Fiber Composite Coolant Pipe With Media-Resistant Inner Hose
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Solution Overview
Problem
Conventional coolant pipes in fuel cell cooling circuits, typically made of metal, face challenges in media resistance and permeability, requiring materials that are resistant to specific mediums while maintaining structural integrity and cost-effectiveness.
Innovation Solution
A method involving a thermoformable fiber composite material with an integrated thermoplastic hose body, which is media-resistant and enhances the pipe's permeability, allowing for the creation of lightweight, cost-effective, and media-resistant coolant pipes by combining a thermoset base body with a thermoplastic functional layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal materials (stainless steel) are used for coolant pipes, then media resistance and structural integrity are improved, but weight and cost increase
Solution Approach 1:
The patent applies composite materials by combining a fiber-reinforced plastic base body (providing structural integrity and low weight) with a thermoplastic functional layer (providing media resistance). This composite structure achieves the reliability of metal pipes while significantly reducing weight, as the fiber-reinforced plastic provides mechanical strength and the thermoplastic layer protects against coolant penetration and ion diffusion.
2Strength
If metal materials (stainless steel) are used for coolant pipes, then structural integrity is improved, but cost increases
Solution Approach 1:
The composite structure uses fiber-reinforced plastic for the base body which is both strong and cost-effective compared to metal. The thermoplastic functional layer is applied through efficient coating processes. This combination achieves comparable structural integrity to metal pipes while reducing material costs and manufacturing complexity.
Solution Approach 2:
The patent changes the material parameters from metal to fiber-reinforced plastic composite, altering the strength-to-cost ratio favorably. The fiber reinforcement provides adequate structural strength for coolant pipe applications at lower cost than stainless steel, while the thermoplastic layer maintains media resistance properties.
3Weight of moving object
If fiber composite material is used for pipe walls, then weight and cost are reduced, but media resistance deteriorates due to permeability
Solution Approach 1:
The patent resolves this contradiction by creating a composite structure where the fiber-reinforced plastic base body provides lightweight structural support, while the thermoplastic functional layer provides the necessary media resistance. The thermoplastic layer acts as a barrier that prevents coolant penetration and ion diffusion, compensating for the inherent permeability of the fiber composite material while maintaining the weight advantages.
Solution Approach 2:
The patent applies local quality by giving different parts of the pipe wall different functions: the base body provides structural strength and lightweight properties, while the functional layer specifically addresses media resistance at the inner surface where coolant contact occurs. This functional differentiation allows each layer to optimize its specific property without compromise.
4Ease of manufacture
If conventional fiber composite material is used, then manufacturing simplicity is improved, but electrical conductivity increases due to ion diffusion from medium permeability
Solution Approach 1:
The composite structure with thermoplastic functional layer prevents ion diffusion from the coolant to the fiber composite base body. The thermoplastic layer acts as a diffusion barrier that blocks ions, preventing the increase in electrical conductivity that would otherwise occur. This maintains manufacturing simplicity while eliminating the harmful electrical conductivity effect.
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 method ensures improved media resistance and tightness of the pipes, allowing for the use of less expensive materials compared to metal pipes, while maintaining structural integrity and reducing the risk of electrical conductivity increases from ion diffusion.
Implementation Method 1
The tube body is then internally pressurized and expanded until it presses against the inner wall of the base body
Implementation Method 2
The matrix component of the fiber composite material is used primarily for this purpose: The hose body and base body are thus consolidated to form the pipe or pipe wall
Data Source
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AI summary
In a method for manufacturing a pipe (2) with a fiber composite material (8), wherein the pipe (2) receives a specific medium (14) during operation, the fiber composite material (8) is arranged as a base body (24) in a molding tool (18) and a medium-resistant hose body (16) is placed in the base body (24), and both are subjected to thermoforming, wherein the hose body (16) is pressurized and pressed against the base body (24) and the base body against the molding tool (18) to consolidate the base body (24) and hose body (16) into the pipe (2), wherein the material of the hose body (16) is such that it is not attacked by this medium (14) at least for a planned service life, wherein the fiber composite material (8) is selected such that it is not medium-resistant to the medium (14) in the above sense at least in one manufacturing state (F).In a pipe (2), the base body (24) is consolidated together with the hose body (16) to form the pipe (2).