Silane-Grafted Polyolefin Hose Weight Reduction
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Solution Overview
Problem
Current rubber hoses used in automotive applications are heavy and complex, requiring multiple ingredients and high processing temperatures, which hinders weight reduction and increases CO2 emissions.
Innovation Solution
Development of silane-grafted polyolefin compositions that are lighter in weight, simpler in formulation, and can be extruded with reduced specific gravity, allowing for efficient production of hoses with reduced wall thickness and lower carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional EPDM rubber formulations with multiple ingredients are used, then performance requirements are met, but hose weight and compound density increase
Solution Approach 1:
The patent changes the chemical composition parameters by replacing conventional EPDM rubber with silane-grafted polyolefin, reducing compound density from 1.10-1.40 g/cm³ to below 1.10 g/cm³. This parameter change maintains performance requirements while achieving weight reduction through fundamentally different material chemistry
Solution Approach 2:
The patent uses composite material strategy by combining silane-grafted polyolefin with specific reinforcement structures (fabric or textile layers) to create a hose that achieves required performance with lighter overall composition, replacing heavy conventional rubber formulations
2Reliability
If conventional EPDM rubber formulations are used, then performance requirements are met, but compound density increases
Solution Approach 1:
The patent fundamentally changes the chemical composition by using silane-grafted polyolefin instead of EPDM rubber, achieving compound density below 1.10 g/cm³ compared to conventional 1.10-1.40 g/cm³ range, thus reducing the quantity of substance while meeting performance requirements
Solution Approach 2:
The patent extracts and removes heavy conventional ingredients (carbon black, petroleum-based oil, zinc oxide, miscellaneous fillers) from the formulation, retaining only essential components needed for performance, thereby reducing overall compound density
3Weight of moving object
If hose wall thickness is reduced, then weight is reduced, but structural integrity may be compromised
Solution Approach 1:
The patent employs composite material structure with silane-grafted polyolefin combined with fabric or textile reinforcement layers, enabling reduced wall thickness while maintaining structural integrity through the synergistic combination of materials
Solution Approach 2:
The patent changes the material properties by using silane-grafted polyolefin with optimized mechanical properties that allow thinner wall designs, reducing weight while compensating for reduced thickness through superior material characteristics
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 silane-grafted polyolefin hoses achieve a 50% weight reduction and lower specific gravity compared to conventional hoses, meeting fuel economy demands and reducing production costs through efficient low-pressure steam vulcanization.
Implementation Method 1
The silane-grafted and cross-linked polyolefin elastomer is vulcanized by exposure to low-pressure steam
Implementation Method 2
The polyolefin is cross-linked upon exposure to moisture and/or heat to form a cross-linked polyolefin elastomer
Implementation Method 3
grafting silanes to a polyolefin to form the silane-grafted polyolefin
Data Source
AI summary
A silane-grafted polyolefin composition is disclosed, and includes a desired reduced specific weight material. The composition finds application in a wide array of uses, and in particular automotive and uses such as hoses, where this composition is used in place of conventional materials such as TPV and EPDM rubber formulations.