PEN-Bonded Insulation Textile Structure for High-Temperature Stability
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Solution Overview
Problem
Existing textile fabrics used for electrical insulation in devices like electric motors and transformers face issues such as sulfur content degradation leading to corrosion, incompatibility of polymers like PPS and PET, and insufficient thermal stability due to low glass transition temperatures.
Innovation Solution
A textile surface structure using core/sheath binding fibers with a sheath comprising PEN, copolymers, and/or blends thereof, where the sheath polymer has a low degree of crystallinity and is subjected to temperatures above its glass transition temperature for bonding, providing high thermal and electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PPS/PET multi-component fibers are used for textile insulation, then mechanical properties and bonding capability are improved, but sulfur content increases leading to corrosion risk and polymer incompatibility complicates production
Solution Approach 1:
The invention extracts and removes the harmful PPS component containing sulfur from the fiber composition. By using only PET components with controlled crystallinity and orientation, the patent eliminates sulfur-related corrosion while maintaining mechanical properties through alternative structural design of the textile fabric.
Solution Approach 2:
The invention changes the critical parameter of crystallinity from high (in PPS) to controlled low levels in PET fibers. By maintaining PET crystallinity below 30% and controlling fiber orientation, the patent achieves both mechanical strength and resistance to thermal degradation without sulfur-containing materials.
2Temperature
If high-crystallinity polymers are used for thermal resistance, then temperature resistance is improved, but glass transition temperature increases reducing flexibility and processability
Solution Approach 1:
The invention inverts the conventional approach by using low-crystallinity PET fibers instead of high-crystallinity polymers. By maintaining crystallinity below 30% and using amorphous or low-crystalline structures, the patent achieves processability while obtaining thermal resistance through alternative mechanisms such as fiber orientation and network structure rather than high crystallinity.
3Object-affected harmful factors
If dense fiber structure is used for electrical insulation, then insulation properties are improved, but air permeability decreases affecting resin impregnation
Solution Approach 1:
The invention applies local quality by creating zones of different fiber orientation and density within the textile fabric. The fabric structure features locally oriented bundles providing insulation in critical areas while maintaining overall porosity for resin penetration, achieving both insulation and impregnation requirements through spatial variation in structure.
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 structure exhibits excellent thermal stability, resistance to sulfur-related corrosion, and improved mechanical properties, maintaining strength and stability even at elevated temperatures.
Implementation Method 1
the binding component is obtainable by subjecting core/sheath binding fibers, in which the binding fiber sheath polymer contains PEN, copolymers and/or blends thereof, to temperatures above the glass transition temperature of the binding fiber sheath polymer
Data Source
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AI summary
The invention relates to a textile flat structure, comprising a base body of at least one layer, wherein the at least one layer comprises PEN, copolymers and/or blends thereof as a binding component, wherein the binding component can be obtained by applying to core/sheath binding fibers, in which the binding fiber shell polymer contains PEN, copolymers and/or blends thereof, temperatures above the glass transition temperature of the binding fiber shell polymer.