Mica paper-based insulating plate for new energy automobile

Abstract

The mica paper-based insulating plate for the new energy automobile comprises a mica plate base plate, the mica plate base plate is formed by hot-pressing and compounding multiple layers of impregnated mica paper, array through holes are formed in the surface of the mica plate base plate, and the array through holes are filled with buffer structural bodies; the buffer structure body is provided with an outer cylinder, the height of the outer cylinder is 80-90% of the thickness of the substrate, the outer cylinder is formed in the array through holes in a cementing mode, the upper side and the lower side of the outer cylinder are sealed through PVC film layers, and a cylinder cavity is filled with inert insulating media. The two sides of the base plate take a gum dipping nylon fabric net surface as a composite interface, a composite surface layer is formed on the surface and comprises a silicone rubber flexible inner layer and a polyimide or epoxy resin plastic outer layer, and a nano reinforced filler layer is clamped between the interfaces. The mica paper-based insulating plate disclosed by the invention has excellent electrical insulation performance, impact resistance, buffer performance, durability, oxidation resistance, processability and the like, and has wide application prospects and remarkable economic benefits.

Description

Technical Field

[0001] The invention relates to mica paper products in the technical field of insulating materials, and in particular to a mica paper-based insulating board material for new energy vehicles. Background Art

[0002] With the rapid development of new energy technologies, especially the urgent need for high-performance insulating materials in key areas such as wind power, solar energy and energy storage systems, mica boards, as a paper-based insulating material, are widely used in the manufacture of core components such as battery diaphragms and separators in the field of new energy due to their excellent insulation properties, outstanding heat resistance, strong corrosion resistance and high stability. In order to meet the internal high temperature, high pressure and complex electrochemical environment that these components need to withstand during operation, they also need to resist extreme conditions such as external high temperature, high humidity and ultraviolet radiation. The application of mica boards can not only effectively prevent the occurrence of current leakage and short circuit phenomena, ensure the safety and stable performance of related components during operation, but also its excellent thermal conductivity can help improve the heat dissipation efficiency of new energy structural components, thereby further extending the overall service life of related structures.

[0003] Although traditional mica boards have shown relatively superior performance, the new energy field has shown its unique advantages and potential, and can meet some of the market needs to a certain extent; but as insulation protection in the field of new energy vehicle power batteries, in addition to considering its insulation performance and high-voltage resistance, it is also necessary to consider its mechanical strength, heat resistance, corrosion resistance, processing performance and cost and other factors. It is necessary to consider not only that in high-voltage and high-voltage environments, the insulation board not only needs to have excellent electrical insulation performance, but also needs to be able to withstand the impact voltage caused by emergencies (such as short circuits after impact damage, etc.).

[0004] The mica board in the prior art is mainly produced by laminating and pressing mica paper prepared by wet papermaking. The finished mica board shows the hard and brittle characteristics of mica, which is a problem for some applications with relatively high mechanical performance requirements. Since power batteries are mostly laid at the bottom of the body of new energy vehicles, their operating environment is harsh and they need to withstand complex external force conditions and mechanical stress. Therefore, the physical properties of new energy power batteries are also crucial to ensure the safe operation of equipment. Considering that power batteries as structural parts may be used as supporting, fixing or isolating components,

[0005] Power batteries must be able to withstand impact and extrusion from other components or external forces. Therefore, for the insulating plates used in power batteries, their impact resistance also plays a pivotal role to avoid cracking or deformation after being subjected to external forces, thereby affecting the stable operation and service life of the equipment. In addition, when insulating plates are used in buffering materials, the quality of their buffering performance also becomes a crucial consideration. Excellent buffering performance can effectively absorb and disperse energy when encountering impact, thereby reducing potential damage to the battery. Taking the shock-absorbing pad or buffer layer as an example, the insulating plate plays a vital role in it, effectively reducing the vibration and impact generated during the driving of the vehicle.

[0006] In summary, in the face of the increasing requirements of new energy industry for material performance, we need to optimize the insulating plates in power batteries, especially when they are used as buffer materials, and we should pay more attention to their impact resistance and buffering performance after being subjected to force. Summary of the invention

[0007] The technical problem solved by the present invention is to provide a mica paper-based insulating sheet for new energy vehicles to solve the defects in the above technical background.

[0008] The technical problem solved by the present invention is achieved by adopting the following technical solutions:

[0009] A mica paper-based insulating sheet material for new energy vehicles, comprising a mica board substrate, wherein the mica board substrate is formed by hot-pressing and compounding multiple layers of impregnated mica paper, and an array of through holes is formed on the surface of the formed mica board substrate; the array of through holes is filled with a buffer structure;

[0010] The buffer structure comprises an outer cylinder matching the outline size of the array through-holes, the cylinder height of the outer cylinder being 80-90% of the thickness of the mica board substrate, and being formed in the middle of the array through-holes in a gluing manner, the outer cylinder being sealed on both sides with a PVC film layer, and the cylinder cavity between the outer cylinder and the PVC film layer being filled with an inert insulating medium;

[0011] The two side surfaces of the mica board substrate use the impregnated nylon fabric mesh as the composite interface, and a composite surface layer is formed on the surface of the composite interface; the composite surface layer includes a flexible material inner layer formed of silicone rubber and a plastic material outer layer formed of polyimide or epoxy resin, and a layer of nano-reinforced filler is formed at the interface position between the flexible material inner layer and the plastic material outer layer;

[0012] The nano-reinforced filler is one or a combination of nano-silicon dioxide and nano-aluminum oxide.

[0013] As a further limitation, the thickness of the mica board substrate in the mica paper-based insulation board material accounts for 60% to 70%; and the overall thickness of the mica paper-based insulation board material is controlled at 8 to 20 mm to ensure that good processability and lightweight requirements are taken into account while maintaining high strength and excellent insulation performance.

[0014] As a further limitation, the glue used in the impregnated mica paper used to prepare the mica board substrate is an epoxy resin glue, and 1-3‰ of an anti-aging agent and 5-15‰ of an antioxidant are also added to the epoxy resin glue;

[0015] The anti-aging agent is a compound mixture of butylated hydroxyanisole (BHA) and butylated hydroxytoluene (BHT) in a mass ratio of 1:1; the antioxidant is a compound mixture of benzotriazole (BTA) and ascorbic acid (AA) in a mass ratio of 2:3.

[0016] As a further limitation, the impregnated mica paper used to prepare the mica board substrate is surface roughened on both sides, and an interface fiber mesh woven with high modulus fiber as raw material for interlayer reinforcement is formed between the two layers of surface roughened mica paper.

[0017] As a further limitation, the array through holes are preferably oblong holes, and the length direction of the oblong holes is arranged along the shear force resistance direction of the mica board substrate to increase the impact resistance and buffering effect of the board in the main force direction.

[0018] As a further limitation, the thickness ratio of the inner layer of the flexible material to the outer layer of the plastic material in the composite surface layer is 3:2 to 2:1.

[0019] As a further limitation, when the composite surface layer is formed, a rough concave-convex structure at the micro-nano level is first processed on the surface of one side of the inner layer of the flexible material by laser etching, and then nano-reinforced fillers are evenly sprayed on the surface of the rough concave-convex structure, and then the outer layer of the plastic material is overlapped and hot pressed, so that these nano-reinforced fillers, with their extremely small size and high specific surface area, can penetrate into the interior of the silicone rubber layer to form a reinforced interface.

[0020] As a further limitation, the inert insulating medium is an insulating gas medium or insulating oil;

[0021] The insulating gas medium is an inert gas or sulfur hexafluoride, and the insulating oil is a mineral insulating oil or a synthetic ester insulating oil.

[0022] As a further limitation, the inert insulating medium is filled with pressurized gas in the cylinder cavity between the outer cylinder and the PVC film layer, so that the PVC film layers on both side surfaces of the outer cylinder are in contact with the inner surface of the inner layer of the flexible material of the composite surface layer.

[0023] As a further limitation, during secondary processing of the mica paper-based insulating board, the positions of the array through holes need to be staggered or a sufficient margin needs to be left before removing the structure of the array through hole area at the margin position.

[0024] Beneficial effect: The mica paper-based insulating sheet material for new energy vehicles of the present invention is constructed with a precise multi-layer composite structure. The base material is a mica board substrate that has been impregnated with glue and prepared through a hot pressing composite process. An array-type through-hole structure is introduced on the mica board substrate, and the holes are filled with a carefully designed buffer structure. This innovative measure significantly enhances the impact resistance and buffering performance of the sheet material, and its physical properties and safety are significantly improved in a complex and changeable operating environment.

[0025] More importantly, an inert insulating medium is incorporated into the structural buffer, which not only strengthens the impact resistance of the plate, but also stabilizes the reliability of its insulation performance. Combined with the outer surface sealing treatment of the composite surface layer, it not only effectively improves the tightness of the plate and other components of the power battery, but also ensures that the power battery has a solid insulation barrier, effectively resisting the external mechanical stress impact that may be encountered in a complex operating environment, providing a solid guarantee for the safe and stable operation of the equipment.

[0026] In view of the above advantages, the insulating board is particularly suitable as an insulating protective material for new energy vehicle power batteries. It can not only effectively resist vibration and impact, reduce the resulting noise and wear, but also significantly extend the service life of the equipment. It is an important innovative achievement in promoting technological progress and safe development in the field of new energy vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of a preferred embodiment of the present invention.

[0028] Among them: 1. Plastic material outer layer; 2. Flexible material inner layer; 3. Rubber-impregnated nylon fabric mesh; 4. Mica board substrate; 5. Outer cylinder; 6. PVC film layer; 7. Inert insulating medium; 8. Nano-reinforced filler. DETAILED DESCRIPTION

[0029] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below with reference to specific diagrams.

[0030] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0031] In the following embodiments, those skilled in the art will understand that, unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as generally understood by those skilled in the art to which this application belongs.

[0032] See also Figure 1 A preferred embodiment of a mica paper-based insulating sheet for new energy vehicles, the mica paper-based insulating sheet is used as an insulating protective material for power batteries of new energy vehicles, and includes a mica board substrate 4 as a base material. The surface structures on both sides of the mica board substrate 4 are consistent, both of which include a dipped nylon fabric mesh surface 3 attached to the surface of the mica board substrate 4 and a composite surface layer formed on the outer surface of the dipped nylon fabric mesh surface 3, which is composed of a flexible material inner layer 2 and a plastic material outer layer 1.

[0033] In this embodiment, the mica board substrate 4 is formed by hot-pressing a plurality of layers of impregnated mica paper. The thickness of the formed mica board substrate 4 is precisely controlled within a 65% range, and the overall board thickness is set to 14 mm. This design takes into account the structural strength, insulation performance and lightweight requirements, ensuring excellent performance under different working conditions.

[0034] In addition, the impregnated mica paper used to form the mica board substrate 4 is impregnated with phlogopite paper as the raw material, and the corresponding phlogopite paper is first roughened on both sides before the impregnation, and an interface fiber mesh woven with high modulus glass fiber or carbon fiber as the raw material for interlayer reinforcement is formed between the two layers of impregnated mica paper that have been surface roughened. Such a multi-layer structure design enables the insulating board to effectively disperse stress when it is subjected to external impact or extrusion, and prevents cracking or failure caused by local stress concentration, which not only significantly improves the mechanical strength of the insulating board, but also enhances its ability to resist deformation under complex stress conditions.

[0035] The glue used in the impregnated mica paper is epoxy resin glue, and 1.5‰ anti-aging agent and 10‰ antioxidant are added to the epoxy resin glue. The anti-aging agent is a compound mixture of butylated hydroxyanisole (BHA) and butylated hydroxytoluene (BHT), which are mixed in a ratio of 1:1, aiming to comprehensively enhance the aging resistance and antioxidant properties of the mica board substrate 4, thereby extending the service life of the insulating board under complex working conditions; and the antioxidant is a compound mixture of benzotriazole (BTA) and ascorbic acid (AA) in a mass ratio of 2:3. The addition of antioxidants is used to improve the aging resistance and antioxidant capacity of the mica board substrate 4, ensuring that it can still maintain stable insulation and mechanical properties in a long-term complex working environment. At the same time, the glue formula ensures that the mica board substrate 4 has good adhesion and stability during the hot pressing composite process by accurately controlling the proportion of additives, which can improve the performance degradation and bulging phenomenon of the mica board caused by oxidation, aging and other reasons during use, and provide a strength basis for subsequent processing.

[0036] The formed mica board substrate 4 has evenly arranged array through holes punched out on the board surface. These array through holes are oblong holes with an aspect ratio of 3:2, and the width of each hole (corresponding to the diameter of the circle in the oblong hole) is precisely controlled between 20mm and 50mm to ensure that the impact force can be effectively dispersed without excessively weakening the overall strength of the board. The length direction corresponding to the oblong holes of the array through holes is arranged along the shear force resistance direction of the mica board substrate, and an interlaced arrangement is adopted. The array through holes of this structure cooperate with the buffer structure to not only improve the shear resistance and deformation resistance of the board when subjected to external forces, but also improve its stability under complex stress conditions, providing a more reliable protective barrier for the power battery system.

[0037] The array through holes are filled with a buffer structure having the same size as the array through holes, and the buffer structure includes an outer cylinder 5 that matches the contour size of the array through holes. The outer cylinder 5 can be made of different insulating plastic materials in different embodiments. In the present embodiment, the outer cylinder 5 is made of PVC material, and the cylinder height is 80 to 90% of the thickness of the mica board substrate 4. It is formed in the middle position of the array through holes in a gluing manner. The two side surfaces of the outer cylinder 5 are sealed by a PVC film layer 6 to ensure the internal integrity of the outer cylinder 5 of the buffer structure and its isolation from the external environment.

[0038] The buffer structure is filled with an inert insulating medium 7 inside the outer cylinder 5. The medium uses high-purity sulfur hexafluoride (SF6) gas, which effectively enhances the electrical insulation properties of the board with its excellent chemical stability and high insulation performance; at the same time, SF6 gas also has good thermal conductivity, which can quickly disperse heat in a high temperature environment and protect the power battery system from overheating damage. In this embodiment, the inert insulating medium 7 is pressurized to ensure that the PVC film layer 6 and the inner side of the composite surface layer are closely attached and the gap between the buffer structure, the mica board substrate 4 and the composite surface layer is minimized, and it is ensured that it can maintain a stable insulation effect and pressure balance under different working conditions.

[0039] In order to further optimize the buffering effect and insulation performance, the filling pressure of the inert insulating medium 7 is precisely controlled between 0.5 and 1.0 MPa. This range not only ensures the effective filling of the medium, but also avoids the potential safety hazards caused by excessive pressure.

[0040] The insulating board of this embodiment also pays special attention to the bonding strength between the layers of materials. It chooses to set a layer of impregnated nylon fabric mesh 3 between the mica board substrate 4 / buffer structure and the composite surface layer. The impregnated nylon fabric mesh 3 is tightly attached to the surface of the mica board substrate 4 on the inside, and the outer surface is sequentially formed with a flexible material inner layer 2 and a plastic material outer layer 1 for forming the composite surface layer. By adopting advanced hot pressing composite technology, the impregnated nylon fabric mesh 3 and the mica board substrate 4, as well as the composite surface layer and the buffer structure, are tightly attached to form a solid overall structure. The mesh structure of the impregnated nylon fabric mesh 3 can effectively enhance the tensile strength and tear resistance of the insulating board, improve the bonding performance with the composite surface layer, and improve the overall toughness and impact resistance of the board together with the composite surface layer, so that the entire insulating board can show excellent internal durability and stability when facing various complex working conditions that may be encountered during the operation of the power battery of new energy vehicles.

[0041] In this embodiment, the thickness ratio of the flexible material inner layer 2 and the plastic material outer layer 1 in the composite surface layer is 3:2; the thickness ratio is intended to balance the flexibility and hardness of the material, so that when the insulating board is subjected to external impact, the flexible material inner layer can initially absorb and disperse the impact force, while the plastic material outer layer provides sufficient structural support to prevent the board from failing due to excessive deformation.

[0042] In addition, the inner side of the flexible material inner layer 2 is subjected to micro-nano roughening treatment, and a layer of nano-reinforced filler 8 is formed at the interface between the flexible material inner layer 2 and the plastic material outer layer 1 .

[0043] Specifically with regard to the forming process of the composite surface layer, when the composite surface layer is formed, a rough concave-convex structure at the micro-nano level is first processed on the surface of one side of the flexible material inner layer 2 by laser etching, and then a nano-reinforced filler is evenly sprayed on the surface of the rough concave-convex structure, and the spraying amount is about 8 to 15 g per square meter of surface. The nano-reinforced filler is a mixture of nano-silicon dioxide and nano-alumina in a mass ratio of 1:1; after the spraying is completed, the plastic material outer layer 1 is overlapped and hot pressed to obtain the nano-reinforced filler 8, and these nano-reinforced fillers in the nano-reinforced filler, with their extremely small size and high specific surface area, penetrate into the interior of the silicone rubber layer to form a reinforced interface, forming a large number of microscopic interfaces, which can significantly improve the hardness, wear resistance and anti-aging properties of the composite surface layer, and can effectively prevent the expansion and extension of cracks on the surface of the plastic material outer layer 1, thereby ensuring the outer surface performance of the plate after forming.

[0044] The composite surface layer of this embodiment uses silicone rubber material in the selection of the flexible material inner layer 2. This material not only has excellent insulation properties, but also can deform when impacted by external forces, absorb and disperse energy, thereby protecting the internal mica board substrate 4 and the power battery from damage; and the good resilience of the silicone material also ensures that the insulating plate can still maintain a good shape and performance after long-term use, further extending the service life. The plastic material outer layer 1 is made of polyimide molding to resist physical and chemical erosion in the external environment. Its smooth surface also reduces friction with surrounding components, reducing noise and wear risks. In addition, the high dimensional stability of polyimide ensures that the insulating plate can still maintain the precise size and shape on the fitting surface under extreme temperature conditions by matching the micro-deformation of the flexible material inner layer 2, which is crucial for the precise assembly and long-term stable operation of the power battery system of new energy vehicles.

[0045] It should be noted that after the mica paper-based insulation board of this embodiment is formed, the buffer structure at the position of the array through-hole cannot be destroyed. Therefore, when the corresponding formed mica paper-based insulation board is subjected to secondary processing (such as cutting, punching, etc.), special attention should be paid to avoid directly acting on the array through-hole and the buffer structure area around it. For this reason, before the secondary processing, the processing area should be accurately measured and marked to ensure that the processing path is staggered from the position of the array through-hole or that the structure of the array through-hole area is removed at the position of the margin after leaving enough margin.

[0046] In summary, the mica paper-based insulation sheet for new energy vehicles in this embodiment achieves efficient insulation protection and performance improvement of new energy vehicle power batteries by adopting a series of innovative technical means such as multi-layer composite structure, array through-hole design, inert insulation medium filling, and nano-enhanced filler addition. The insulation sheet not only has excellent insulation performance, mechanical strength and durability, but also has the advantages of light weight and easy maintenance. It is an important innovative achievement to promote technological progress and safe development in the field of new energy vehicles.

[0047] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A mica paper-based insulation board for new energy vehicles, characterized in that: The mica substrate comprises a mica board substrate, which is formed by hot pressing and compounding multiple layers of impregnated mica paper, and an array of through holes is formed on the surface of the formed mica board substrate; the array of through holes is filled with a buffer structure; The buffer structure comprises an outer cylinder matching the outline size of the array through-holes, the cylinder height of the outer cylinder being 80-90% of the thickness of the mica board substrate, and being formed in the middle of the array through-holes in a gluing manner, the outer cylinder being sealed on both sides with a PVC film layer, and the cylinder cavity between the outer cylinder and the PVC film layer being filled with an inert insulating medium; The two side surfaces of the mica board substrate use impregnated nylon fabric mesh as a composite interface, and a composite surface layer is formed on the surface of the composite interface; the composite surface layer includes an inner layer of a flexible material formed with silicone rubber and an outer layer of a plastic material formed with polyimide or epoxy resin, and a layer of nano-reinforced filler is formed at the interface between the inner layer of the flexible material and the outer layer of the plastic material.

2. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The thickness of the mica board substrate accounts for 60% to 70% of the mica paper-based insulation board; and the overall thickness of the mica paper-based insulation board is controlled to be 8 to 20 mm, so as to ensure good processability and lightweight requirements while maintaining high strength and excellent insulation performance.

3. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The glue used for the impregnated mica paper used to prepare the mica board substrate is epoxy resin glue, and 1-3‰ anti-aging agent and 5-15‰ antioxidant are also added to the epoxy resin glue.

4. The mica paper-based insulating sheet material for new energy vehicles according to claim 3, characterized in that: The anti-aging agent is a compound mixture of butylated hydroxyanisole and butylated hydroxytoluene in a mass ratio of 1:1; and the antioxidant is a compound mixture of benzotriazole and ascorbic acid in a mass ratio of 2:

3.

5. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The impregnated mica paper used to prepare the mica board substrate is roughened on both sides, and an interface fiber mesh surface woven with high modulus fiber as raw material for interlayer reinforcement is formed between the two layers of impregnated mica paper that have been roughened.

6. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The array through holes are oblong holes, and the length direction of the oblong holes is arranged along the shear force resistance direction of the mica board substrate.

7. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The thickness ratio of the inner layer of the flexible material to the outer layer of the plastic material in the composite surface layer is 3:2 to 2:

1.

8. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: When the composite surface layer is formed, a rough concave-convex structure of micro-nano scale is first processed on one side surface of the inner layer of the flexible material by laser etching, and then nano-reinforced fillers are evenly sprayed on the surface of the rough concave-convex structure, and then the outer layer of the plastic material is overlapped and hot pressed, so that these nano-reinforced fillers, with their extremely small size and high specific surface area, can penetrate into the interior of the silicone rubber layer to form a reinforced interface.

9. The mica paper-based insulating sheet material for new energy vehicles according to claim 1, characterized in that: The inert insulating medium is an insulating gas medium or insulating oil; The insulating gas medium is an inert gas or sulfur hexafluoride, and the insulating oil is a mineral insulating oil or a synthetic ester insulating oil.

10. The mica paper-based insulation sheet for new energy vehicles according to claim 1, characterized in that: The inert insulating medium is filled with pressure in the cylinder cavity between the outer cylinder and the PVC film layer, so that the PVC film layers on both sides of the outer cylinder are attached to the inner surface of the inner layer of the flexible material of the composite surface layer.

Images