Bio-Based EPDM Hose Composition for Pressure and Flexibility
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Solution Overview
Problem
Current rubber hoses used in various applications rely on petroleum-based materials for reinforcement and rubber, which are not sustainable, and there is a need for alternatives that are environmentally friendly while maintaining performance under high pressure and flexibility requirements.
Innovation Solution
The development of hoses with layers formed from sustainable rubber materials and reinforcements, specifically using EPDM/EPR sustainable polymers derived from renewable sources like sugar cane, combined with sulfur or peroxide-based curing systems, and incorporating recovered carbon black and sustainable oils, along with fiber reinforcement layers from sustainable materials, to achieve a high sustainable content weight percentage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based materials (EPDM, EPR) are used for hose layers, then the hose achieves sufficient flexibility and pressure resistance, but the environmental sustainability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber layers by substituting petroleum-based EPDM and EPR with sustainable alternatives including bio-based polymers, recycled rubber compounds, and synthetic rubbers with modified molecular structures. This parameter change maintains the elastomeric properties and curing characteristics while eliminating dependence on fossil fuels, thereby resolving the contradiction between reliability and environmental sustainability
Solution Approach 2:
The patent employs composite material formulations in the rubber layers, combining multiple rubber types (natural rubber, synthetic rubber, recycled rubber) with specific proportions of fillers, curatives, and processing aids. This composite approach allows optimization of mechanical properties, flexibility, and pressure resistance while incorporating sustainable materials, thus maintaining reliability while reducing environmental harm
2Strength
If reinforcement layers are added to ensure pressure resistance, then the hose strength improves, but the hose complexity increases
Solution Approach 1:
The patent applies local quality by providing reinforcement layers only in specific zones where pressure resistance is most critical, rather than uniformly throughout the entire hose. The reinforcement layers are strategically positioned between rubber layers at high-stress areas, allowing the hose to achieve sufficient strength while minimizing the addition of structural complexity in non-critical regions
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 resulting hoses exhibit improved sustainability and performance characteristics, such as increased burst pressure and tensile strength, while reducing environmental impact by utilizing renewable resources.
Implementation Method 1
EPDM polymer is made from ethylene, propylene, and a diene comonomer that enables crosslinking via sulfur vulcanization
Data Source
AI summary
Hoses include an inner tube, a reinforcement layer disposed outwardly from the inner tube, and a cover layer disposed outwardly from the reinforcement layer, where the cover layer and/or the inner tube includes a cured composition having a sustainable content and formed from a mixture including EPDM/EPR sustainable polymer and a sulfur or peroxide based curing system. In some cases, the EPDM/EPR sustainable polymer has ethylene monomer derived from one or more renewable sources, such as, ethylene monomer derived from sugar cane. The mixture may further include one or more of recovered carbon black and sustainable oils from renewable sources. The hose embodiments may also include the reinforcement layer formed of fibers from sustainable material. The hose may contain the sustainable content in an amount of up to 75% by weight based upon total hose weight, or even greater than 25% by weight based upon total hose weight.