A Complete Guide to Thermopol Hoses and Their Industrial Applications

An Introduction to Thermopol Hose

Thermopol hoses are a specialized type of hose made from thermoplastic materials. They are designed for a wide range of industrial and commercial applications where flexibility, durability, and resistance to heat are required. In this article, we'll take a closer look at what thermopol hoses are, their key properties and advantages, and some of their common uses and applications.

What is Thermopol Hose?

Thermopol hose is made by extruding thermoplastic materials to create a flexible hose. The term 'thermopol' comes from 'thermoplastic polymer' which refers to types of plastic that soften or melt when heated and harden when cooled. This gives thermopol hoses the ability to be shaped and formed into continuous lengths of piping and tubing.

Some of the common thermoplastic materials used to manufacture thermopol hoses include:

• Polyvinyl chloride (PVC)
• Polyurethane (PU)
• Thermoplastic elastomer (TPE)
• Thermoplastic rubber (TPR)
• Polyethylene (PE)
• Nylon

The exact materials used can be customized to meet specific temperature, chemical, and flexibility requirements of different applications. Thermoplastic materials also allow for the incorporation of reinforcing fibers to increase strength and durability.

Key Properties and Advantages

There are several key properties and advantages that make thermopol hoses useful across various industries:

• Heat resistance - Thermopol hoses can withstand high temperatures, often up to 200°C depending on the material used. This makes them well-suited for hot fluids and environments.
• Chemical resistance - Properly engineered thermopol hoses have excellent chemical resistance against acids, bases, oils, and solvents. This allows their use in harsh industrial applications.
• Lightweight - Thermopol hoses are lighter in weight than rubber, metal, or fabric hoses. This makes them easier to work with and transport.
• Flexible - Thermopol materials can be highly flexible and pliable, even at low temperatures. This gives the hoses excellent bend radius and ease of routing.
• Durable - Reinforced thermopol hoses have high tensile strength and abrasion resistance. They can withstand high pressures and last for years even in demanding environments.
• Cost-effective - Thermopol hoses are cost-effective compared to some metal and rubber alternatives, making them an economical solution.

Common Applications and Uses

Here are some of the most popular uses and applications for thermopol hoses:

• Hot water delivery - For hot water transport in plumbing and heating systems. The heat resistance prevents melting or softening issues.
• Vehicle radiator hoses - As replacement hoses for vehicle engine cooling systems, thanks to their durability and high heat tolerance.
• High pressure washers - Thermopol provides a lightweight, flexible, and abrasion-resistant solution for power washers.
• Chemical transfer - Allows safe and controlled transfer of chemicals like acids, solvents, and petrochemicals that would degrade rubber.
• Compressed air lines - For workshop and industrial compressed air lines. Handle high pressures without kinking.
• Gasoline and fuel handling - For use with gasoline, LPG, CNG, and diesel fuels while resisting corrosion.
• Industrial waste discharge - Where resistance to acids, alkalis, and high temperatures is needed for waste and slurry flows.
• Robotics and machinery - Flexible movement of air, water, or hydraulic fluids in manufacturing and automation equipment.

Specialty Thermopol Hose Types

There are also some specialty types of thermopol hoses designed for niche applications:

• Conductive hoses - These have an electrically conductive inner core to prevent static charge buildup when conveying flammable media.
• Food grade hoses - For food and beverage transfer applications, made from FDA and NSF approved materials.
• High purity hoses - Ultra-smooth inner bore provides low particulate generation for industries like pharmaceuticals and semiconductors.
• High pressure hoses - Heavy duty reinforced construction for pressures up to 5000+ PSI in hydraulic applications.
• XLPE insulated hoses - Insulated with cross-linked polyethylene for hot oil and steam heating media.

Thermopol Hose Construction and Composition

Thermopol hoses have a specific construction and material composition that provides their unique properties. Some key elements include:

Tube

The innermost layer that makes contact with the conveying media is called the tube or liner. It needs to have excellent heat and chemical resistance. Common tube materials include polyamide, polyethylene, polyurethane, and PTFE.

Reinforcement

One or more reinforcements are added over the tube to increase strength and prevent kinking. These are usually spiral wound synthetic yarn, textile braiding, or steel wire coils.

Cover

The outermost cover provides abrasion and ozone resistance. Rubber, PVC, polyethylene, nylon, or polyurethane are typical cover materials.

Bonded Construction

The multiple layers are tightly bonded together to prevent delamination. Extrusion and vulcanization bonding processes are commonly used.

Couplings

End fittings like crimped metal couplings allow easy, leak-proof connections. Custom fittings can be molded directly over the hose for special applications.

Standards and Certifications

There are various standards and certifications applicable to industrial-grade thermopol hoses which ensure quality, safety, and reliability:

• ISO 4413 - International standards for rubber and plastics hoses and hose assemblies.
• EN 853 - European standards for rubber hoses and hose assemblies for hydraulic systems.
• SAE J1273 - SAE standards for hydraulics hoses used in motor vehicle applications.
• DIN 20066 - German national standards for plastics and rubber hoses.
• ASTM F1548 - ASTM standards for thermoplastic hoses and tubing materials.
• CSA Z227.11 - Canadian standards for non-metallic hoses.
• AS/NZS 2053 - Australian/New Zealand standards for fuel, oil and heat resistant hoses.
• NSF/ANSI 61 - Covers food grade potable water system hoses.
• UL 94 - Flame resistance certification for hoses.

Reputable thermopol hose brands will have their products certified to the relevant standards. This ensures the hoses meet all mandatory dimensional, strength, temperature, flexibility, and durability requirements.

Thermopol Hose Selection Factors

There are several important factors to consider when selecting the right thermopol hose for an application:

Temperature Range

The hose must be rated to safely handle the highest and lowest temperatures the media can reach. Otherwise, melting, softening, embrittlement or explosive failure can occur.

Pressure Rating

The hose pressure rating should be 20-30% higher than the maximum system pressure to create a safety margin. Reinforced thermopol hoses are available for pressures up to 5000 PSI.

Media Compatibility

Chemical compatibility charts are used to ensure the hose materials can handle the specific media without degrading. Look for excellent fluid impermeability.

Bend Radius

The minimum bend radius indicates how tightly the hose can be bent without kinking. Oversized bend radii add flexibility for routing.

Abrasion Resistance

Look for hoses with covers that resist abrasion and ozone for long service life. Consider nylon or Hytrel covers in highly abrasive conditions.

Couplings

Proper couplings that match the hose size, materials, pressure rating, and connection type are vital for leak-free performance.

Standards Compliance

Using hoses certified to recognized standards like SAE, EN, or ISO ensures quality materials and construction. Food, potable water, and flammable service may need specialized standards.

Maintaining and Caring for Thermopol Hoses

To get the maximum service life out of thermopol hoses, proper maintenance and care is required:

• Avoid twisting, crushing, or excessive bending beyond minimum bend radius.
• Use quality couplings and proper installation procedures to prevent leakage.
• Inspect regularly for cracks, bulges, kinks, cuts, abrasions or leaks and replace compromised hoses.
• Keep exterior clean and free of grease, oil, chemicals to prevent degradation.
• Replace safety restraints, guards, and shields if damaged.
• Store unused hoses properly away from heat, moisture, ozone, rodents.
• Never repair or use damaged hoses. Replace with new assembly.
• Follow manufacturer guidelines for maximum pressure, temperature and shelf life.

With proper care, industrial thermopol hoses can easily achieve service lifetimes of 5 years or longer. Their lightweight flexibility, combined with rugged durability, will continue making thermopol the hose material of choice for tough applications.

FAQs

What is the maximum temperature thermopol hoses can handle?

The maximum temperature capacity depends on the specific thermoplastic material used. Typical maximum temperatures range from 130°C to 200°C. Specialty high-temp hoses are rated for up to 250°C.

Can I use thermopol hoses for food applications?

Yes, food grade thermopol hoses meeting FDA and NSF standards are available. They are used for applications like food processing, beverage dispensing, and tap water supply.

How long can thermopol hoses last with proper care?

With regular inspection and proper maintenance as per manufacturer guidelines, industrial thermopol hoses can provide a reliable service life of 5-8 years.

Are thermopol hoses suitable for compressed air lines?

Yes, reinforced thermopol hoses handle compressed air very well. Their flexibility prevents kinking under repeated movement and bending in workshop air line applications.

Can I repair a leaking or damaged thermopol hose?

It is not recommended to repair thermopol hoses. For safety it is best to replace the entire hose assembly. Splicing or mending can compromise the integrity and lead to failures.