Fiber-Reinforced Hose Composite With Void-Filling Resin Binder
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Solution Overview
Problem
Current hose assembly manufacturing processes are slow, capital-intensive, and prone to quality issues such as inhomogeneous mixtures and burst strength inconsistencies, particularly when dealing with thermoset rubber hose assemblies used for transferring pressurized fluids under extreme conditions.
Innovation Solution
The use of fiber-reinforced composites with low viscosity and low molecular weight resin-binders, such as metallocene polyethylene or polypropylene polymers, to fill voids and improve compatibility between reinforcement fibers and polymeric matrices, allowing for continuous extrusion and cross-linking without a mandrel, thereby enhancing mechanical properties and reducing processing artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional thermoset rubber hose assembly manufacturing processes are used, then the hose assemblies can withstand extreme pressures and temperatures, but the manufacturing process is slow, capital-intensive, and produces inhomogeneous mixtures with burst strength inconsistencies
Solution Approach 1:
The patent changes the material parameters by using thermoplastic polymers instead of traditional thermoset rubbers, and employs resin-binders with controlled low molecular weight and low viscosity. This parameter change enables continuous extrusion processing at high speeds while maintaining homogeneous mixing and consistent burst strength through the use of melt-processable materials that eliminate the need for batch processing and autoclaving.
Solution Approach 2:
The patent creates a composite material system consisting of reinforcement fibers (such as glass, carbon, or aramid) combined with thermoplastic polymers and resin-binders. This composite structure allows for continuous manufacturing while maintaining mechanical properties, as the fiber reinforcement provides structural integrity and the thermoplastic matrix enables continuous processing without the defects associated with traditional thermoset processing.
2Manufacturing precision
If low molecular weight and low viscosity resin-binders are used, then voids and interstices are reduced improving material compatibility, but the flex modulus may increase unless carefully controlled
Solution Approach 1:
The patent applies local quality by using resin-binders with specific low molecular weight and low viscosity characteristics in targeted applications where void reduction is critical, while carefully selecting the molecular weight range to avoid excessive increases in flexural modulus. The resin-binder properties are locally optimized for the specific reinforcement fiber type and application requirements, balancing void reduction with flexibility maintenance.
Solution Approach 2:
The patent carefully controls the molecular weight and viscosity parameters of the resin-binders to achieve the desired balance between void reduction and flexural modulus maintenance. By selecting resin-binders within specific molecular weight ranges and adjusting their viscosity characteristics, the patent optimizes the balance between filling voids effectively and maintaining the required flexibility of the final composite material.
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
This approach results in hose assemblies with improved tensile strength and flexural modulus, reduced failure modes, and a more efficient, cost-effective manufacturing process capable of withstanding extreme pressures and environmental conditions.
Implementation Method 1
the one or more resin-binders, having sufficiently low molecular weight and viscosity, can fill or otherwise reduce interstices, voids, air bubbles, or flaws within the reinforcement fiber
Implementation Method 2
thereby reducing interfacial surface tension and providing greater compatibility between the materials
Data Source
AI summary
A fiber-reinforced composite material having at least one reinforcement layer having one or more woven mats, unwoven mats, or bundle of fibers comprising a plurality of reinforcement fibers that has a binder-resin filling at least a portion of the voids of the reinforcement fibers. In some aspects, the binder-resin adheres to the reinforcement fibers and displaces the air voids at the interface between the reinforcement fibers and the binder-resin. The binder-resin has a relatively low viscosity less than at least about 20,000 centipoise at 176° C. and low molecular weight, which allows the reinforcement layer to maintain a low flex modulus while maintaining or increasing tensile modulus. The fiber-reinforced composite material can be utilized in various articles, such as a flexible fiber reinforced hose adapted for conveying fluids under pressure having at least one polymer layer that bonds to the binder-resin of the reinforcement layer, preferably being cross-linkable or cross-linked to the polymer layer.