Polyester Cable Insulation Shrinkage Control
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Solution Overview
Problem
Conventional flexible flat cables (FFCs) face issues with insufficient heat resistance and moisture resistance due to the use of polymers like PET, PEN, and PI, which also have high production costs.
Innovation Solution
A cable with an insulating part featuring a polymer resin layer composed of diol-based repeating units with a cyclohexane skeleton, specifically a polyester layer with a product of shrinkage ratios less than 0.24 and an intrinsic viscosity retention ratio of 70% or greater, achieved through biaxial stretching and heat setting, providing improved heat and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymers (PET, PEN, PBT, PI) are used as insulating layers, then the cable can be produced with standard materials and processes, but the heat resistance and moisture resistance are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer by specifying a polyester resin with particular diol-based repeating units (85-95 mol%) and controlled intrinsic viscosity (0.45-0.75 dl/g), achieving improved heat and moisture resistance while maintaining manufacturability through parameter optimization rather than material substitution
Solution Approach 2:
The patent creates a composite polymer structure by combining specific diol-based repeating units (cyclohexane skeleton) with dicarboxylic acid-based repeating units in controlled ratios, forming a polyester composite that achieves superior thermal and moisture properties compared to conventional homogeneous polymers
2Reliability
If the insulating layer uses polymers with better heat and moisture resistance, then reliability improves, but the unit cost increases
Solution Approach 1:
The patent replaces expensive long-lasting materials (polyimide) with a cost-effective polyester resin that achieves comparable performance through optimized composition and processing, reducing material cost while maintaining functional longevity
Solution Approach 2:
By optimizing the intrinsic viscosity range (0.45-0.75 dl/g) and compositional ratios of the polyester resin, the patent achieves maximum performance at minimum cost, avoiding the need for expensive alternative materials
3Stability of the object's composition
If the polymer resin layer has high shrinkage resistance, then dimensional stability improves, but the manufacturing process complexity increases
Solution Approach 1:
The patent incorporates heat-setting treatment during the manufacturing process to pre-establish the dimensional stability of the insulating layer, preventing shrinkage issues later without requiring complex post-processing or specialized equipment
Solution Approach 2:
By controlling the intrinsic viscosity and compositional parameters of the polyester resin, the patent achieves inherent dimensional stability that reduces the need for complex manufacturing controls and post-processing steps
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 solution enhances the heat and moisture resistance of the cable while reducing production costs, making it suitable for use in miniaturized electronic devices without significant changes in external appearance or physical properties.
Implementation Method 1
biaxially stretching and heat setting
Implementation Method 2
biaxially stretching and heat setting
Implementation Method 3
improved heat and moisture resistance
Data Source
AI summary
A cable includes an insulating part and one or more conducting parts disposed inside the insulating part. The insulating part includes a polymer resin layer with a product of shrinkage ratios CMD*TD, which is expressed as a product of a longitudinal shrinkage ratio and a transverse shrinkage ratio, of less than 0.24.