Hose Protector Layer Dual-Accelerator Vulcanization

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Solution Overview

Problem

The use of high activation vulcanization accelerators in fuel hoses leads to significant degradation of storage stability due to uncontrolled vulcanization reactions, which can cause scorch and thermal degradation of resin materials.

Innovation Solution

A method for manufacturing a hose with a protector layer that involves dividing the rubber composition into two formulation systems: one with a sulfur-releasing primary accelerator and another with a sulfur non-releasing secondary accelerator, allowing for controlled vulcanization by continuously extruding and vulcanizing the rubber composition onto a polyamide resin layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a high activation vulcanization accelerator (e.g., thiuram vulcanization accelerator) is used to accelerate vulcanization, then vulcanization time is reduced, but storage stability significantly degrades due to uncontrolled vulcanization reactions at room temperature

Engineering Contradiction:

Improvevulcanization speedVSAvoidstorage stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The rubber composition is divided into two separate formulation systems: a first rubber material containing sulfur-releasing primary accelerator (thiuram) and sulfur vulcanization agent, and a second rubber material containing sulfur non-releasing secondary accelerator. This segmentation prevents premature vulcanization while enabling accelerated vulcanization when combined

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a composite rubber composition by mixing two distinct rubber materials with different accelerator systems. The combination of sulfur-releasing primary accelerator and sulfur non-releasing secondary accelerator in specific proportions (0.3-2.0 parts primary, 1.5-4.0 parts secondary per 100 parts rubber) achieves both storage stability and accelerated vulcanization

Inventive Principle:

Principle #40Composite materials

2Productivity

If vulcanization temperature is increased to accelerate vulcanization, then vulcanization speed increases, but resin material undergoes melt and thermal degradation

Engineering Contradiction:

Improvevulcanization speedVSAvoidthermal degradation of resin

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical parameters of the vulcanization system by introducing a dual-accelerator formulation with specific melting points (primary accelerator: 66-105°C, secondary accelerator: 120°C or higher). This allows vulcanization to proceed at lower temperatures that do not degrade the polyamide resin while still achieving accelerated vulcanization kinetics

Inventive Principle:

Principle #35Parameter changes

3Productivity

If continuous extrusion and vulcanization is implemented, then manufacturing time is reduced and productivity increases, but process control becomes more complex

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The rubber composition is prepared in advance with the optimized dual-accelerator formulation before extrusion. The first and second rubber materials are pre-mixed in specific proportions, so that when extruded and exposed to heat, the vulcanization proceeds rapidly and controllably without requiring complex real-time process control

Inventive Principle:

Principle #10Preliminary action

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 achieves excellent storage stability and accelerated vulcanization while preventing thermal degradation, improving workability, reducing manufacturing time, and lowering costs.

Implementation Method 1

a sulfur-releasing primary accelerator

Methodology Applied

Scientific EffectSulfur release:

Implementation Method 2

accelerate vulcanization

Methodology Applied

Scientific EffectVulcanization:

Implementation Method 3

continuously extruded onto the outer periphery of the previously formed polyamide resin layer

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 4

continuously vulcanizing unvulcanized rubber after the rubber composition is continuously extruded

Methodology Applied

Scientific EffectThermal energy transfer: Heating

Data Source

PatentUS8747951B2Method for manufacturing hose with protector layer

Publication Date: 2014.06.10 SUMITOMO RIKO CO LTD

AI summary

A method for manufacturing a hose with a protector layer 2 on the outer periphery of a tubular polyamide resin layer 1 includes steps of: preparing a rubber composition for forming the protector layer by separately preparing a first rubber material containing components (A) to (C) and a second rubber material containing components (a) and (b) but substantially free of a sulfur vulcanization agent and mixing them in a mixer; and forming the protector layer 2 by continuously vulcanizing unvulcanized rubber after continuous extrusion of the rubber composition onto the outer periphery of the previously formed polyamide resin layer 1. (A) Ethylene-propylene rubber(B) Sulfur vulcanization agent(C) Thiuram vulcanization accelerator (mp. 66 to 105° C.)(a) Ethylene-propylene rubber(b) Vulcanization accelerator (mp. 120° C. or higher).