Monolayer Thermoplastic Elastomer Conduits for High-Heat Flexibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fluid conduits in the automotive industry fail to withstand high operating temperatures for extended periods while maintaining necessary mechanical properties and flexibility, particularly in applications like turbocharger ducts where temperatures exceed 160°C.
Innovation Solution
A process for preparing a mono-layer fluid conduit using a thermoplastic elastomer with at least 80 wt% composition, involving melting, forming a parison, and blow-molding to create a conduit with a thermoplastic elastomer that has a high heat resistance and retention of elongation at break, ensuring flexibility and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If mono-layer air ducts are made from semi-crystalline thermoplastic materials to reduce weight, then weight is reduced and flexibility is improved, but heat resistance deteriorates and the conduit cannot withstand long term high temperatures
Solution Approach 1:
The patent changes the material parameter from conventional semi-crystalline thermoplastics to thermoplastic elastomers with specific properties (MFR ≤40 g/10 min at 230°C, heat resistance ≥250 hours at 175°C). This parameter change enables the material to maintain both flexibility and heat resistance, resolving the contradiction between weight reduction and heat resistance.
Solution Approach 2:
The patent uses a mono-layer construction made from a specific thermoplastic elastomer composition that combines the properties of both flexibility and heat resistance in a single material system, eliminating the need for multi-layer composite structures and achieving weight reduction while maintaining thermal performance.
2Temperature
If the conduit material is made harder to withstand high temperatures, then heat resistance is improved, but flexibility deteriorates and handling becomes difficult
Solution Approach 1:
The patent specifies thermoplastic elastomers with controlled MFR (≤40 g/10 min at 230°C) and heat resistance (≥250 hours at 175°C), achieving an optimal balance between flexibility for easy handling and heat resistance for high-temperature applications. This precise parameter control resolves the contradiction between hardness and flexibility.
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 process results in fluid conduits that can withstand high temperatures for longer periods without losing flexibility, as demonstrated by maintaining elongation at break and mechanical properties, making them suitable for high-temperature applications such as turbocharger ducts.
Implementation Method 1
a. Melting a composition comprising at least a thermoplastic elastomer
Implementation Method 2
e. Cooling down the mold, thereby obtaining the fluid conduit comprising the mono-layer
Data Source
AI summary
Processes for making a fluid conduits and fluid conduits made thereby are disclosed. The fluid conduits include a mono-layer formed of at least 80 wt %, based on total weight of the mono-layer, of a thermoplastic elastomer in an amount of at least 80 wt % with respect to the total weight of the mono-layer. The thermoplastic elastomer is preferably a block copolymer elastomer formed of hard segments (e.g., polyesters, polyamides and/or polyurethanes) and soft segments (e.g., aliphatic polyethers, aliphatic polyesters and/or aliphatic polycarbonates) and exhibits a melt flow rate measured at 230° C. under a load of 10 kg (MFR 230° C./10 kg), according to ISO1133 (2011) of at most 40 g/10 min and having a heat resistance of at least 250 hours at 175° C. at which the elongation at break remains at least 100% as measured according to ISO 527 with a test speed of 50 mm/min.