Multilayer Tube Structure for Pressure Resistance and Recyclability

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Solution Overview

Problem

Existing tubes used in vehicles, particularly electric vehicles, face challenges in providing mechanical strength while being cost-effective and recyclable, as they often require additional reinforcing materials like metal meshes, increasing manufacturing complexity and cost.

Innovation Solution

A multilayer tube design featuring a polyolefin blend with different melt flow indices and a thermoplastic vulcanizate layer, eliminating the need for additional reinforcing materials, enhancing pressure resistance and flexibility, and allowing for recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional tube materials (e.g., polyamide) are used to provide mechanical strength, then the tube can withstand increased pressures, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent uses a composite material structure consisting of an inner layer made from polyolefin blend and an outer layer made from thermoplastic vulcanizate. This composite structure provides the necessary mechanical strength and pressure resistance without requiring additional reinforcing materials like metal meshes, thereby reducing manufacturing complexity while maintaining structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by selecting specific polyolefin blends with controlled melt flow indices and thermoplastic vulcanizates with appropriate elastomer content. By optimizing these material parameters, the tube achieves sufficient mechanical strength and pressure resistance through material selection alone, eliminating the need for complex reinforcing structures

Inventive Principle:

Principle #35Parameter changes

2Strength

If additional reinforcing materials like metal meshes are used, then the tube can withstand increased pressures, but the cost and manufacturing complexity increase

Engineering Contradiction:

Improvepressure resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces expensive metal mesh reinforcements with a cost-effective composite structure using polyolefin blend and thermoplastic vulcanizate. This composite material system provides equivalent or superior pressure resistance at lower cost and with simpler manufacturing processes, as it can be produced through standard extrusion and molding techniques without additional reinforcement steps

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs inexpensive thermoplastic materials that can be easily manufactured and processed. The thermoplastic vulcanizate outer layer provides the necessary strength and flexibility at low cost, replacing expensive metal reinforcements while maintaining manufacturability through conventional plastic processing methods

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If polyamide materials are used to provide strength, then the tube can withstand increased pressures, but the manufacturing complexity increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes from polyamide materials to polyolefin blend and thermoplastic vulcanizate materials with optimized parameters. The polyolefin blend with controlled melt flow index and the thermoplastic vulcanizate with appropriate elastomer content provide the necessary mechanical strength while being easier to manufacture using standard plastic processing techniques, eliminating the manufacturing complexity associated with polyamide processing

Inventive Principle:

Principle #35Parameter changes

4Strength

If metal meshes are used for reinforcement, then the tube can withstand increased pressures, but recyclability is compromised

Engineering Contradiction:

Improvepressure resistanceVSAvoidrecyclability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent creates a fully recyclable composite structure using polyolefin blend and thermoplastic vulcanizate layers. Both materials are thermoplastics that can be melted and reprocessed, enabling the entire tube to be recycled without the contamination issues that arise from metal mesh reinforcements. This composite structure maintains pressure resistance while achieving full recyclability

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250257821A1Multilayer Tube

Publication Date: 2025.08.14 CELANESE INTERNATIONAL CORP

AI summary

A multilayer tube for transporting fluid is disclosed. The multilayer tube includes a first layer including a polyolefin blend including a first polypropylene and a second polypropylene. The first polypropylene and second polypropylene copolymer have different and non-overlapping melt flow indices. The multilayer tube includes a second layer including a thermoplastic vulcanizate including a thermoplastic resin and an at least partially cured elastomer.