Dual Layer Heat Shrink Tubing Encapsulation Control

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Solution Overview

Problem

Existing heat shrink tubing designs often fail to provide adequate encapsulation of underlying components due to voids, irregularities, or improper contraction, leading to issues like increased tube length and overflow during the recovery process.

Innovation Solution

A dual layer heat shrink tubing design featuring a non-crosslinked outer layer of poly(ether-block-amide) copolymer (PEBA) and a maleated polyolefin inner layer, where the inner layer melts and flows while the outer layer contracts, ensuring optimal encapsulation and protection of components with controlled recovery characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the inner tube melts early or the outer tube recovery force is too high, then the polymer flows excessively causing unacceptable increase in recovered tube length and overflow, but if the inner tube polymer is not sufficiently deformable or the outer tube recovery force is too low, then the underlying component is not properly encapsulated

Engineering Contradiction:

Improveencapsulation qualityVSAvoidrecovered tube length control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The heat shrink tubing is divided into two distinct layers with different functional properties: the inner layer composed of low-melt-point polymer for encapsulation and the outer layer composed of high-recovery polymer for dimensional control. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between encapsulation quality and length control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the tubing wall are assigned different material properties: the inner region uses polymer with lower melt point and higher deformability for component encapsulation, while the outer region uses polymer with higher recovery force for dimensional stability. This local differentiation of material properties enables simultaneous achievement of good encapsulation and controlled recovery.

Inventive Principle:

Principle #3Local quality

2Reliability

If the outer layer is made with high recovery force to ensure proper encapsulation, then the underlying component is properly encapsulated, but the recovered tube length increases excessively and polymer overflows

Engineering Contradiction:

Improveencapsulation qualityVSAvoidrecovered tube length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The tubing is segmented into inner and outer layers with differentiated recovery characteristics. The outer layer provides controlled recovery to minimize length increase, while the inner layer provides encapsulation through melting and flowing. This segmentation resolves the contradiction between encapsulation quality and length control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner layer acts as an intermediary between the outer layer and the underlying component. It melts and flows to encapsulate the component while the outer layer maintains dimensional control, preventing excessive length increase and overflow.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the inner tube polymer is made sufficiently deformable to ensure proper encapsulation, then the underlying component is properly encapsulated, but the polymer flows excessively causing overflow and increased recovered tube length

Engineering Contradiction:

Improveencapsulation qualityVSAvoidpolymer overflow

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The tubing is divided into functional layers: the inner layer uses highly deformable, low-melt-point polymer for encapsulation while the outer layer provides containment through controlled recovery. This segmentation prevents overflow by confining the molten inner polymer within the recovering outer layer structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tubing uses a composite structure combining two different polymers with complementary properties: the inner layer uses a soft, low-melt-point polymer for encapsulation and the outer layer uses a more stable polymer for dimensional control and overflow prevention.

Inventive Principle:

Principle #40Composite materials

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 dual layer design achieves effective encapsulation with minimal voids and overflow, maintaining a recovered length increase of less than 20% of the original length, enhancing the reliability and performance of heat shrink applications.

Implementation Method 1

the inner layer melts and flows while the outer layer contracts, ensuring optimal encapsulation and protection of components

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the outer layer contracts (serving as an effective heat shrink tubing)

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS20240326379A1Dual layer heat shrink tubing

Publication Date: 2024.10.03 ZEUS CO LLC

AI summary

The present disclosure provides a dual layer heat shrink tube having: an inner polymeric layer and an outer polymeric layer. The disclosure further provides associated methods for preparing and using such tubes, as well as to products comprising such tubes.