Process for the manufacture of a flexible polymeric structure by extrusion and the flexible structure manufactured therefrom

Claim 2

Process for the manufacture of a motor vehicle hose and using the motor vehicle hose on an internal combustion engine of a motor vehicle, said process comprising the steps of: extruding a first polymeric layer; applying a sealant barrier to said first polymeric layer, said sealant barrier comprising a multilayer film, said multilayer film being a few microns thick, said multilayer film comprising a polymeric barrier film; said polymeric barrier film consisting essentially of a material configured for minimizing permeation of motor fluids through said motor vehicle hose; overlapping a first portion of said sealant barrier with a second portion of said sealant barrier to create an overlapped portion of said sealant barrier; extruding a second polymeric layer onto said sealant barrier, so that said sealant barrier lies between said first polymeric layer and said second polymeric layer; applying a reinforcement layer to said second polymeric layer; extruding a third polymeric layer onto said reinforcement layer, said third polymeric layer being the outermost layer of said motor vehicle hose, said third polymeric layer being configured for withstanding influences external to said motor vehicle hose in an engine compartment in a motor vehicle; heat treating said motor vehicle hose to achieve an intimate bonding of all layers of said motor vehicle hose and to seal said overlapped portion of said sealant barrier; and mounting the motor vehicle hose on the internal combustion engine of the motor vehicle.

Claim 3

The process according to claim 1, wherein: said motor vehicle hose is configured for conveying at least one of the following internal aggressive agents: oxygenated automotive fuels, said multilayer film being configured for sealing against the oxygenated automotive fuels; and two-phase fluids in cooling systems, said multilayer film being configured for sealing against the two-phase fluids; said first polymeric layer comprises a first tubular structure, said first tubular structure having an internal surface and an external surface; said first tubular structure comprises an internal cavity and being configured for conveying fluid through said internal cavity; said step of applying said sealant barrier comprises applying said sealant barrier directly onto said external surface of said first tubular structure; said second polymeric layer comprises a second tubular structure; and said step of extruding said second polymeric layer comprises extruding said second tubular structure directly onto said sealant barrier, to make contact with said sealant barrier.

Claim 4

The process according to claim 2, wherein said motor vehicle hose is a flexible tube.

Claim 5

The process of claim 3, wherein: said first polymeric layer and said second polymeric layer have substantially the same thickness; said overlapped portion of said sealant barrier has a length essentially equal to 200 times the thickness of said sealant barrier; said multilayer film further comprises: two contact films for bonding said barrier films to said first and second polymeric layers, said barrier film is sandwiched between said two contact films; said multilayer film is between 16 and 40 microns thick; said barrier film is between 10 and 30 microns thick; said two contact films are each between 3 and 5 microns thick; said barrier film comprises polyethylene terephthalate; and said contact film comprises polyvinyl chloride; said multilayer film is configured for performing a sealing function against external aggressive agents, the external aggressive agents including oxygen and ozone; said step of applying a sealant barrier comprises applying a sealant barrier to the outside of said first tubular structure, said sealant barrier comprising a multilayer film is in the form of a continuous ribbon having two longitudinal edges and said ribbon is applied to the first tubular structure as follows: orienting said ribbon longitudinally along said first tubular structure; wrapping said first tubular structure with said ribbon; overlapping said two edges of said ribbon longitudinally along said first tubular structure to form said overlapped portion; a first of said two contact films is for being disposed towards said first polymeric layer; a second of said two contact films is for being disposed towards said second polymeric layer; said first contact film is configured for: bonding a major portion of said barrier film to said first polymeric layer; and bonding with said second contact film at a minor portion of said barrier film to form said overlapped portion of said sealant barrier; said second contact film is configured for: bonding a major portion of said barrier film to said second polymeric layer; and bonding with said first contact film at a minor portion of said barrier film to form said overlapped portion of said sealant barrier; said reinforcement layer comprises a textile material; said barrier film has a relative thickness with respect to said first polymeric layer and a relative thickness with respect to said second polymeric layer; said relative thickness of said barrier film with respect to said first polymeric layer and said relative thickness of said barrier film with respect to said second polymeric layer are configured for compensating for differences in modulus of elasticity between said barrier film, said first polymeric layer and said second polymeric layer; said second tubular structure comprises an internal surface for being disposed towards said first tubular structure and an external surface for being disposed away from said first tubular structure; and said step of applying said reinforcement layer comprises applying said reinforcement layer directly onto said external surface of said second tubular structure; said first tubular structure is configured for conveying motor fluids in an internal combustion engine of a motor vehicle; and said first tubular structure is made of a material configured for conveying said at least one of: oxygenated automotive fuels; and two-phase fluids in cooling systems.