TPV High-Voltage Housings for Recyclable Fast Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-voltage assembly materials based on thermosetting polymers require specialized equipment for processing and are not recyclable, leading to increased production costs and inefficiencies.
Innovation Solution
The use of thermoplastic vulcanizates (TPVs) as housing materials in high-voltage assemblies, which can be processed in standard plastic molding machines, are recyclable, and offer improved processing times and storage stability compared to thermosetting polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting polymers (EPDM, silicone) are used for high-voltage housing, then the material provides good electrical insulation and mechanical properties, but the material requires specialized crosslinking equipment and cannot be recycled
Solution Approach 1:
The patent changes the fundamental material parameter from thermosetting to thermoplastic vulcanizate, which maintains the crosslinked network structure (providing electrical insulation and mechanical properties) but allows the material to be processed using standard thermoplastic molding equipment and enables recyclability through melting and remolding.
Solution Approach 2:
The patent uses thermoplastic vulcanizate (TPV), which is a composite material system combining thermoplastic polymers with crosslinked elastomeric phases. This composite structure integrates the advantages of both thermoplastics (processability, recyclability) and thermosets (electrical insulation, mechanical strength) into a single material that satisfies all requirements.
2Reliability
If thermosetting elastomers are used for high-voltage housing, then the material provides good electrical insulation, but the processing time is excessive due to specialized equipment requirements
Solution Approach 1:
The patent changes the processing parameter from crosslinking-cure cycles to thermoplastic melting and molding cycles, dramatically reducing processing time while maintaining electrical insulation properties through the retained crosslinked elastomeric phase structure.
Solution Approach 2:
The patent replaces the chemical crosslinking process (requiring specialized equipment and long cycles) with a mechanical thermoplastic molding process, enabling faster production using standard injection molding machines while the crosslinked structure provides the necessary electrical insulation.
3Reliability
If thermosetting polymers are used for high-voltage housing, then the material provides good electrical insulation, but the production cost increases due to specialized equipment and non-recyclability
Solution Approach 1:
The patent changes the material state parameter to allow melting and remolding, enabling recyclability and the use of standard equipment, which reduces both capital investment in specialized equipment and operational costs associated with material waste from non-recyclability.
Solution Approach 2:
The patent employs thermoplastic vulcanizate as a composite material that combines the electrical insulation properties of crosslinked elastomers with the cost advantages of thermoplastic processing and recyclability, thereby reducing overall production costs while maintaining reliability.
Data Source
AI summary
Disclosed herein are high-voltage assemblies that take advantage of a thermoplastic vulcanizate to improve performance and ease of manufacture. An example high-voltage assembly includes a component capable of operating in a high-voltage environment, and a thermoplastic vulcanizate housing that encloses the component. Also disclosed herein are methods of making the thermoplastic vulcanizate and the high-voltage assembly.