Tempered Polyphenylene Sulfide Insulation for Vulcanized Heating Hoses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The vulcanization process of heatable articles, such as hoses, often results in a reduced or destroyed insulation layer due to heat and pressure, leading to 'braid imprints' and increased waste rates, as the insulation tears when the heating conductor is pulled out, compromising the electrical connection.
Innovation Solution
Using a polymeric sheathing material based on polyphenylene or its derivatives, specifically polyphenylene sulfide (PPS), which is tempered to enhance thermal resistance and adhesive strength, and embedding the tempered heating conductor in a vulcanizable polymer mixture for subsequent vulcanization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polymeric insulation material is used during vulcanization, then the article can be manufactured, but the insulation layer is locally reduced or destroyed due to heat and pressure
Solution Approach 1:
The patent changes the material parameter from conventional polymeric insulation to polyphenylene-based insulation material, which has superior thermal stability and maintains its mechanical properties at vulcanization temperatures (130-200°C), preventing insulation layer destruction
Solution Approach 2:
The patent uses composite material structure by combining polyphenylene-based polymer with the insulation layer, creating a material that resists both heat and pressure during vulcanization while maintaining insulation integrity and preventing braid imprint formation
2Ease of operation
If the heating conductor is pulled out after vulcanization, then electrical connection is enabled, but the insulation tears open due to braid imprints
Solution Approach 1:
The patent applies preliminary action by pre-tempering the polyphenylene-based insulation material before vulcanization, which stabilizes the material structure and prevents braid imprint formation, ensuring insulation integrity during subsequent conductor extraction and electrical connection
3Strength
If polyphenylene-based material is used for sheathing, then thermal resistance and adhesive strength increase, but the material requires tempering treatment
Solution Approach 1:
The patent applies parameter changes by implementing a tempering process that heats the polyphenylene-based sheathing material to specific temperatures and holds it there, which modifies the material's crystalline structure and achieves the desired adhesive strength and thermal resistance properties
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 significantly reduces waste rates and ensures the heating conductor can be exposed for electrical connection without damage, maintaining insulation integrity and increasing the strength of the heatable article.
Implementation Method 1
the sheathing is a polymeric material based on a polyphenylene or a polyphenylene derivative, the polymeric material being tempered
Implementation Method 2
The heating conductor comprises a metallic core and a sheath as an insulating layer... In order to heat a medium flowing in the hose
Data Source
Figure 1~3
AI summary
The article has an elastic base body made up of vulcanized rubber, where a heating conductor (1) is embedded in the base body. The heating conductor is electrically connected to an electrical connection device. The heating conductor includes an inner cover (2) as a heating wire, and a sheath (3) made of electrically insulating polymer material. The polymer material is selected from a group consisting of polyphenylene, polyphenylene oxide, polyphenylene sulfide and polyphenylene ether, where the polymer material is tempered. An independent claim is also included for a method for manufacturing a heatable article.