Sheath/Core Non-Woven Sheet for Electrical Insulation
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Solution Overview
Problem
Current non-woven sheets lack superior mechanical strength, initial tear resistance, elongation, and voltage endurance, making them inadequate for advanced electrical insulation applications.
Innovation Solution
A non-woven sheet composed of multicomponent sheath/core polymeric fibers with a higher melting point sheath and lower melting point core, where the sheath forms a continuous phase and the core forms a disperse phase, providing enhanced mechanical properties and voltage endurance when combined with a dielectric film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional non-woven sheets are used, then manufacturing is simple, but mechanical strength and voltage endurance are insufficient
Solution Approach 1:
The patent employs bicomponent fibers with sheath/core construction, where the sheath comprises a first polymer and the core comprises a second polymer with different melting points. This composite fiber structure combines the advantages of both polymers to achieve superior mechanical strength and voltage endurance while maintaining manufacturability through established spinning processes.
Solution Approach 2:
The invention applies local quality by creating distinct phases within the fiber structure - the sheath phase and core phase - each with specific properties. The sheath provides structural integrity while the core contributes to mechanical strength, allowing different regions of the fiber to perform different functions that collectively enhance overall performance.
2Strength
If conventional non-woven sheets are used, then production is straightforward, but initial tear resistance and elongation are inadequate
Solution Approach 1:
The bicomponent fiber construction with sheath/core architecture utilizes composite materials to achieve enhanced initial tear resistance and elongation. The differential melting points of the sheath and core polymers enable controlled phase separation during consolidation, creating a structure that resists tearing while accommodating manufacturing processes.
3Reliability
If conventional non-woven sheets are used, then processing is simple, but voltage endurance is insufficient for advanced electrical insulation applications
Solution Approach 1:
The patent utilizes composite bicomponent fibers where the sheath comprises a first polymer and the core comprises a second polymer with a melting point at least 15°C lower. This composite structure provides enhanced voltage endurance by creating a heterogeneous morphology that impedes electrical breakdown, while the polymers selected are compatible with standard processing methods.
Solution Approach 2:
The invention applies parameter changes by controlling the melting point difference between the sheath and core polymers (at least 15°C difference). This parameter control enables the core polymer to melt and form a disperse phase within the continuous sheath phase during consolidation, creating a structure that enhances voltage endurance through phase separation rather than requiring complex multi-component systems.
4Reliability
If bicomponent fibers with melting point difference of at least 15°C are used, then voltage endurance improves, but fiber structure complexity increases
Solution Approach 1:
The patent applies parameter changes by establishing a specific melting point difference threshold (at least 15°C) between the sheath and core polymers. This quantitative parameter control enables predictable phase separation and morphology development during fiber consolidation, achieving enhanced voltage endurance through a well-defined structural transition rather than requiring complex multi-phase systems.
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 non-woven sheet exhibits superior mechanical strength, initial tear resistance, elongation, and significantly improved voltage endurance when used in electrical insulation components, outperforming traditional materials in voltage endurance tests.
Implementation Method 1
the network of filaments being consolidated and fused such that (a) the first polymer forms a continuous phase in the fused consolidated network and (b) the second polymer forms a disperse phase in the fused consolidated network
Implementation Method 2
the melting point of the first polymer being at least 15 degrees C higher than the melting point of the second polymer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A non-woven sheet contains sheath/core polymer fibers with the polymer in the sheath having a melting point at least 15 degrees centigrade higher than the melting point of the polymer of the core. Preferably, the polymer of the sheath is polyphenylenesulfide and the polymer of the core is polyethyleneterephthlate. The nonwoven sheet can be used with a film to make a composite laminate suitable for use in electrical insulation.