Laminated Body with Matched Crystallization for Forming Yield
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Solution Overview
Problem
Conventional electric insulation sheets lack three-dimensional formability and exhibit high variability in shapes during the forming process, resulting in poor forming process yield due to high crystallization in either the fiber sheet layer or resin sheet layer, or both, and inhomogeneous structure.
Innovation Solution
A laminated body comprising a thermoplastic resin sheet layer with a heat of crystallization of 10 J/g or more and a wet-laid polyphenylene sulfide fiber nonwoven layer with a heat of crystallization of 10 J/g or more, both in a low crystalline state, stacked without adhesive, where the nonwoven layer is produced by a wet-laid papermaking process to ensure homogeneous structure and uniform stress transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional insulation sheets are used, then electrical insulation function is provided, but three-dimensional formability is poor and shape variability is high
Solution Approach 1:
The patent changes the crystallization parameter by controlling the heat of crystallization to be 10 J/g or more for both the thermoplastic resin sheet layer and the polyphenylene sulfide fiber nonwoven layer. This parameter change enables both layers to be softened at similar temperatures, allowing them to be simultaneously formed into three-dimensional shapes with uniformity, thereby improving formability and reducing shape variability
Solution Approach 2:
The patent creates a composite laminated body consisting of a thermoplastic resin sheet layer and a polyphenylene sulfide fiber nonwoven layer bonded together. By selecting materials with matched crystallization characteristics (heat of crystallization ≥10 J/g), the composite structure achieves coordinated softening and forming behavior, enabling excellent three-dimensional formability while maintaining electrical insulation properties
2Stability of the object's composition
If high crystallization materials are used, then structural stability is improved, but formability deteriorates
Solution Approach 1:
The patent optimizes the crystallization parameter by setting the heat of crystallization to 10 J/g or more, which represents a balanced state that provides sufficient structural stability while maintaining adequate formability. This parameter value allows the material to be softened during forming processes yet retain structural integrity in the final product
3Strength
If adhesive is used to bond layers, then bonding strength is improved, but formability deteriorates
Solution Approach 1:
The patent employs self-bonding between the thermoplastic resin sheet layer and the polyphenylene sulfide fiber nonwoven layer through direct contact and heating. The materials bond to each other without requiring external adhesives, allowing the laminated body to be softened and formed into three-dimensional shapes while maintaining strong interlayer bonding. This self-service bonding mechanism eliminates the formability limitations imposed by adhesive layers
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 laminated body achieves good three-dimensional formability with low variability in product shapes and excellent forming process yield, allowing deep drawing at high ratios with high success rates and suitable for electric insulation applications.
Implementation Method 1
bonding the layers by thermocompression bonding
Implementation Method 2
the nonwoven layer is produced by a wet-laid papermaking process to ensure homogeneous structure and uniform stress transmission
Data Source
Figure 1
Figure 2(A)~2(B)
AI summary
Provided is a laminated body that exhibits heat resistance, chemical resistance, good interfacial adhesion, good varnish-impregnation, etc., and also has a three-dimensional formability and results in low variability in the shapes of the products in a forming process and an excellent forming process yield. In particular, provided is a laminated body comprising a thermoplastic resin sheet layer having a heat of crystallization of 10 J/g or more as measured with a differential scanning calorimeter and a wet-laid nonwoven layer comprising polyphenylene sulfide fibers and having a heat of crystallization of 10 J/g or more as measured with a differential scanning calorimeter, the wet-laid nonwoven layer being stacked on at least one surface of the thermoplastic resin sheet layer without an adhesive therebetween.