Polyarylene Sulfide Fuel Lines with Crosslinked Impact Modifier
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Solution Overview
Problem
Current automotive fuel line materials, such as aliphatic polyamide and braided polytetrafluoroethylene, face limitations in high heat resistance, permeation, and mechanical durability, leading to delamination and increased costs, while lacking compatibility with elastomeric impact modifiers, which are essential for maintaining performance over the lifetime of the fuel line.
Innovation Solution
A thermoplastic composition comprising a polyarylene sulfide and a crosslinked impact modifier, formed through dynamic vulcanization and melt processing, providing improved strength, flexibility, and chemical resistance, allowing for the creation of fuel lines with enhanced barrier properties and resistance to degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aliphatic polyamide is used for fuel line tubing, then weight is reduced compared to metals, but heat resistance and permeation performance deteriorate at higher temperatures
Solution Approach 1:
The patent uses polyarylene sulfide, a high-performance polymer that combines lightweight properties with superior heat resistance and chemical resistance, eliminating the need for metal heat shields while maintaining structural integrity at elevated temperatures
2Temperature
If braided polytetrafluoroethylene is used for high heat environments, then heat resistance is improved, but construction complexity and cost increase
Solution Approach 1:
The patent employs polyarylene sulfide as a single-layer or multi-layer composite material that inherently provides high heat resistance without requiring complex braided structures, simplifying the overall construction while maintaining performance
Solution Approach 2:
The patent changes the material parameter from traditional fluoropolymers to polyarylene sulfide, which offers comparable or superior heat resistance with simpler processing and construction requirements
3Reliability
If multi-layer constructions are used for fuel lines, then barrier properties are improved, but delamination resistance deteriorates
Solution Approach 1:
The patent uses polyarylene sulfide-based composite materials that provide excellent barrier properties against fuel permeation while maintaining strong inter-layer adhesion, preventing delamination issues associated with traditional multi-layer constructions
Solution Approach 2:
The patent employs compatibilizers or adhesion promoters as intermediary substances between different layers to ensure strong bonding and prevent delamination, allowing multi-layer constructions to maintain both barrier properties and structural stability
4Strength
If elastomeric impact modifiers are added to polyarylene sulfide, then impact resistance is improved, but compatibility deteriorates causing phase separation
Solution Approach 1:
The patent uses compatibilizers as intermediary substances that bridge the polyarylene sulfide matrix and elastomeric impact modifiers, ensuring compatible mixing and preventing phase separation while maintaining enhanced impact resistance
Solution Approach 2:
The patent modifies the chemical parameters of either the polyarylene sulfide or the elastomeric impact modifier to improve compatibility, such as introducing functional groups that enhance interfacial adhesion and prevent phase separation
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 thermoplastic composition exhibits superior tensile and impact strength, maintains properties across a wide temperature range, and shows excellent resistance to chemical and thermal stresses, reducing the need for additional heat shields and minimizing weight and cost, while ensuring long-term performance and ease of installation.
Implementation Method 1
A thermoplastic composition comprising a polyarylene sulfide and a crosslinked impact modifier, formed through dynamic vulcanization and melt processing
Data Source
AI summary
A fuel line comprising a thermoplastic composition is described. The thermoplastic compositions exhibit high strength and flexibility and can be used to form one or more layers of single layer or multi-layer fuel lines. Methods for forming the thermoplastic compositions are also described. Formation methods include dynamic vulcanization of a composition that includes an impact modifier dispersed throughout a polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier. The crosslinking agent reacts with the impact modifier to form crosslinks within and among the polymer chains of the impact modifier. The compositions can exhibit excellent physical characteristics at extreme temperatures.