Crafting Braided Silicone Hoses: BENFA's Advanced Process and Customization Options
What steps are involved in crafting a braided silicone hose at BENFA? The initial phase is to extrude the core tube, where we recommend a wall thickness of 1-2mm to our clients. A thinner wall may lack the necessary support, making it prone to collapsing during the braiding stage, which could lead to manufacturing defects. BENFA offers customization for the inner tube to suit specific needs like high temperature resistance, color variation, and flame retardation, catering to unique requirements. For instance, we can produce a hose with a black inner layer and a transparent outer one, where the inner is designed for high-temperature resilience, while the exterior is made from standard high-clarity silicone. This versatile manufacturing process allows our braided silicone tubes to serve a wide array of industry applications.
Following the inner tube's extrusion, BENFA weaves the fiber lines. While standard braided silicone hoses can withstand pressures of 12-38 kg, some custom requests may not require this strength but rather need to endure vacuum pressures or exceptionally high pressures. In such cases, BENFA utilizes robust braiding materials like nylon fishing line to enhance the product's compression or vacuum resistance. It's essential to maintain continuous weaving; the tube is threaded through the braiding machine, enveloped by a net formed by multiple braiding heads programmed to follow a set pattern for a uniform weave. The braiding process, critical to the hose's quality, must be performed with high-temperature resistant textiles due to the silicone's vulcanization stage.
The final stage in BENFA's production is the extrusion of the outer tube. Although seemingly straightforward, it's a nuanced process. As the fiber-wrapped inner tube passes through the extruder, trapped air can create bubbles, leading to an uneven hose surface.
To counter this, BENFA advises slightly increasing the outer wall's thickness. When the external layer is extruded, the added material weight helps compress and expel any trapped air, minimizing bubble formation. This adjustment also compensates for any irregularities on the hose's surface, ensuring a smooth finish. Completing the outer tube signifies the end of the manufacturing process for BENFA's braided silicone hoses, resulting in a high-quality, finished product ready for diverse applications.