Foamed Thermoplastic Elastomer Tube for Stable Thermal Insulation
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Solution Overview
Problem
Existing fluid transport tubes face challenges in achieving consistent thermal insulation and manufacturing stability due to difficulties in simultaneously balancing vulcanization and foam molding processes, leading to insufficient strength or inadequate foaming.
Innovation Solution
A fluid transport tube design comprising multiple layers, where the outer layer is made of thermoplastic elastomer foam with a foaming factor of 2 to 5.5 times, and the inner layer is made of thermoplastic elastomer or resin, with optional reinforcement, ensuring close adherence and controlled bonding to enhance thermal insulation and manufacturing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If priority is given to foam molding of the rubber, then the foaming properties are improved, but vulcanization molding becomes insufficient and strength decreases
Solution Approach 1:
The patent divides the manufacturing process into two separate sequential steps: first performing foam molding to create the insulating layer with proper cellular structure, then performing vulcanization molding in a second step to achieve adequate cross-linking and strength. This segmentation allows each process to be optimized independently without compromising the other, resolving the contradiction between foaming quality and vulcanization strength.
2Strength
If priority is given to vulcanization molding, then the strength is improved, but the foaming agent may not foam sufficiently or the foaming gas may escape, resulting in low foaming
Solution Approach 1:
The patent performs foam molding as a preliminary action before vulcanization molding. The foaming agent is allowed to expand and form the cellular structure first, creating the insulating layer's shape and porosity. Only after this preliminary foaming action is complete does the vulcanization process begin, ensuring that the foam structure is already established and will not be compromised by subsequent heating and pressure conditions.
3Productivity
If simultaneous vulcanization and foam molding are attempted, then manufacturing efficiency is improved, but manufacturing consistency deteriorates due to inability to match both process conditions
Solution Approach 1:
The patent segments the manufacturing process into distinct sequential stages (foam molding first, then vulcanization molding) rather than attempting simultaneous processing. This segmentation may slightly increase total process time compared to simultaneous operation, but it ensures that each process condition can be independently optimized and controlled, thereby achieving consistent manufacturing quality and eliminating the variability that would result from trying to balance conflicting process requirements simultaneously.
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 design reduces thermal conductivity variations and improves manufacturing stability by optimizing the foaming factor, resulting in higher thermal insulation and reduced cracking, while maintaining structural integrity.
Implementation Method 1
the outer layer is made of a thermoplastic elastomer foam... reduce the thermal conductivity of the outer layer and reduce the variations in thermal conductivity
Data Source
AI summary
There is provided a fluid transport tube in which plurality of layers are laminated on one another. The plurality of layers include an outer layer composed of a thermoplastic elastomer foam. The plurality of layers also include an inner layer composed of thermoplastic elastomer or thermoplastic resin. The outer layer and inner layer closely adhere with each other. Thermoplastic elastomer foam has a foaming factor of 2 times or more to 5.5 times or less. This makes it possible to improve the thermal insulation and manufacturing stability of the fluid transport tube.