Meta-Aramid PPS Wet Nonwoven for Void-Free Electrical Insulation
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Solution Overview
Problem
Conventional insulating papers and laminates exhibit issues such as through-holes allowing air passage, weak tension and stiffness, partial discharge due to voids, insufficient dielectric breakdown strength, and inadequate wear durability, particularly in high-temperature environments like industrial motors.
Innovation Solution
A wet nonwoven fabric composed of meta-aramid fibers and polyphenylene sulfide short fibers, where the polyphenylene sulfide fibers are partially fused, forming a film between meta-aramid fibers to eliminate gaps and enhance dielectric breakdown strength, while maintaining thermal and hygroscopic stability and tear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-performance fibers such as meta-aramid are used to achieve high strength and heat resistance, then mechanical strength and thermal stability are improved, but processing difficulty increases and manufacturing complexity worsens
Solution Approach 1:
The patent uses composite materials by combining meta-aramid fibers with polyphenylene sulfide (PPS) binder fibers. The PPS component acts as a binder that facilitates processing while the meta-aramid provides high strength and heat resistance. This composite approach allows the difficult-to-process meta-aramid to be manufactured into nonwoven fabrics using standard equipment.
2Temperature
If high-performance fibers such as meta-aramid are used to achieve heat resistance, then thermal stability is improved, but processing difficulty increases
Solution Approach 1:
The patent introduces polyphenylene sulfide (PPS) as an intermediary material that mediates between the heat-resistant meta-aramid fibers and the processing equipment. The PPS has lower melting point and better processability, acting as a bridge that allows standard textile processing equipment to handle and process the heat-resistant meta-aramid fibers without requiring specialized high-temperature processing equipment.
3Ease of manufacture
If conventional nonwoven fabrics are used to achieve ease of manufacture, then manufacturing simplicity is improved, but flame retardancy and heat resistance worsen
Solution Approach 1:
The patent creates a composite nonwoven fabric where meta-aramid fibers provide inherent flame retardancy and heat resistance properties, while PPS binder fibers maintain ease of manufacture. The meta-aramid component contributes excellent flame resistance without requiring additional flame-retardant treatments, thus maintaining manufacturing simplicity while improving thermal safety.
4Ease of manufacture
If conventional nonwoven fabrics are used to achieve ease of manufacture, then processing simplicity is improved, but mechanical strength and durability worsen
Solution Approach 1:
The patent employs composite materials where meta-aramid fibers provide high mechanical strength and durability, while PPS binder fibers ensure processing simplicity. The meta-aramid component contributes exceptional tensile strength and abrasion resistance, significantly improving the mechanical properties of the nonwoven fabric while the PPS matrix maintains ease of processing through standard equipment.
Data Source
AI summary
In order to provide electrical insulating paper and an electrical insulating sheet including the same which exhibit excellent dielectric breakdown strength, excellent hygroscopic dimensional stability and thermal dimensional stability, and excellent tear strength and wear durability, a nonwoven fabric is fabricated wherein the fabric is a wet nonwoven fabric containing a meta-aramid fiber and a polyphenylene sulfide short fiber and a proportion of the polyphenylene sulfide short fiber at least partially fused in the wet nonwoven fabric is 40% or less, and the wet nonwoven fabric has a dielectric breakdown strength of 17 kV/mm or more.