Single-Layer Coolant Hose Composition for Lightweight Engine Cooling
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Solution Overview
Problem
Current fluid flow pipes for motor vehicles, such as engine cooling pipes, face issues with weight, bulk, complex manufacturing processes, and difficulty in recycling due to multi-layer structures, which hinder their efficiency and economic viability, especially when exposed to high temperatures and pressures.
Innovation Solution
A single-layer fluid flow pipe made from a mixture of polyolefin and thermoplastic polymer elastomer, with a polyolefin content of at least 30% by weight, providing improved mechanical strength, flexibility, and chemical resistance, manufactured through a simplified extrusion process that reduces thickness and weight while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-layer structures with reinforcing materials are used, then mechanical strength is improved, but weight and bulk increase
Solution Approach 1:
The patent uses a composite material consisting of a polyolefin base polymer mixed with thermoplastic elastomer particles (20-80 wt% of the total composition). This composite provides both the mechanical strength needed for cooling pipes and the flexibility required, while avoiding the weight penalty of traditional multi-layer reinforced structures. The elastomer particles act as micro-reinforcements within the polyolefin matrix, creating a homogeneous single-layer composite that delivers enhanced tensile strength and elongation properties.
Solution Approach 2:
The patent changes the material composition parameters by incorporating specific amounts of thermoplastic elastomer (20-80 wt%) into the polyolefin matrix. This parameter adjustment transforms the base polyolefin into a composite material with superior mechanical properties, including increased elongation at break (50-200%) and tensile strength, while maintaining processability and reducing weight compared to traditional reinforced multi-layer pipes.
2Reliability
If multi-layer structures with numerous polymer materials are used, then performance requirements are met, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple material functions into a single homogeneous layer by mixing thermoplastic elastomer particles directly into the polyolefin matrix. This eliminates the need for separate reinforcing layers, adhesive layers, and multiple polymer coatings that characterize traditional multi-layer pipes. The single-layer composite structure can be manufactured using conventional extrusion processes, dramatically simplifying manufacturing while meeting all performance requirements for flexibility, strength, and chemical resistance.
Solution Approach 2:
The patent creates a homogeneous single-layer composite material where thermoplastic elastomer particles are uniformly distributed throughout the polyolefin matrix. This homogeneous structure eliminates the interfaces and bonding requirements between multiple layers, simplifying manufacturing processes and ensuring consistent performance throughout the pipe wall thickness. The homogeneous composite can be processed in a single extrusion step, reducing manufacturing complexity significantly.
3Object-affected harmful factors
If traditional multi-layer pipes are used, then chemical resistance is achieved, but recycling difficulty increases
Solution Approach 1:
The patent employs a homogeneous single-layer composite structure consisting of polyolefin and thermoplastic elastomer particles, eliminating the multiple polymer layers that make traditional pipes difficult to recycle. This homogeneous composition can be processed together through conventional recycling methods, whereas multi-layer pipes require complex separation processes. The single-layer structure maintains chemical resistance to cooling fluids while enabling easier mechanical recycling and material recovery.
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 single-layer pipe design enhances installation in restricted spaces, simplifies manufacturing, facilitates easier recycling, and offers improved mechanical properties, including resistance to high temperatures and pressures, while reducing vehicle weight by approximately 40% compared to traditional pipes.
Implementation Method 1
manufactured through a simplified extrusion process
Implementation Method 2
resistance to high temperatures and pressures
Implementation Method 3
thermoplastic polymer elastomer (TPE)
Data Source
AI summary
A motor vehicle cooling fluid flow pipe, such as an engine cooling fluid pipe, characterized in that the wall of the pipe is constituted by a single layer made of a polymer material comprising a mixture of at least two polymer materials of different natures, one of which, referred to as a first material, being a polyolefin, and the other of which, referred to as a second material, being a thermoplastic polymer elastomer (TPE).The method of manufacturing this pipe comprises an operation of mixing at least the polyolefin and the thermoplastic polymer elastomer (TPE), a step of extruding said mixture in a screw extruder followed by a step of forming the pipe, the operation of mixing the polyolefin and the thermoplastic polymer elastomer (TPE) being performed upstream from the extruder or at its inlet.