Single-Step Polymer Hose Mixture for Charge Air Systems
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Solution Overview
Problem
Charge air hoses require multiple materials and manufacturing processes, making production inefficient, and need to be flexible, temperature-resistant, and resistant to aggressive media.
Innovation Solution
A polymer mixture combining fluororubber, active fillers, and thermoplastics, with a compatibility additive, allowing for single-process production of hoses that are flexible, temperature-resistant, and media-resistant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials and manufacturing processes are used for charge air hoses, then the hose can achieve flexibility, temperature resistance, and media resistance, but the production complexity and manufacturing effort increase
Solution Approach 1:
The patent combines multiple materials (fluororubber, thermoplastic, active fillers) into a single polymer mixture that can be processed in one manufacturing step. This merging of materials and processes eliminates the need for separate production and assembly steps while maintaining the required temperature and media resistance properties.
Solution Approach 2:
The invention uses a composite polymer mixture containing fluororubber for temperature and media resistance, thermoplastic for structural properties, and active fillers for enhanced performance. This composite approach allows achieving multiple performance requirements simultaneously while enabling single-process manufacturing.
2Reliability
If multiple materials and assembly steps are used, then the hose can achieve required physical properties, but the production time and manufacturing effort increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single extrusion or injection molding process. The polymer mixture containing all necessary components (fluororubber, thermoplastic, active fillers) is processed in one step, eliminating sequential production and assembly operations, thereby significantly improving productivity.
3Ease of manufacture
If a single-process production method is used, then manufacturing effort is reduced, but achieving adequate temperature and media resistance becomes difficult
Solution Approach 1:
The invention employs a specifically formulated composite polymer mixture where fluororubber provides temperature and media resistance, thermoplastic contributes structural integrity, and active fillers enhance overall performance. This composite formulation enables single-process manufacturing while maintaining the required resistance properties.
Solution Approach 2:
The patent uses compatibility additives as intermediaries to ensure proper mixing and bonding between the fluororubber and thermoplastic components. These additives facilitate the formation of a homogeneous polymer mixture that can be processed in a single step while maintaining the functional properties of each component.
4Reliability
If various components are produced and assembled separately, then each component can be optimized, but the overall manufacturing complexity increases
Solution Approach 1:
The patent merges the production of multiple components into a single extrusion or injection molding process. The polymer mixture containing all necessary components is formed in one operation, eliminating the need for separate production and assembly steps, thereby simplifying manufacturing while maintaining component optimization.
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
Enables the production of hoses in a single process step with maintained physical properties, providing flexibility, high temperature resistance, and media resistance.
Implementation Method 1
a combination of at least one fluororubber with active fillers and at least one thermoplastic and at least one compatibility additive... is particularly suitable for producing hoses
Implementation Method 2
the polymer mixture contains at least one fluororubber and at least one active filler and at least one thermoplastic
Implementation Method 3
the charge air hose must not only be flexible, but also have particularly good resistance to higher temperatures and / or aggressive media, such as. E. g. acids or fuels
Data Source
AI summary
The invention relates to a polymer mixture and a hose, in particular a charge air hose, containing the polymer mixture. The polymer mixture contains at least one fluororubber, at least one active filler, and at least one thermoplastic polymer. This makes it possible to provide a hose that can be manufactured in only one process step and from only one polymer mixture.