[0001]The present invention relates to a flexible hose used as, for example, a shower hose or a similar hose or tube, and a method for producing the flexible hose.
Specifically, the present invention relates to a metai-tone flexible hose having an external appearance of a metallic color, and a method for producing the same. [Background Art] [0002]
A conventional plastic hose of this type of metal-tone flexible hose includes a carrier hose made of a thermoplastic material such as PVC, a hot stamping film having a metalized layer of vapor deposited aluminum (aluminum vapor deposition part) and an adhesive layer to be heat-bonded, and an outside hose made of colorless transparent PVC (see, for example, PTL 1).
During the extrusion molding step, multifilament threads are pressed into the material of the carrier hose that is still soft, so that a thread reinforcing portion is embedded in which the multifilament threads cross spirally. Accordingly, the surface of the carrier hose has groove-like recessed parts extending along the lines of the multifilament threads.
When the piastic hose is used as a shower hose, a hot stamping film (strip) spirals around on the outside surface of the carrier hose. This allows the metalized layer to cover and adhere to the outside surface of the carrier hose through the adhesive layer, so that an outside hose is integrally molded as a protective sheet of the metalized layer.
The method for making a plastic hose (decorative hose) is to cover the pre-made carrier hose with a hot stamping film (strip) that is bonded to a carrier strip on an outside of the carrier hose and to firmly bond the entire surface of the hot stamping film to the outside of the carrier hose by applying heat and pressure, and thereafter to peel off the carrier strip. [Citation List] [Patent Literature] [0003]
[PTL 1] Japanese Patent No. 3853396 [Summary of Invention] [Technical Problem] [0004]
A flexible hose is produced uniformly in the axial direction through extrusion molding or the like and has a same external appearance. For this reason, the directionality cannot be identified from the external appearance, For example, the flow direction of the fluid passing through the inside of the flexible hose cannot be
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easily identified from the outside of the flexible hose even when the flexible hose is made of a transparent or translucent material. As such, there is a demand for easy identification of the directionality.
Furthermore, for a metal-tone flexible hose whose external appearance is important, such as a shower hose, there is a demand for a hose that not only has a lustrous metal texture but also has an excellent visual appearance and a high decorative effect.
However, in PTL 1, the hose surface only includes the spirally crossing groove-like recessed parts formed by the thread reinforcing portion, and the butting edge parts and circumferentiaily overlapping parts of the ' hot stamping fiim (strip), which are uniformly arranged over the entire length. The hose lacks any feature that allows the identification of the directionality and does not have a special visual appearance other than the metal texture. In addition, the butting edge parts of the hot stamping film (strip) may have seams and interspace.
Also, when PTL 1 is used as a shower hose, the metalized layer (aluminum vapor deposition part) fails to follow the deformation of the carrier hose since the carrier hose, which is made of a thermoplastic material such as PVC, and the metalized layer, which is firmly bonded to the entire surface of the carrier hose by the adhesive layer, differ significantly in the elongation amount in bending deformation, tensile deformation, or temperature change.
This may cause cracks or fractures in the metalized layer when used for a long period of time, and hot water or cold water and the like may enter between the surface of the carrier hose and the metalized layer through the cracks or fractures and the adhesive layer, causing a problem that the metalized layer is peeled off from the surface of the carrier hose.
In addition, foreign matter, such as water scale or boiling scale, is likely to collect and adhere to the groove-like recessed parts formed over the entire surface of the hose. Furthermore, the foreign matter such as water scale or boiling scale accumulated in such groove-like recessed parts cannot be easily removed by cleaning, and thus tends to cause uncleanliness and deteriorate the external appearance with long-term use. . [Solution to Problem] [0005]
In order to solve such problems, a flexible hose according to the present invention includes a foundation layer having a colored outside surface and a coating layer provided on the outside of the foundation layer. A plurality offtakes having reflective surfaces are dispersed and arranged in the coating layer, and the plurality of flakes are oriented in an inclined state in one direction with respect to the outside surface of the foundation layer.
Furthermore, in order to solve such problems, a method for producing a flexible hose according to the present invention is a method for producing a flexible hose that performs extrusion molding of a foundation layer having a colored outside surface and a coating layer provided on the outside of the foundation layer. The method includes a mixing step of dispersing a plurality of flakes having reflective surfaces in a second material that is to become the coating layer and a molding step of performing extrusion molding of the second material in which the plurality of flakes are dispersed so that the second material is laminated on the outside of a first material that is to become the foundation layer. In the molding step, the plurality of flakes are oriented in an inclined state in one direction with respect to the outside surface of the foundation layer. [Brief Description of Drawings]
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[0006]
[Fig. 1]
Fig. 1 is an explanatory view showing the overall configuration of a flexible hose (metai-tone flexible hose)
according to an embodiment of the present invention, and is a longitudinal cross-sectional front view in which the
main part is partially enlarged.
[Fig. 2]
Fig. 2 is an enlarged photograph showing the orientation state of a plurality of flakes.
[Fig. 3]
Fig. 3 is an explanatory view and photographs showing the external appearance of a flexible hose (metal-tone
flexible hose). Fig. 3(a) is a photograph taken from the arrow direction (3A) in Fig. 1, and Fig. 3{b) is a
photograph taken from the arrow direction (3B) in Fig. 1.
[Description of Embodiments]
[0007]
Referring to drawings, embodiments of the present invention are now described in detail.
As shown in Fig. 1 to Fig. 3, a flexible hose A according to an embodiment of the present invention is a tubular body used as, for example, a shower hose or a similar hose or tube. The flexible hose A is preferably a metal-tone flexible hose A1 having an external appearance of a metallic color. The metallic color may be a silver color, a bronze color, a gold color, and the like.
Specifically, the flexible hose A according to an embodiment of the present invention includes a foundation layer 1, which has a colored outside surface 1a, and a coating layer 2, which is provided on the outside of the foundation layer 1, as main components.
Furthermore, it preferably includes a protective layer 3, which is provided on the outside of the coating layer 2, and an inner layer 4, which is provided on the inside of the foundation layer 1. In this case, a four-iayer structure is formed in which the three layers of the foundation layer 1, the coating layer 2, and the protective layer 3 are laminated as the outer part on the single inner layer 4 serving as the inner part, and the coating layer 2 is laminated as an intermediate layer between the foundation layer 1 and the protective layer 3.
As shown in Fig. 3(a) and Fig 3(b), a reinforcing layer 5 may be provided between the foundation layer 1. and the inner layer 4 as required. [0008]
The foundation layer 1 may be made of a soft material (first material) 11, which may be a soft synthetic resin such as vinyl chloride resin, silicone rubber, or other rubber, and formed into a flexible hose.
In a specific example of the foundation layer 1, a plasticizer for appropriate softening, a stabilizer for preventing deterioration during processing and in use, and other materials such as a lubricant, filler, processing aid, and improving material are added to a thermoplastic resin, such as vinyl chloride resin, in a predetermined ratio.
At least the outside surface 1 a of the foundation layer 1 is formed to be colored.
Specific examples of the colored outside surface 1a include adding a pigment to the soft material forming the foundation layer 1 to color the entire foundation layer 1 with a predetermined color, and forming a
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colored layer integrally by painting and the like with respect to the outside surface 1a of the foundation layer 1 which is made of a colorless soft material, which may be transparent or translucent. In the illustrated, example, the entire foundation layer 1 including the outside surface 1a is colored black.
in other examples not illustrated, modifications may be made such as modifying the outside surface 1a to have a color other than black, such as white, and printing a mark, such as an arrow, or a sign, such as a character. [0009]
The coating layer 2 includes a plurality (iarge number) of flakes 21. The coating layer 2 is made of a transparent or translucent soft material {second material) 22 having the same elongation rate as the foundation layer 1, laminated along the outside surface 1 a of the foundation iayer 1, and formed in a cylindrical shape and in close contact with the outside surface 1 a. Before the coating layer 2 is formed, a large number of flakes 21 are blended in the soft material (second materia!) 22 that is to become the coating layer 2, and the large number of flakes 21 are dispersed substantially evenly in the second material 22.
The large number of flakes 21 are micron-sized or nano-stzed thin piates, which may be referred to as flakes or cells. The surface of each flake 21 that has a long diameter forms a reflective surface 21a, which reflects light in a manner different from that of the outside surface 1a of the foundation layer 1.
When the flexible hose A according to an embodiment of the present invention is a metal-tone flexible hose A1, the reflective surfaces 21a of the flakes 21 are metallic color surfaces. In a specific example of a large number of flakes 21, the metal-tone flexible hose A1 has "scale-like metal fiakes" disclosed in Japanese Patent Application Publication No. 2005-298905 or a similar configuration as the large number of flakes 21. [0010]
The protective layer 3 is made of a transparent or translucent soft material (third material) 31 having the same elongation rate as the foundation layer 1 and the coating layer 2 and laminated along the outer surface 2a of the coating layer 2. Thus, the protective layer 3 is formed so as to be in close contact with the outer surface 2a of the coating layer 2 and to cover in a cylindrical shape, and the outside surface 3a of the protective layer 3 is smoothed.
As a result, the dispersed and arranged plurality (large number) of flakes 21 in the coating layer 2 is composed to be visible so that the external appearance of protective layer 3 can be viewed through the protective layer 3 which is transparent or translucent.
As for the color of the protective layer 3, the protective layer. 3 is preferably colorless transparent or colorless translucent and may also be modified to colored transparent or colored translucent. The colored transparent or colored translucent protective layer 3 may be formed by mixing a transparent or translucent soft material (third material) 31 with a pigment (not shown) having a color such as red, blue, green, or yellow. [0011]
The inner layer 4 is made of a transparent, translucent, or opaque soft material (fourth material) 41 having the same eiongation rate as the foundation iayer 1, the coating layer 2 and the protective layer 3, and laminated along the inner surface of the foundation layer 1.
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Thus, the inner layer 4 is formed so as to be in close contact with the inner surface of the foundation layer 1 and cover it in a cylindrical shape, and the inside surface 4a of the inner layer 4 Is smoothed. [0012]
The reinforcing layer 5 is embedded between the inner layer 4 and the foundation layer 1 by winding a reinforcing wire 51 in a spiral or net shape along the outer peripheral face of the inner layer 4 to improve the physical properties, such as pressure resistance and shape retention, of the flexible hose A (metal-tone flexible hoseAl).
As the reinforcing wire 51, a reinforcing thread made of synthetic resin fibers such as polyester, nylon (registered trademark), and aramid is mainly used. Alternatively, a metal wire of stainless steel or the like, or a coil made of a similar hard material may be used. Examples of the reinforcing thread include a multifilament made by twisting a plurality of fine synthetic resin fibers, a monofilament (single fiber) made of a single synthetic resin fiber, and flat yarn (or strip yarn) made of strip-shaped synthetic resin fibers.
In a specific example of the reinforcing wire 51 shown in Fig. 3(a) and Fig. 3(b), a net-shaped braid structure is formed by spirally winding reinforcing threads made of multifilament respectively along the outer peripheral face of the inner layer 4.
In other examples not illustrated, modifications may be made in which monofilament or flat yarn, instead of multifilament is wound as the reinforcing thread of the reinforcing wire 51 in a spiral or net shape, or a reinforcing thread or the like is knitted along the outer peripheral face of the inner layer 4 into a net of a hollow cylindrical shape. [0013]
A method for producing the flexible hose A (metal-tone flexible hose A1) according to an embodiment of the present invention includes, as main steps, a mixing step of dispersing a plurality (large number) offtakes 21 into a soft material (second material) 22 that is to become the coating layer 2, and a molding step of performing extrusion molding of the second material 22 in which the plurality (large number) of flakes 21 are dispersed on the outside of the first material 11 that is to become the foundation layer 1.
In the mixing step, a large number of flakes 21 are mixed and kneaded into the second material 22, which is to become the coating layer 2, so that the large number of flakes 21 are dispersed substantially evenly in the second material 22.
in the molding step, the second material 22 in which the large number of flakes 21 are dispersed in the mixing step, is extruded overlapping the first material 11 of the foundation layer 1 by an extrusion molding machine (not shown), so that the first material 11 of the foundation layer 1 and the second material 22 of the coating layer 2 are successively laminated and molded.
The pressure generated during this extrusion molding controls the orientation of the large number of flakes 21 in the second material 22 so as to incline toward the axial direction at a predetermined angle with respect to the outside surface 1a of the foundation layer 1. As a result, the large number of flakes 21 are oriented in an inclined state in one direction with respect to the outside surface 1 a of the foundation layer 1. [0014]
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Furthermore, in the molding step, the third material 31 that is to become the protective layer 3 is preferably added, and co-extrusion molding is preferably performed with the second material 22 of the coating layer 2 is sandwiched between the first material 11 of the foundation layer 1 and the third material 31 of the protective layer 3.
In the specific example of the molding step shown in Fig. 1, when the first material 11 of the foundation layer 1 is extruded from the extrusion molding machine along the outside surface 4b of the inner layer 4, the second material 22 into which a large number of flakes 21 of the coating layer 2 have been kneaded and the third material 31 of the protective layer 3 are simultaneously extruded.
In this case, the pressure from both sides applied by the first material 11 of the foundation layer 1 and the third material 31 of the protective layer 3 ensures that all of the large number of flakes 21 are oriented to incline in one direction with respect to the outside surface 1 a of the foundation layer 1.
In Fig. 1, the first material 11 of the foundation layer 1 extruded from the extrusion molding machine is indicated by the arrow of reference sign "1e", the second material 22 of the coating layer 2 extruded from the extrusion molding machine and into which a large number of flakes 21 have been kneaded is indicated by the arrow of reference sign "2e", and the third material 31 of the protective layer 3 extruded from the extrusion molding machine is indicated by the arrow of reference sign "3e". The arrow designated by the reference sign "E" indicates the extrusion molding direction.
In another example not shown, all the materials {the first material 11 of the foundation layer 1, the second material 22 of the coating layer 2 into which a large number of flakes 21 have been kneaded, and the third material 31 of the protective layer 3), including a fourth material 41 of the inner layer 4 serving as the inner part, may be co-extruded and molded. [0015]
Fig. 2, Fig. 3(a) and Fig 3(b) show the results of demonstration experiments of such orientation control.
Fig. 2 is photographed in a state in which the coating layer 2 is magnified 500 times with an oscilloscope and the light incident on the reflective surfaces 21a of the large number of flakes 21 is mirror reflected.
Fig. 3(a) is a photograph of the flexible hose A (metal-tone flexible hose A1) taken from the arrow direction (3A) in Fig. 1.
In this case, this photographing direction is in a state of crossing the reflective surfaces 21a of the large number of flakes 21, so that the incident light is reflected by the large number of reflective surfaces 21a, resulting in a high brightness effect. Accordingly, as shown in Fig. 3{a), the external appearance as viewed from this reflection direction is the color tone of the reflective surfaces 21 a as a whole.
Fig. 3(b) is a photograph of the flexible hose A (metal-tone flexible hose A1) taken from the arrow direction (3B) in Fig. 1.
This photographing direction is substantially parallel to the reflective surfaces 21 a of the large number of flakes 21, so that the incident light does not cross the large number of reflective surfaces 21a, passes through without being obstructed by the large number of flakes 21, and is absorbed by the outside surface 1a of the foundation layer 1. Accordingly, as shown in Fig. 3(b), the external appearance as viewed from this n on-reflection direction is the color of the outside surface 1a of the foundation layer 1.
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In the illustrated example, since the outside surface 1a of the foundation layer 1 is black, the color is darker than that in Fig. 3(a).
in another example in which the color of the outside surface 1a of the foundation layer 1 is modified to white, the color will be lighter than that in Fig. 3(a). In another example in which a mark, such as an arrow, or a sign, such as a character, is printed on the outside surface 1 a, the mark or sign will appear. [0016]
According to the flexible hose A and the method for producing the same according to the embodiment of the present invention, a plurality of flakes 21 are dispersed in the coating layer 2 substantially evenly and oriented in an inclined state toward the axial direction or the like in one direction with respect to the outside surface 1a of the foundation layer 1. This allows the light incident in a direction that crosses the reflective surfaces 21a of the plurality of flakes 21 to be reflected by the reflective surfaces 21a. Accordingly, the external appearance as viewed from the reflection direction is the color tone of the reflective surfaces 21a as a whole.
The light that is incident along the inclination direction of the plurality of flakes 21 without crossing the reflective surfaces 21a passes through without being obstructed by the plurality of flakes 21 and is absorbed by the outside surface 1a of the foundation layer 1. Accordingly, the external appearance as viewed from the direction along the inclination direction of the plurality of flakes 21 has the color of the outside surface 1 a of the foundation layer 1.
As such, the color tone of the external appearance changes with change of the line-of-sight direction with respect to the plurality of flakes 21.
Thus, the directionality of the hose can be identified by a change in the external appearance caused by a change in the viewing direction.
As a result, as compared to a conventional hose with recessed parts or the like formed uniformly over the entire surface of the hose, the flow direction and the like of fluid flowing through the flexible hose A can be easily identified from the outside even if the fluid in the hose is not visible through the flexible hose A.
In addition to changing the viewing direction with respect to the flexible hose A, bending the whole or a part of the flexible hose A also changes the line-of-sight direction with respect to the plurality of flakes 21 located in the bent part. Since such bending also changes the color tone of the external appearance, the visual appearance is excellent and the decorative effect is improved.
In addition, as compared to a conventional configuration that may cause seams or interspace at the butting edge parts of the hot stamping film (strip), the foundation layer 1 and the coating layer 2 do not cause seams or interspaces. This further adds a quality appearance. [00171
In particular, it is preferable that the transparent or translucent protective layer 3 be provided on the outside of the coating layer 2, and that the protective layer 3 be laminated so as to press the coating layer 2 toward the outside surface 1a of the foundation layer 1.
In this case, the protective layer 3 evenly presses the entire coating layer 2 toward the outside surface 1 a of the foundation layer 1, so that the inclination angles of the plurality of flakes 21 with respect to the outside surface 1a of the foundation layer 1 are uniform and do not vary.
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This ensures that the light incident through the transparent or translucent protective layer 3 in a direction crossing the reflective surfaces 21a of the plurality of flakes 21 is reflected by the reflective surfaces 21a, and the reflected light passing through the protective layer 3 enters the eyes of the user.
The color thus changes reliably according to the difference in the viewing direction improving the identification performance of the directionality.
As a result, since the color tone of the external appearance changes reliably even when the hose is bent, the visual appearance is excellent and the decorative effect is further improved.
Furthermore, when the flexible hose A is used as a shower hose, as compared to a conventional shower hose having groove-like recessed parts formed over the entire surface of the hose, the outside surface 3a of the protective layer 3 is smoothed by covering the outside of the coating layer 2 in a cylindrical shape with the protective layer 3, so that foreign matter, such as water scale or boiling scale, is less likely to adhere to the protective layer 3, and stains can be removed by simple cleaning. This maintains the flexible hose A clean for a long period of time. [0018]
Also, it is preferable that the flexible hose A be a metal-tone flexible hose A1 of a metallic color and that the reflective surfaces 21a of the plurality of flakes 21 be metallic color surfaces.
In this case, the light incident on the metallic color surfaces, which are the reflective surfaces 21a of the plurality of fiakes 21, is mirror reflected on the pluraiity of reflective surfaces (metallic color surfaces) 21a, and the mirror-reflected light enters the user's eyes.
As such, the metal-tone flexible hose A1 can be provided that causes mirror reflection according to the difference in the viewing direction.
Consequently, as compared to a conventional shower hose that has recessed parts uniformly formed over the entire surface of hose, the metal-tone flexible hose A1, even when used as a shower hose for a long period of time, does not suffer from cracks or fractures in the coating layer 2, maintains its metallic luster and flexibility, and thus can improve commercial value. [0019]
In addition to that the flexible hose A is a metal-tone flexible hose A1 of a metallic color and the reflective surfaces 21 a of the plurality of flakes 21 are metallic color surfaces, the protective layer 3 is preferably configured to be colored transparent or colored translucent.
In this case, only by changing the color of the colored transparent or colored translucent protective layer 3, an arbitrary metallic color can be given to the external appearance of the metallic color surfaces of the reflective surfaces 21a of the flakes 21 in the coating layer 2 as viewed from the outside of the protective layer 3 through the colored transparent or colored translucent protective layer 3.
It is thus possible to provide a metal-tone flexible hose A1 that can have various colors while maintaining the luster of the metallic color.
This achieves various metallic colors with a uniform tone and quality at a low cost, increasing the quality and the cost-effectiveness. [0020]
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The illustrated example of the embodiment described above has a four-layer structure of the inner layer 4, the foundation layer 1, the coating layer 2, and the protective layer 3. - However, the structure is not limited to this and may be a two-layer structure including the foundation layer 1 and the coating layer 2, a three-layer structure without the inner layer 4, a multi-layer structure of five or more layers including an innermost layer inside the inner layer 4, or a multi-layer structure of five or more layers including an outermost layer outside the protective layer 3.
The illustrated example has the reinforcing layer 5 between the foundation layer 1 and the inner layer 4. However, the configuration is not limited to this, and the reinforcing layer 5 may be provided in a position other than between the foundation layer 1 and the inner iayer 4. [Reference Signs List] [0021]

A Flexible hose
A1 Metal-tone flexible hose
1 Foundation layer
1a Outside surface
11 First material
2 Coating layer
21 Flake
21a Reflective surface
22 Second materia!
3 Protective layer

WE CLAIMS

A flexible hose comprising:
a foundation layer having a colored outside surface; and
a coating layer provided on an outside of the foundation layer,
wherein a plurality offtakes having reflective surfaces are dispersed and arranged in the coating layer, and the plurality offtakes are oriented in an inclined state in one direction with respect to the outside surface of the foundation layer. [Claim 2]
The flexible hose according to claim 1, including a transparent or translucent protective layer provided on an outside of the coating layer, wherein the protective layer is laminated so as to press the coating layer toward the outside surface of the foundation layer. [Claim 3]
A metal-tone flexible hose that is the flexible hose according to claim 1 or 2 and has a metallic color,
wherein the reflective surfaces of the plurality of flakes are metallic color surfaces. [Claim 4]
A method for producing a flexible hose that performs extrusion molding of a foundation layer having a colored outside surface and a coating layer provided on an outside of the foundation layer, the method comprising:
a mixing step of dispersing a plurality of flakes having reflective surfaces in a second material that is to become the coating layer; and
a molding step of performing extrusion molding of the second material in which the plurality of flakes are dispersed so that the second material is laminated on an outside of a first material that is to become the foundation layer,
wherein in the molding step, the plurality of flakes are oriented in an inclined state in one direction with respect to the outside surface of the foundation layer.