Bio-Based EPDM Industrial Hose for Pressure-Resistant Sustainability
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Solution Overview
Problem
Current rubber hoses used in various applications rely on petroleum-based materials for reinforcement and production, which are not sustainable, and there is a need for alternatives derived from renewable sources that maintain performance under high pressure and flexibility requirements.
Innovation Solution
The development of hoses with layers formed from sustainable rubber materials such as EPDM/EPR polymers derived from renewable sources, combined with sulfur or peroxide-based curing systems, and reinforcement layers made from sustainable fibers, allowing for up to 95% sustainable content by weight, enhancing durability and environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based materials (EPDM, EPR) are used for hose layers, then the hose achieves sufficient durability and pressure resistance, but the environmental sustainability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber material by replacing petroleum-based ethylene with bio-based ethylene derived from renewable resources such as sugar cane. This substitution maintains the essential properties of EPDM/EPR polymers while eliminating dependence on fossil fuels, thereby resolving the contradiction between reliability and environmental sustainability
Solution Approach 2:
The patent creates a composite material system combining bio-based EPDM/EPR polymers with traditional reinforcing materials (carbon black, silica) and curing agents. This composite approach allows the sustainable polymer matrix to provide environmental benefits while the composite structure maintains the mechanical strength and durability required for high-pressure hose applications
2Object-affected harmful factors
If renewable source materials are used to replace petroleum-based materials, then environmental sustainability improves, but the material performance and processing reliability may deteriorate
Solution Approach 1:
The patent carefully controls and optimizes the compositional parameters of the bio-based polymer compound, including the ratio of bio-ethylene to traditional components, filler content, and curing agent proportions. These parameter adjustments ensure that the renewable materials achieve performance consistency comparable to petroleum-based materials while maintaining sustainability benefits
Solution Approach 2:
The patent implements quality control and testing protocols to monitor the performance of bio-based materials during production. By establishing feedback mechanisms for material property verification (such as tensile strength, elongation, and pressure resistance testing), the patent ensures consistent performance reliability despite using renewable sources with natural variability
3Object-affected harmful factors
If high sustainable content (up to 95% by weight) is achieved in hose composition, then environmental sustainability significantly improves, but the manufacturing complexity and material formulation difficulty increase
Solution Approach 1:
The patent achieves high sustainable content by fundamentally changing the base polymer source to bio-based ethylene, which allows up to 95% or more of the hose weight to come from renewable materials. This parameter change in the fundamental material composition simplifies the path to sustainability compared to adding minor renewable additives to traditional formulations
Solution Approach 2:
The patent uses bio-based EPDM/EPR polymers that are chemically homogeneous and compatible with standard rubber processing techniques and existing hose manufacturing equipment. This chemical homogeneity allows the high sustainable content material to be processed using conventional methods, thereby reducing manufacturing complexity despite the high renewable content
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 hoses exhibit improved durability with burst pressures exceeding 2.76 MPa and tensile strengths of 5 MPa or greater, while significantly reducing the environmental impact by utilizing renewable resources, making them suitable for diverse industrial and automotive applications.
Implementation Method 1
The 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.