Multi-Layer Insulation Film Puncture Strength and Folding Endurance
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Solution Overview
Problem
Insulation films made of PC or PET lack both good puncture strength and folding endurance, making them unsuitable for applications requiring both properties.
Innovation Solution
A multi-layered insulation film structure comprising a PC or PET upper and lower layer with a PP and/or PE intermediate layer, where the PC or PET layers contain a phosphor-, silicon-, bromine-, or chlorine-containing flame retardant, and the intermediate layer is made of blends of PP and/or PE and PC and/or PET, enhancing both puncture strength and foldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layered PC or PET insulation film is used, then good puncture resistance is achieved, but poor folding endurance results in tearing when folded
Solution Approach 1:
The insulation film is divided into multiple layers with distinct functions: outer layers of PC or PET provide puncture resistance and flame retardance, while the intermediate layer of PP and/or PE provides flexibility and folding endurance. This segmentation allows each layer to optimize its specific function without compromising the others.
Solution Approach 2:
The invention uses a composite multi-layer structure combining different materials (PC/PET for rigidity and flame retardance, PP/PE for flexibility) to achieve properties that single materials cannot provide alone. The composite structure maintains puncture strength while enabling good folding endurance.
2Productivity
If the thickness of the insulation film is reduced to save material and cost, then manufacturing efficiency improves, but puncture strength decreases
Solution Approach 1:
Different layers are assigned different thicknesses based on their specific functions. The outer layers containing PC or PET are designed with sufficient thickness to provide puncture resistance and flame retardance, while the intermediate flexible layer has optimized thickness for folding endurance. This local quality optimization ensures minimum puncture strength is maintained while reducing overall thickness for cost efficiency.
Data Source
AI summary
The present invention provides an insulation film, comprising a film upper layer and a film lower layer, wherein both of the film upper layer and film lower layer are made of a PC or PET material, the PC or PET material contains a flame retardant to meet the flame retardance and puncture resistance property thereof; a film intermediate layer located between the film upper layer and the film lower layer, the film intermediate layer is made of the blends of PP and/or PE and PC and/or PET; an upper surface of the film intermediate layer is bound together with a lower surface of the film upper layer, a lower surface of the film intermediate layer is bound together with an upper surface of the film lower layer.