Description:TECHNICAL FIELD
[001]The present subject matter is related to a material composition, moreparticularly relates to a lightweight material composition.
BACKGROUND
[002]
Typically, in industry products are manufactured using the raw material5 which can be metal, non- metal or combination of both. In the automobile industry it is recommended, or an industrial practice is established to use metal and non- metal both. If for example any vehicle is manufactured, industries prefer to use metal to the part where more stress and strain is provided, and non- metals, such as polymers, are used where there less stress and strain as compared to other metal made parts. 10 Further, it also challenges the automotive industry to reduce the weight of the vehicle because as metal in the vehicle increases, the weight also gets increased.
[003]
Conventionally, to reduce the weight of the vehicle industries tend to usemore non-metals such as polymers, monomers, and other petroleum products. Further there comes a challenge of accommodating the one or more polymers or 15 other petroleum products with the replacement of metal parts of the vehicles. In recent times the automotive industry is working on accommodating the one or more polymers made parts at the places which require stress and strain.
[004]
In recent time the painted parts or style parts are made polymer material, butit is challenge to identify the perfect composition of the polymer because the one or 20 more polymers having single monomers type chain tends to have weak surface energy which then becomes problem for industry to paint and with less tensile strength it can only be used in hidden parts.
[005]
Further another challenge is to identify the composition of the polymer whichis providing strength and rigidity of the part with less weight as well because in the 25
3
end reduction of weight of the vehicle becomes the huge challenge to OEMs to
improve the efficiency of the vehicle.
[006]Thus, there is a need in the art to provide the polymer composition withreduces weight which addresses at least the aforementioned problems without adopting any complex mechanism or designs. 5
SUMMARY OF THE INVENTION
[007]
In one aspect, a composition of a material, the composition including one ormore polymers and at least one fluid component wherein, the one or more polymers may be mixed with the at least one Fluid component in a predetermined ratio at a predefined pressure. 10
[008]
In an embodiment of the invention, the at least one Fluid component may bean inert Fluid component.
[009]
In another embodiment of the present invention, the one or more polymersmay be a thermoplastic polymer.
[010]
In further embodiment of the present invention, the one or more polymers15 and the at least one Fluid component may be in the ratio ranging from 85:95 and 15:5.
[011]
In further embodiment of the present invention, the pressure of mixing the atleast one Fluid component may be in the range of 90 bar to 160 bar.
[012]
In further embodiment of the present invention, a method manufacturing the20 material, wherein adding, to a molding container one or more polymers, treating, the one or more polymers by supplying heat to the molding container, mixing, the one or more polymers with at least one Fluid component by adding in the molding container, one or more components may be manufactured by the mixing of the one or more polymers with the at least one Fluid component. Wherein, the one or more 25
4
polymers
and the at least one Fluid component may be in the ratio ranging from 85:95 and 15:5.
[013]
In further embodiment of the present invention, the one or more polymersmay be heat treated at a predefined temperature.
[014]
In further embodiment of the present invention, the one or more polymers5 and the at least one Fluid component from different zones of the molding container.
[015]
In further embodiment of the present invention, the mixture of the one ormore polymers and at least one Fluid component may be solidified to manufacture the one or more components.
[016]
In further embodiment of the present invention, the one or more components10 including a side panel of a vehicle, a frame assembly of a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[017]
The detailed description is described with reference to an embodiment of adevice along with the accompanying figures. The same numbers are used throughout 15 the drawings to reference features and components.
[018]
Fig. 1 depicts a flow chart for a method for manufacturing a material, inaccordance with an embodiment of the present invention.
[019]
Fig. 2 depicts a graph which indicates the test result, in accordance with anembodiment of the present invention. 20
[020]
Fig. 3 depicts an exemplary component having resultant pores, in accordancewith an embodiment of the present invention.
5
DETAILED DESCRIPTION
[021]In an aspect of the present invention, a composition of material which ishaving combination of one or more polymers and a Fluid component, which tends to be mixed together at a predetermined pressure and temperature.
[022]
The object of the present invention is to provide a composition of material5 which tends to use one or more polymers and a chemical forming agents to manufacture a lightweight material which could be implemented in a vehicle for reducing the weight of the vehicle.
[023]
Another object of the present invention is to provide a solution to increasethe performance of the vehicle by reducing the weight of the vehicle. 10
[024]
The yet another object of the present invention is to reduce the dependencyof polymer for manufacturing parts by addition of the Fluid components and to increase the efficacy of the already existing polymers.
[025]Figure 1 illustrates a flow diagram 100 for manufacturing one or morecomponents of a vehicle by a composition of a material. The one or more 15 components can a household and a consumer goods, in the embodiment of present invention the one or more components can be panels, mufflers, other style parts of the vehicles. The vehicle can be 2 wheeled, 3 wheeled, 4 wheeled or multi-wheeled. For the present embodiment of the invention vehicle can be 2 wheeled, 3 wheeled, 4 wheeled or multi wheeled. 20
[026]At step 110, a raw material is to be selected. The raw material can be one ormore polymers based on occurrence, one or more polymers based on structure, one or more polymers based on molecular force, or one or more polymers based on thermal behaviour. In an embodiment of the present invention the one or more polymers based on thermal behaviour which are thermoplastic polymers are used 25
6
such as Acrylic, Nylon, Polylactic Acid, Polybenzimidazole, Polycarbonate,
Polyether Sulfone, Polyether Ether Ketone, Polyetherimide, Acrylonitrile butadiene styrene, Polyethylene, Polytetrafluoroethylene (Teflon), Polyvinylidene fluoride and Polyvinyl chloride. In an embodiment of the present invention the raw material used is the Acrylonitrile butadiene styrene. Further, the granules of the Acrylonitrile 5 butadiene styrene are taken as the raw material.
[027]At step 120, a pre- heating treatment is performed on the one or morepolymers. The pre- heat treatment is performed to remove the unwanted substances such as moisture, dust particles etc. in an embodiment of the present invention, the pre-heat treatment is performed at temperature in the range of 80 degrees to 150 10 degrees for time ranging from 2 hrs to 5 hrs.
[028]
At step 130, a moulding container is taken. The molding process can be Blowmoulding, Powder metallurgy, Compression, Extrusion, Injection, Reaction injection, Rotational, Transfer, Thermoforming, Fiber glass moulding, Hand layout, Resin transfer, Vacuum bag, Bladder, Spray and Matrix moulding. In an 15 embodiment of the present invention, the injection moulding process is used. Further from a hopper zone a storage container of the injection moulding is filled with the one or more polymers.
[029]
At step 130 in conjunction with step 140, in an embodiment, the storagecontainer is filled with the Acrylonitrile butadiene styrene granules, then is liquefy 20 at the predetermined temperature inside the mould. In an embodiment, the temperature can be ranging from 100 degrees to 300 degrees.
[030]
At step 150, the one or more polymers in liquefy state is poured inside themould with at least one Fluid component. The at least one Fluid component is an
7
inert
gas. Further at least one Fluid component can be Helium, Neon, Argon, Nitrogen gas, Carbon dioxide, krypton, xenon. In an embodiment of the present invention, the at least one Fluid component is Nitrogen gas. The use of nitrogen gas eliminates the presence of oxygen and secures a nonflammable environment.
[031]
In an exemplary embodiment, the one or more polymers and the at least5 one Fluid component being in the ratio ranging from 85:95 and 15:5. In an embodiment of the present invention the Acrylonitrile butadiene styrene polymer and the Nitrogen gas is in ratio of 93:7 by weight of the total substate in one embodiment.
[032]
In an embodiment, the Nitrogen gas is added to the mould and with it the10 Acrylonitrile butadiene styrene polymer in liquefy state is added to the mould. Further, the Nitrogen gas tends to entrap with the Acrylonitrile butadiene styrene polymer matrix.
[033]At step 160, the mould is then solidified. The mould is solidified at thefreezing temperature of the one or more polymers. In an embodiment, the 15 Acrylonitrile butadiene styrene polymer is solidified in the temperature ranging from 20degrees to 70 degrees. Further, after solidification, the mould is taken out from the mould cavity.
[034]At step 170, the at least one Fluid component tends to release from themould. the release of Fluid component let behind a vacant spacing 302. The vacant 20 spacing 302 is provided inside the resultant components. The vacant spacing 302 tends to accommodate the space inside the Acrylonitrile butadiene styrene polymer made components, which provides the less use of the Acrylonitrile butadiene styrene polymer in the components which are manufactured.
8
[035]Figure 2 illustrates a graphical analysis of the mould manufactured by theuse of Acrylonitrile butadiene styrene polymer and the Nitrogen gas mixture. A conventional Acrylonitrile butadiene styrene polymer made components can have tensile strength of 40 MPA with 20% elongation. In the embodiment of present invention, the moulded Acrylonitrile butadiene styrene with the Nitrogen gas have 5 tensile strength of 28 MPA with elongation of 7% which are obtained through experimentation. The test results provide that after adding the Nitrogen gas tensile strength and elongation are in permissible limits as per industry standards. Further, reduction of weight of the components are also in the range of 15% to 25% of the conventional components weight. 10
[036]Figure 3 illustrates an exemplary component 300. The exemplarycomponent 300 is having vacant spacing 302 inside it, which shows the reduction of the one or more polymers use. Further, many pores are observed inside the component, which is a confirmation of the presence of nitrogen gas bubbles.
[037]
The claimed invention as disclosed above is not routine, conventional, or15 well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies.
[038]
The incorporation of the composition of this material tends to savings ofraw material to manufacture more products and increased productivity for manufacturers. 20
[039]
Moreover, the present invention provides the composition of material whichtends to reduce the overall weight of the components and it also provides reduction in use of more amount of polymer to manufacture.
[040]
The various embodiments described above can be combined to providefurther embodiments. Also, aspects of the embodiments are not necessarily limited 25
9
to
specific embodiments.
[041]
Depicted figures are for illustrative purposes, many modifications andvariations of the present subject matter are possible within the scope of the present subject matter, in the light of above disclosure.
[042]
While the present invention has been described with respect to certain5 embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims
List of reference signs:
100-Flow chart10
110-Step 1
120-Step 2
130-Step 3
140-Step 4
150-Step 515
160-Step 6
170-Step 7
200-Graphical data
300-Exemplary component
302-Vacant spacing , Claims:We claim:
1.
A composition of a material, the composition comprising:
One or more polymers; and
at least one fluid component; 5
wherein, the one or more polymers being mixed with the one or more one fluid component in a predetermined ratio at a predefined pressure for producing a lightweight material.
2.
The composition of a material as claimed in claim 1, wherein the at least one fluidcomponent being an inert gas.10
3.
The composition of a material as claimed in claim 1, wherein the one or morepolymers being a thermoplastic polymer.
4.
The composition of a material as claimed in claim 1, wherein the one or morepolymers and the at least one fluid component being in the ratio ranging from 85:95and 15:5.15
5.
The composition of a material as claimed in claim 1, wherein the pressure of mixingthe at least one fluid component being in the range of 90 bar to 160 bar.
6.
The composition of a material as claimed in claim 1, wherein the material beingmanufactured by a method (100), the method comprising the steps of:
adding (120), to a molding container one or more polymers; 20
treating (140), the one or more polymers by supplying heat to the molding container;
mixing (150), the one or more polymers with at least one Fluid component by adding in the molding container;
11
one or more components being manufactured by the mixing (150) of the one or more polymers with the at least one Fluid component.
Wherein, the one or more polymers and the at least one Fluid component being in the ratio ranging from 85:95 and 15:5.
7.
The composition of a material as claimed in claim 1, wherein the method (100)5 comprising the one or more polymers being heat treated at a predefined temperature.
8.
The composition of a material as claimed in claim 1, wherein the method (100)comprising the one or more polymers and the at least one fluid component insertedfrom different zones of the molding container.
9.
The composition of a material as claimed in claim 1, wherein the method (100)10 comprising the mixture of the one or more polymers and at least one fluid componentbeing solidified to manufacture the one or more components.
10.
The composition of a material as claimed in claim 1, wherein the method (100)comprising the one or more components comprising a side panel of a vehicle, a frameassembly of a vehicle.