Resin Fuel Inlet Pipe Impact Resistance Weight Reduction
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Solution Overview
Problem
Resin-made fuel inlet pipes face challenges in achieving lightweight, high impact resistance, and preventing fuel leakage, as existing designs either lack sufficient strength or increase weight when attempting to enhance impact resistance.
Innovation Solution
A resin-made fuel inlet pipe is developed with a structure comprising high-density polyethylene (HDPE) or linear short-chain branched polyethylene (LLDPE) and metallocene-based polyethylene, where carbon black is dispersed in a soft tissue inserted between linear crystalline tissues, and extrusion molding is used to form the resin layer, enhancing both strength and ductility while preventing fuel leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the resin hose is increased to provide impact resistance comparable to metal pipe, then impact resistance is improved, but weight increases which is contrary to weight reduction demand
Solution Approach 1:
The patent applies composite materials by combining HDPE or LLDPE (component A) with metallocene-based polyethylene (component B) in a multi-layer structure. This composite resin layer provides enhanced impact resistance and strength comparable to metal pipes while maintaining the lightweight advantage of resin materials, resolving the contradiction between strength and weight.
Solution Approach 2:
The patent implements local quality by creating a multi-layer structure where different resin components are strategically positioned: component A forms the base layer providing structural integrity, while component B forms an intermediate layer providing impact absorption. This localized functional distribution achieves high impact resistance without uniformly increasing wall thickness throughout the entire pipe, thus controlling weight.
2Weight of moving object
If a resin-made hose is used instead of metal pipe for weight reduction, then weight is reduced, but impact resistance becomes insufficient
Solution Approach 1:
The patent uses composite materials combining HDPE/LLDPE with metallocene-based polyethylene to create a resin-made hose that achieves impact resistance comparable to metal pipes. The synergistic combination of these resin components provides the necessary strength and toughness while maintaining the inherent weight advantage of resin over metal.
Solution Approach 2:
The patent applies parameter changes by carefully controlling the weight mixing ratio between component A and component B within specific ranges (95/5 to 50/50), and adjusting the thickness of each layer. This optimization of material parameters enables the resin hose to achieve metal-level impact resistance while keeping weight low.
3Weight of moving object
If a resin-made hose is used instead of metal pipe, then weight is reduced, but fuel leakage occurs due to crack propagation from inner layer to outer layer
Solution Approach 1:
The patent applies local quality by creating a multi-layer structure where component A (HDPE/LLDPE) forms the inner layer in direct contact with fuel, providing fuel resistance and containment. The intermediate layer of component B (metallocene-based polyethylene) provides a transition zone that stops crack propagation. This localized functional assignment ensures fuel leakage prevention while maintaining the lightweight resin construction.
Solution Approach 2:
The patent uses an intermediary approach by introducing component B as an intermediate layer between the inner fuel-contacting layer and the outer protective layer. This intermediate layer acts as a barrier that prevents crack propagation from the inner layer to the outer layer, thereby preventing fuel leakage while maintaining the overall lightweight resin structure.
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 solution provides a resin-made fuel inlet pipe with improved impact resistance, elongation, and weather resistance, maintaining high-speed tensile elongation and conductivity, and prevents fuel leakage during collisions, while also offering weight reduction and enhanced chipping resistance through a protective layer.
Implementation Method 1
a polyethylene polymerized with a metallocene-based catalyst
Implementation Method 2
the carbon black (C) is dispersed in the soft tissue (Y)
Data Source
AI summary
A resin-made fuel inlet pipe that has a light weight, excellent impact resistance, and causes no fuel leakage includes at least one resin layer comprising a resin composition containing (A) a high-density polyethylene (HDPE) or a linear short-chain branched polyethylene; (B) a polyethylene polymerized with a metallocene-based catalyst; and (C) a carbon black. A weight mixing ratio ((A)/(B)) is in a range of from 10/90 to 90/10; a content of component (C) is in a range of from 0.1 to 5 parts by weight with respect to 100 parts by weight of a total of components (A) and (B); a tissue (Y) comprising component (B) is inserted between linear crystalline tissues (X) comprising component (A) to expand an interval between the tissues (X); and component (C) is dispersed in the tissue (Y).