Peroxide-Crosslinked Fuel Cell Hose With Low Additive Extraction
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Solution Overview
Problem
Cooling water hoses for fuel cell applications face challenges with resistance to media components, such as ethylene glycol and corrosion inhibitors, and require improved temperature and pressure resistance, while also minimizing extraction of additives that can harm fuel cell units.
Innovation Solution
The hose features a peroxide-crosslinked rubber mixture for both the inner and outer layers, with reduced amounts of plasticizers, adhesives, and other additives, and an optional reinforcement layer made from textile materials, ensuring resistance to hot air, UV radiation, and ozone, and minimizing extraction of harmful substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rubber mixtures with high additive content are used, then processing properties and manufacturing ease are improved, but extraction of harmful substances increases which harms fuel cell units
Solution Approach 1:
The patent changes the concentration parameters of additives in the rubber mixture by specifying reduced amounts: plasticizers ≤3 phr, adhesives ≤3 phr, and metal oxides ≤3 phr. This parameter optimization maintains sufficient processing properties while minimizing extraction of harmful substances that could damage fuel cell units.
Solution Approach 2:
The patent uses composite rubber mixtures combining EPM or EPDM base polymers with minimized additive packages. The specific composite formulation achieves the right balance between manufacturability and low extraction, creating a material that is both processable and safe for fuel cell applications.
2Temperature
If peroxide-crosslinked rubber mixtures are used for temperature resistance, then resistance to hot air and UV radiation is improved, but resistance to coolant mixtures with corrosion inhibitors may be compromised
Solution Approach 1:
The patent applies different rubber compositions to different layers: the inner layer uses EPM or EPDM optimized for coolant resistance, while the outer layer uses peroxide-crosslinked rubber optimized for temperature and UV resistance. This local differentiation allows each layer to excel at its specific function without compromising the other.
Solution Approach 2:
The patent creates a composite hose structure with multiple layers having different rubber compositions. The inner layer provides chemical resistance to coolant mixtures, while the outer layer provides thermal and UV resistance, achieving both requirements simultaneously through material composition.
3Strength
If reinforcement layers are added for pressure resistance, then strength and pressure resistance are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent uses a textile reinforcement layer embedded within the rubber matrix to provide pressure resistance. This flexible reinforcement approach maintains the hose's flexibility while significantly improving its strength and pressure resistance capabilities without excessive complexity.
4Object-generated harmful factors
If plasticizers and adhesives are reduced to minimize extraction, then harmful substance extraction is decreased, but manufacturing precision and layer bonding may be affected
Solution Approach 1:
The patent optimizes the concentration parameters of plasticizers and adhesives to specific ranges (≤3 phr each) that maintain sufficient layer bonding and manufacturing precision while minimizing the total amount of extractable additives. This precise parameter control ensures both low extraction and adequate bonding quality.
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 hose provides enhanced resistance to coolant mixtures and fuels, maintains low extraction of harmful substances, and meets DIN 73411 B requirements, making it suitable for fuel cell applications with improved durability and reduced contamination risks.
Implementation Method 1
The inner layer and outer layer each consist of a peroxide-crosslinked rubber mixture
Data Source
AI summary
The invention relates to a hose (1) which has at least the following layer construction: - an inner layer (2) of a crosslinked rubber mixture which is in contact with a medium to be transported; and - an outer layer (3) of a likewise crosslinked rubber mixture which protects against external influences. The hose (1) according to the invention is distinguished by the fact that the inner layer (2) and outer layer (3) consist in each case of a peroxidically crosslinked rubber mixture on the basis of blend-free EPM or an EPM blend or of blend-free EPDM or an EPDM blend, wherein the respective rubber mixture contains a filler, wherein, furthermore, at least the rubber mixture of the inner layer is low in, or in particular free of, a plasticizer. The hose (1) is usually additionally provided with a strength support layer (4). Furthermore, the special applications and also method variants for producing a hose (1) of this type are presented.