Multi-Layer Fluid Conduit With Resin-Crosslinked Barrier
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Solution Overview
Problem
Existing fluid lines for vehicles, particularly charge air lines, face challenges in withstanding high temperatures and maintaining chemical and mechanical resistance against corrosive fluids like acid-containing condensates and engine oil, leading to potential damage and compromised performance.
Innovation Solution
A fluid line design featuring an outer layer of ethylene-propylene-diene rubber (EPDM) with a reinforcement layer and an intermediate layer of resin-crosslinked ethylene-propylene-diene rubber or ethylene-vinyl acetate copolymer, along with a barrier layer made of amine or peroxide crosslinked acrylate rubber, which reduces fluid diffusion and enhances temperature resistance, mechanical stability, and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer rubber hose is used, then the structure is simple and easy to manufacture, but the chemical resistance to corrosive fluids and temperature resistance are insufficient
Solution Approach 1:
The patent applies composite materials by constructing a multi-layer hose structure where each layer serves a specific function: the inner layer provides chemical resistance to corrosive fluids, the reinforcement layer provides mechanical strength and temperature resistance, and the outer layer provides protection and flexibility. This composite structure resolves the contradiction by achieving superior chemical and temperature resistance through material composition rather than relying on a single material to perform all functions.
Solution Approach 2:
The patent segments the hose into distinct functional layers: an inner layer for chemical resistance, a reinforcement layer for mechanical strength and temperature stability, and an outer layer for protection. This segmentation allows each layer to be optimized for its specific function, achieving overall reliability without requiring every layer to perform all functions, thus managing complexity through functional specialization.
2Strength
If the hose wall thickness is increased to improve mechanical strength and temperature resistance, then the structural stability improves, but the fluid flow capacity decreases
Solution Approach 1:
The composite structure allows the hose to achieve high mechanical strength and temperature resistance through the reinforcement layer without requiring excessive wall thickness. The reinforcement layer's high strength-to-weight ratio enables thinner walls compared to a homogeneous structure, thereby preserving fluid flow capacity while maintaining structural integrity.
Solution Approach 2:
The reinforcement layer is strategically positioned to provide localized mechanical strength and temperature resistance exactly where needed, rather than uniformly thickening the entire hose wall. This local quality approach maintains optimal fluid flow capacity in the conduit while providing enhanced protection at critical locations.
3Reliability
If a multi-layer composite structure is used to achieve high chemical and temperature resistance, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the hose into standardized functional layers (inner layer, reinforcement layer, outer layer), the patent enables specialized manufacturing processes for each layer that can be efficiently integrated. The segmentation allows for modular production where each layer can be manufactured and quality-checked independently before assembly, managing manufacturing complexity through standardization and modularity.
4Duration of action of stationary object
If the hose is designed with high chemical resistance to corrosive fluids, then the durability improves, but the flexibility and ease of installation decrease
Solution Approach 1:
The outer layer is specifically designed as a rubber material that combines chemical inertness with excellent flexibility and elasticity. This allows the hose to maintain its durability against corrosive fluids while preserving the flexibility needed for easy installation and operation in various configurations, resolving the contradiction through careful material selection in the outer layer.
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 fluid line achieves effective chemical and mechanical resistance, ensuring reliable fluid conduction at high temperatures and pressures, even in the presence of corrosive substances, while maintaining structural integrity and durability.
Implementation Method 1
the barrier layer is designed to reduce diffusion of the fluid through the barrier layer
Implementation Method 2
the barrier layer comprises an amine- or peroxide-crosslinked acrylate rubber (AEM) and/or an amine- or peroxide-crosslinked polyacrylate rubber (ACM)... has a particularly advantageous diffusion-inhibiting effect against a variety of different fluids
Implementation Method 3
a reinforcement arranged within the outer layer... has effective mechanical resistance to external influences
Implementation Method 4
an intermediate layer comprising a resin-crosslinked ethylene-propylene-diene rubber (EPDM) and/or a resin-crosslinked ethylene-vinyl acetate copolymer (EVM)... can effectively withstand high temperatures
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a fluid line (100) for conveying a fluid, comprising an outer layer (101) comprising an ethylene propylene diene monomer (EPDM) rubber, a reinforcing layer (103) arranged within the outer layer (101), an intermediate layer (105) comprising a resin-crosslinked ethylene propylene diene monomer (EPDM) rubber and/or a resin-crosslinked ethylene vinyl acetate copolymer (EVM), arranged within the reinforcing layer (103), and a barrier layer (107) arranged within the intermediate layer (105) and which delimits a conduit interior (109) of the fluid line (100) for conveying the fluid, wherein the barrier layer (107) is designed to reduce diffusion of the fluid through the barrier layer (107).