Turbo Engine Intake Hose Resin Composition for Heat Resistance

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Solution Overview

Problem

Conventional air intake hoses for turbo engines face issues with heat resistance, weight, and manufacturing costs due to the use of materials like epichlorohydrin rubber and ethylene methyl acrylate, which require antioxidants and have limitations in resistance to certain chemicals and high temperatures.

Innovation Solution

A resin composition combining 20-40% polyamide resin, 10-30% polypropylene resin, 30-50% polyester elastomer, along with additives such as phenol-based or phosphorous-based antioxidants, sulfur-based heat stabilizers, olefin-based lubricants, and master batches, to create a material with improved heat resistance, elongation, and mechanical rigidity while reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If epichlorohydrin rubber is used as the polymer material for intake hoses, then oxygen resistance and ozone resistance are improved due to high saturation degree of polymer chains, but the material requires addition of antioxidant for stabilizing vulcanizates when exposed to high temperature and has limited resistance to aromatic chlorinated hydrocarbons, alcohols, ketones, and esters

Engineering Contradiction:

Improveoxygen resistance and ozone resistanceVSAvoidvulnerability to aromatic chlorinated hydrocarbons, alcohols, ketones, and esters

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite material system consisting of epichlorohydrin rubber combined with polypropylene resin and specific antioxidants. This composite approach allows the material to maintain the oxygen and ozone resistance of epichlorohydrin rubber while the polypropylene and antioxidant components provide resistance to aromatic chlorinated hydrocarbons, alcohols, ketones, and esters, thereby resolving the vulnerability issue.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces antioxidant compounds as intermediary substances that mediate between the epichlorohydrin rubber and harmful environmental factors. These antioxidants act as protective intermediaries that stabilize the vulcanizate at high temperatures and provide chemical resistance to aromatic chlorinated hydrocarbons, alcohols, ketones, and esters without compromising the base material's oxygen and ozone resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If ethylene methyl acrylate (EMA) is used as the material for intake hoses, then certain mechanical properties are achieved, but weight reduction becomes difficult due to high weight and specific gravity

Engineering Contradiction:

Improvemechanical propertiesVSAvoidweight of intake hose

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material composition parameters by replacing EMA with a combination of epichlorohydrin rubber, polypropylene resin, and antioxidants. This parameter change results in a material with lower specific gravity and weight while maintaining or improving mechanical properties, thereby achieving weight reduction without sacrificing strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system where epichlorohydrin rubber provides the base mechanical properties and chemical resistance, while polypropylene resin contributes to weight reduction due to its lower density. The synergistic combination of these materials achieves both mechanical integrity and weight reduction, resolving the contradiction between strength and weight.

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional materials are used for intake hoses, then basic functionality is provided, but manufacturing costs remain high

Engineering Contradiction:

Improvebasic functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent adopts a cost-effective material formulation using epichlorohydrin rubber combined with polypropylene resin and antioxidants, which provides the necessary functionality at lower material costs compared to conventional EMA-based materials. This approach achieves basic functionality with reduced manufacturing costs by selecting more economical raw materials that maintain performance requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent optimizes the material composition parameters to achieve cost efficiency. By adjusting the formulation to use epichlorohydrin rubber with polypropylene resin and antioxidants in specific proportions, the patent reduces material costs while maintaining functionality, thereby resolving the contradiction between reliability and manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10428215B2Resin compositions for intake hoses of turbo engines with enhanced thermal resistance

Publication Date: 2019.10.01 HYUNDAI MOTOR CO LTD

AI summary

A resin composition for intake hoses is provided. The resin composition includes a predetermined amount of polyester elastomer incorporated into a polyamide resin and a polypropylene resin and further includes an antioxidant, a heat stabilizer, a lubricant and a master batch if necessary, thereby exhibiting excellent durability, heat resistance, elongation, mechanical rigidity, pressure resistance and cold resistance, and reducing weight and production costs.