ACM Air Intake Pipe Sulfur Crosslinking PET Reinforcement
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Solution Overview
Problem
Existing air intake pipes for turbocharged motor vehicle engines face high manufacturing costs due to complex and expensive crosslinking systems, particularly when using ACM or AEM elastomers with carboxyl sites, which also suffer from aminolysis issues when in contact with PET reinforcement.
Innovation Solution
A pipe design featuring internal and external ACM elastomeric layers crosslinked by a soap-sulfur system or a thiadiazole-based system, eliminating the need for amine crosslinking agents and incorporating a PET-based reinforcing structure, which provides thermal and mechanical resistance without increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ACM or AEM elastomers with carboxyl sites are used and crosslinked with amine, then thermal resistance to high temperatures is improved, but manufacturing cost increases and aminolysis deterioration occurs when in contact with PET reinforcement
Solution Approach 1:
The patent changes the crosslinking chemistry parameter from amine-based to sulfur-based crosslinking. This parameter change maintains the thermal resistance performance while eliminating the harmful aminolysis reaction with PET and reducing manufacturing costs by using more common materials and processes.
Solution Approach 2:
The patent replaces expensive amine crosslinking systems with cheaper sulfur-based crosslinking systems. Sulfur is a more common and less expensive material, and the crosslinking process is simpler and more widely available in standard rubber processing facilities.
2Temperature
If ACM or AEM elastomers with carboxyl sites are used and crosslinked with amine, then thermal resistance to high temperatures is improved, but manufacturing cost increases
Solution Approach 1:
The patent simplifies the crosslinking system by changing from a complex amine-based chemistry to a simpler sulfur-based vulcanization system. This reduces the number of components needed and simplifies the processing conditions while maintaining thermal performance.
3Temperature
If amine crosslinking agents are used in ACM or AEM elastomers, then thermal resistance is improved, but mechanical resistance deteriorates due to aminolysis of PET reinforcement
Solution Approach 1:
The patent converts the potential harm of chemical reactions at the elastomer-reinforcement interface into a benefit by using sulfur crosslinking instead of amine crosslinking. Sulfur does not cause aminolysis of PET, thereby preserving the mechanical strength of the reinforcement structure while maintaining thermal resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The pipe effectively withstands high internal and external temperatures (up to 200°C and 150°C respectively) while maintaining mechanical resistance and fatigue durability, reducing manufacturing costs through the use of widely available crosslinking ingredients and avoiding aminolysis-related deterioration.
Implementation Method 1
each of the intermediate and outer layers being made up of a composition specifically based on at least one ACM which is crosslinked by a system chosen from the group consisting of those based on at least one soap associated with sulfur
Implementation Method 2
a reinforcing structure located radially between the intermediate and external layers and comprising threads based on an aliphatic polyester such as a PET
Data Source
Figure 1
AI summary
The pipe (1) comprises an internal elastomer layer (10), an external elastomer layer (16), an intermediate elastomer layer (12) intended to facilitate an adhesion between the internal and external elastomer layers, and a reinforcement structure (14), which is radially disposed between the intermediate elastomer layer and the external elastomer layer. The reinforcement structure comprises a knitted or plaited multifilament fabric made of a polyethylene teraphtalate material. An independent claim is included for an air intake system of an automobile motor vehicle.