Thermoplastic vs Rubber Hydraulic Hoses

[MikePhua]

When it comes to hydraulic systems, selecting the appropriate hydraulic hose is critical for the longevity, efficiency, and safety of the machinery. Among the options available, thermoplastic and rubber hydraulic hoses are the two most commonly used materials. Both materials have their unique characteristics, advantages, and limitations. Understanding the differences between these two types of hoses can help operators and maintenance teams choose the right one for their specific needs.
What Are Hydraulic Hoses?
Hydraulic hoses are designed to carry high-pressure fluid in hydraulic systems. They are commonly found in construction equipment, agricultural machinery, aircraft, and other heavy-duty industrial machines. These hoses are responsible for transmitting energy from one point of the system to another, facilitating the movement of mechanical parts.
The hydraulic fluid, typically oil, is forced through the hoses, creating the pressure required to power various functions like lifting, steering, and rotating. A hydraulic hose must be durable, flexible, and resistant to high pressures, heat, and wear.
Thermoplastic Hydraulic Hoses
Thermoplastic hydraulic hoses are made from synthetic polymers that become soft and pliable when heated and harden as they cool. This unique property makes them ideal for a range of applications where flexibility, light weight, and resistance to abrasion are necessary.
Advantages of Thermoplastic Hoses

1. Lightweight Construction: Thermoplastic hoses are significantly lighter than rubber hoses, making them easier to handle and install. This is particularly beneficial in applications where the equipment needs to be mobile, such as in aerial lifts and mobile cranes.
   
2. Higher Pressure Rating: Thermoplastic hoses typically offer higher pressure ratings compared to rubber hoses of similar size. This makes them a good choice for high-performance hydraulic systems that require intense pressure.
   
3. Resistant to Abrasion: Thermoplastic hoses are more resistant to abrasion than rubber hoses, which makes them ideal for use in rugged environments where hoses are exposed to sharp edges, rocks, and debris.
   
4. Chemical Resistance: Thermoplastic hoses often have better resistance to chemicals, oils, and fuels, making them ideal for systems exposed to harsh working environments or corrosive substances.
   
5. Cost-Effective: While the initial cost of thermoplastic hoses may be higher in some cases, their longevity and resistance to wear can save money in the long term, especially in heavy-duty applications.
   
6. Excellent Flexibility: Thermoplastic hoses remain flexible even in cold conditions, making them an excellent choice for operations in freezing temperatures or cold climates.
   

Disadvantages of Thermoplastic Hoses

1. Less Resistant to Heat: One of the main limitations of thermoplastic hoses is their reduced resistance to high temperatures. They can soften or degrade when exposed to excessive heat, limiting their performance in high-temperature environments.
   
2. Limited Durability in Harsh Weather: In extreme weather conditions, such as prolonged exposure to ultraviolet (UV) rays or extreme cold, thermoplastic hoses may degrade more quickly compared to rubber hoses.
   
3. Less Impact Resistance: While they are resistant to abrasion, thermoplastic hoses tend to be more brittle and less impact-resistant than rubber hoses. This means they may crack or fracture under sudden force or rough handling.
   

Rubber Hydraulic Hoses
Rubber hydraulic hoses, made from natural or synthetic rubber compounds, are one of the oldest and most commonly used types of hydraulic hoses. Rubber hoses are known for their excellent flexibility, durability, and ability to withstand high temperatures.
Advantages of Rubber Hoses

1. High Temperature Resistance: Rubber hoses can perform well in environments with high temperatures, especially those that exceed the limits of thermoplastic hoses. They can maintain their strength and flexibility under intense heat, making them suitable for heavy-duty industrial machinery operating in hot conditions.
   
2. Better Durability Under Impact: Rubber hoses are more resistant to impact than thermoplastic hoses. They are better equipped to handle shock loads, rough handling, or accidental drops during operation.
   
3. Excellent Flexibility: Rubber hoses are highly flexible, which makes them easy to install and maneuver, especially in tight spaces.
   
4. Long Track Record: Rubber hoses have been in use for decades and have a proven track record in a wide variety of applications, from construction equipment to mining vehicles.
   
5. Resistance to Aging: Rubber hoses are resistant to the effects of aging and ozone degradation, which can be a significant concern in certain applications that require long-term reliability.
   

Disadvantages of Rubber Hoses

1. Heavier Than Thermoplastic Hoses: Rubber hoses are heavier than thermoplastic hoses, which can make installation and handling more difficult. In applications where weight is a concern, this could be a disadvantage.
   
2. Prone to Abrasion: While rubber hoses are durable, they are not as resistant to abrasion as thermoplastic hoses. In applications where hoses are exposed to sharp edges, gravel, or rough surfaces, rubber hoses may wear out more quickly.
   
3. Chemical Sensitivity: Rubber hoses are generally more sensitive to certain chemicals and oils compared to thermoplastic hoses. In highly corrosive environments, rubber hoses may degrade faster, requiring more frequent replacements.
   
4. More Expensive to Repair: If a rubber hose gets damaged, it can be more expensive and time-consuming to repair compared to thermoplastic hoses. The repair process may involve replacing the entire hose rather than just a section of it.
   

Which Hose is Better for Your Application?
The choice between thermoplastic and rubber hydraulic hoses depends on the specific demands of your machinery and environment. Here’s a breakdown of when each type may be the better choice:
When to Choose Thermoplastic Hoses

• High-pressure systems: If your system requires hoses that can handle high pressure, thermoplastic hoses are often the better choice.
  
• Lightweight machinery: For applications that require lightweight hoses, such as aerial lifts or cranes, thermoplastic hoses are ideal due to their reduced weight.
  
• Chemical or abrasion resistance: If your hydraulic system is exposed to harsh chemicals or rough working conditions, thermoplastic hoses will offer better protection.
  
• Cold environments: In colder climates where flexibility is crucial, thermoplastic hoses will remain flexible and functional.
  

When to Choose Rubber Hoses

• High-temperature environments: If your machinery operates in environments with elevated temperatures, rubber hoses will provide superior resistance.
  
• Heavy-duty or rugged applications: For equipment that requires durability under shock loads, rough handling, or impact, rubber hoses are a good option.
  
• Long-term, reliable operation: In applications where the longevity of the hose is paramount, rubber hoses offer a well-established track record.
  

Conclusion
Both thermoplastic and rubber hydraulic hoses offer unique benefits depending on the specific requirements of your hydraulic system. Thermoplastic hoses are known for their high-pressure ratings, lightweight nature, and chemical resistance, making them an excellent choice for applications where flexibility, cost-effectiveness, and resistance to wear are crucial. Rubber hoses, on the other hand, provide superior impact resistance, high-temperature performance, and long-term reliability in a wide variety of industrial settings.
By evaluating the environmental factors, pressure requirements, and the type of machinery you’re using, you can make an informed decision about which hydraulic hose material is best for your application. Regular maintenance, including inspecting and replacing hoses as needed, will help ensure optimal performance and extend the lifespan of your hydraulic system.