliness in mind. Because the thermoplastic core is self-supported and doesn’t require a mandrel, the prospect for contaminants is significantly reduced, leak points are minimized and long continuous lengths of hose are possible.
Advantages of using a thermoplastic hose
Resistance to abrasion:
The inherent strengths of thermoplastic hose materials makes it highly immune to abrasion and actually used as covers for rubber hoses to extend abrasion resistance. Thermoplastic hoses could also be five times more immune to rubber hoses
Reduced contamination levels:
Due to the character of producing of thermoplastic hose as compared to rubber hoses, contamination levels during a thermoplastic hose is far less than rubber hoses. Rubber hose may have flushing and thorough cleaning before use for production.
Resistance to permeation:
The permeation resistance of thermoplastic hoses with the utilization of varied thermoplastic is far quite rubber hoses against gases like Oxygen, CO2 and Nitrogen.
Thermoplastic hoses can endure high working pressures upto 58000 psi (4000 bar) with the utilization of various reinforcement methods.
To counter environment sound pollution and enhance operator comfort, special reinforcement on thermoplastic hose can reduce noise on machines to a high degree.
Disadvantages of using a thermoplastic hose
- Limited service temperature performance
- It tend to form weaker adhesive bonds
There are many potential reasons your hydraulic hose to fail. From fluid incompatibility to tube erosion and dry air, one or more of these issues can cause your organization to experience downtime and interfere with your productivity. Now that you understand some of the reasons why hydraulic hoses can fail, you can implement several precautionary measures that can help you prolong the lifetime of your hydraulic hoses.Read more