Flat cable assembly with rapid heat energy transfer function

Abstract

The utility model discloses a flat cable assembly with a rapid heat energy transfer function, which comprises a plurality of flat cable conductors arranged in parallel, a polyimide-fluoropolymer main insulation film layer and a rapid heat conduction layer, the polyimide-fluoropolymer main insulation film layer covers the surfaces of the flat cable conductors and among the flat cable conductors, and the rapid heat conduction layer is arranged on a heat dissipation path of the main insulation film layer, is connected with the main insulation film layer in a covering manner and is used for rapidly conducting out heat of the flat cable conductors. Through the above mode, the flat cable assembly is high in insulating strength, and under the condition of 10 GHz, the dielectric constant of the flat cable assembly is less than or equal to 2.9, and the dielectric loss tangent value is less than or equal to 0.0020; the peeling strength (90-degree peeling) is greater than or equal to 1200 N / m, and the flame retardant property reaches UL 94: V-0; and rapid cooling can be realized to avoid electrical fire, so that the flattened electrical equipment can work safely and reliably.

Description

Technical Field

[0001] The utility model relates to a flat cable assembly with a function of rapid heat energy transfer. Background Art

[0002] Flat cables (FFCs) offer new development opportunities for electrical architectures, and new energy electric vehicle architectures are at a critical transition. The rise of electric vehicles presents a significant architectural breakthrough, presenting an excellent opportunity to rethink electrical and electronic architecture design. At the same time, the substantial amount of existing content still present in hybrid and internal combustion engine vehicles makes innovative approaches equally important. The shift from 12V to 48V spans all vehicle types, providing an opportunity to re-examine the insulation structure, conductor material, heating issues, and connectors of the flat cables used throughout the process.

[0003] To support feature-rich, electrified vehicles, the industry is demanding unprecedented cabling and connectivity density. In this context, flat cables offer unique advantages, including weight reduction, size reduction, improved heat dissipation, and support for a higher degree of automation.

[0004] Flat cables are particularly important in modern zone-based architecture designs. By consolidating input / output connections, zone controllers simplify and optimize the wiring harness into a point-to-point architecture, enabling parallel power and signal connections to the central computing unit, distributed devices, and even other zone controllers. This reduces both the length and number of wires compared to traditional architectures.

[0005] Flat cables are also suitable for wiring harness designs in confined spaces, such as doors, seats, antennas, roof linings, front and rear aprons, windshield wiper heaters, electric rearview mirrors, headlights, and taillights.

[0006] Emerging applications for flat cables include power / data buses, flexible sensors connected directly to electronic control units (ECUs), camera de-icing and defogging systems, current collectors for electric vehicle batteries, and electric vehicle battery interconnect systems that integrate voltage sensing, temperature sensing, and fuse protection.

[0007] Existing flat cables are made from flexible copper-clad laminates. The conductors are insulated by extruding a thermoplastic insulating material, such as polyurethane, or laminating it with a covering material, such as polyethylene terephthalate. Subsequently, the copper is removed by masking and chemical etching using laser technology according to the desired pattern. A covering material with cutouts is then applied to expose the conductor contact areas. Flat cables with this structure suffer from the low dielectric strength and poor heat dissipation of the extruded thermoplastic insulation. Furthermore, flat cables are typically limited to 2 ounces of copper thickness and 1.2 meters in length, and the chemical etching process results in significant material waste. Utility Model Content

[0008] The main technical problem solved by the utility model is to provide a flat cable assembly with a function of rapid heat transfer, which can solve the problems of low current carrying capacity of the above-mentioned cables, low insulation strength of extruded thermoplastic insulation materials, large losses and poor self-heating.

[0009] To solve the above technical problems, the present invention adopts a technical solution: providing a flat cable assembly with a rapid heat transfer function, comprising: a plurality of parallel arranged flat cable conductors, a main insulating film layer of polyimide-fluoropolymer, and a rapid thermal conductivity layer. The main insulating film layer of polyimide-fluoropolymer is laminated on the surface of each flat cable conductor and between each flat cable conductor. The rapid thermal conductivity layer is arranged on the heat dissipation path of the main insulating film layer and is laminated and connected to the main insulating film layer to quickly conduct heat away from the flat cable conductors.

[0010] In a preferred embodiment of the present invention, the main insulating film layer of polyimide-fluoropolymer includes an upper film layer and a lower film layer arranged relative to the conductor, and the upper film layer and the lower film layer are fixedly connected by a welding layer to form a main insulating film layer covering the surface of each flat cable conductor and between each flat cable conductor.

[0011] In a preferred embodiment of the present invention, the rapid thermal conductive layer is a graphene rapid thermal conductive layer, which is laminated and connected to the main insulating film layer via a thermal conductive pressure-sensitive adhesive layer.

[0012] In a preferred embodiment of the present invention, the rapid heat-conducting layer quickly conducts heat away from the conductor through a heat sink or a heat-conducting housing.

[0013] The beneficial effects of the utility model are as follows: the utility model combines the polyimide-fluoropolymer insulation composite material and the graphene fast thermal conductive film, thereby improving the overall performance of the flat cable assembly, having high insulation strength. Under 10 GHz conditions, the dielectric constant of the flat cable assembly reaches ≤2.9, and the dielectric loss tangent value is ≤0.0020; the peel strength (90° peeling) is ≥1200 N / m, and the flame retardant performance reaches UL 94: V-0; it can quickly cool down to avoid electrical fires, so that flat electrical devices and equipment can operate safely and reliably. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work. Among them:

[0015] Figure 1 This is a structural diagram of a preferred embodiment of a flat cable assembly with a rapid heat transfer function according to the present invention;

[0016] Figure 2 yes Figure 1 A top view of a flat cable assembly showing the rapid transfer of heat energy;

[0017] Figure 3 yes Figure 1 Cross-sectional view of a flat cable assembly showing the rapid heat transfer function. DETAILED DESCRIPTION

[0018] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are also within the scope of protection of the present invention.

[0020] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0021] In the description of this utility model, it should be noted that the terms "front" and "rear" and the like indicate positions or locations based on the positions shown in the accompanying drawings, or the positions or locations in which the utility model product is typically placed when in use. These terms are intended solely to facilitate the description of this utility model and simplify the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" and the like are used solely for distinction and should not be construed as indicating or implying relative importance.

[0022] It should also be noted that, in the description of this utility model, unless otherwise expressly specified or limited, the terms "disposed" and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections, electrical connections; direct connections, indirect connections through an intermediate medium, and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this utility model based on the specific circumstances.

[0023] In the present invention, unless otherwise expressly specified or limited, a first feature being above or below a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being above, above, and above the second feature includes the first feature being directly above and obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being below, below, and below the second feature includes the first feature being directly below and obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0024] See also Figure 1 、 Figure 2 , the embodiments of the present utility model include:

[0025] A flat cable assembly with a rapid heat transfer function comprises: a plurality of parallel arranged flat cable conductors 1, a main insulating film layer 2 of a polyimide-fluoropolymer, and a rapid heat transfer layer 3. The main insulating film layer 2 of the polyimide-fluoropolymer is laminated on the surface of each flat cable conductor 1 and between each flat cable conductor 1. The rapid heat transfer layer 3 is arranged on the heat dissipation path of the main insulating film layer 2 and is laminated and connected to the main insulating film layer 2 to quickly transfer heat from the flat cable conductor 1.

[0026] Preferred embodiment, such as Figure 3 As shown, the main insulating film layer 2 of polyimide-fluoropolymer includes an upper film layer 21 and a lower film layer 22 arranged relative to the conductor 1. The upper film layer 21 and the lower film layer 22 are fixedly connected by a welding layer 23 to form a main insulating film layer 2 covering the surface of each flat cable conductor 1 and between each flat cable conductor 1.

[0027] The rapid thermal conductive layer 3 is a graphene-based rapid thermal conductive layer, laminated and connected to the main insulating film layer 1 via a thermally conductive pressure-sensitive adhesive layer 31. This layer 3 rapidly dissipates heat from the conductor via a heat sink or heat-conducting housing. This rapidly cools the flat cable, preventing electrical fires and ensuring safe and reliable operation of flattened electrical devices.

[0028] Among them, the composite film material used for the main insulating film layer 2 of polyimide-fluoropolymer is disclosed in the Chinese authorized utility model patent: CN111844976B, a polyimide-fluoropolymer insulating composite material, a preparation method and its application. Its main electrical performance parameters are: tensile strength ≥130 MPa, elongation at break ≥40%; film thickness 0.050 mm; withstand voltage strength ≥185 kV / mm; volume resistivity (23°C) ≥1×1016Ω·cm; and the composite system has strong adhesion.

[0029] The graphene fast thermal conductive layer is preferably a graphene fast thermal conductive film, and its main technical parameters are: thermal conductivity (W / (m·K)) ≥ 1300, specific heat capacity (W / (g·K)) 0.85; tensile strength (MPa) > 20; electrical conductivity (S / m) > 5×10 5 ; Bending test (R2, 180°, times) >2×10 5 ; Heat-resistant temperature 400℃.

[0030] A method for preparing a flat cable assembly with a rapid heat transfer function using the above-mentioned material comprises the following steps:

[0031] 1) Laying an upper insulating film and a lower insulating film in a special fixture, and placing the flat cable conductor between the two insulating films, wherein the upper insulating film and the lower insulating film are insulating films made of a polyimide-fluoropolymer composite material;

[0032] 2) When the hot pressing temperature of the hot pressing roller reaches the range of 170℃~178℃, the upper and lower insulating films are thermally laminated and bonded to the flat cable conductors. Due to the strong self-adhesion of the polyimide-fluoropolymer insulation composite material, a fusion layer is formed on the bonding surface of the upper and lower insulating films, ensuring that the surface of each flat cable conductor and the spaces between the flat cable conductors are covered with the main insulating film;

[0033] 3) After bonding and cooling, a quick thermal conductive sheet is bonded and laid on the insulating film on the larger outer surface of the flat cable conductor. The quick thermal conductive sheet is a graphene thermal conductive sheet; it is connected to the insulating film on the larger outer surface of the flat cable conductor through a thermal conductive pressure-sensitive adhesive to form a flat cable assembly with a rapid heat transfer function.

[0034] The flat cable assembly with rapid heat energy transfer function manufactured by the utility model has a dielectric constant of ≤2.9 and a dielectric loss tangent of ≤0.0020 under 10 GHz conditions; the peel strength (90° peeling) is ≥1200 N / m; welding thermal stress (288°C, 10s, 10 times): the flat cable assembly has no burn spots, surface resin loss, resin softening, delamination, blistering, white spots, cracking, or voids on both the front and back sides, both before and after etching; the linear expansion coefficient (CTE) of the flat cable assembly (50-250°C) is 24.01 ppm / °C (X direction) / 10.52 ppm / °C (Y direction); and the flame retardant performance reaches UL94: V-0.

[0035] In summary, the flat cable assembly with rapid heat transfer function of the present invention improves the convenience of use and operating efficiency, has high insulation strength and strong self-heating properties, can quickly cool the flat cable, avoid electrical fires, and ensure safe and reliable operation of flat electrical devices.

[0036] Based on the above characteristics, flat cable assemblies have a wide range of applications.

[0037] Flat cable assemblies make it possible to use thinner conductors while maintaining mechanical strength and durability, typically resulting in a 40% weight reduction and a 35% volume reduction in the overall harness system, including all related components such as connectors, clamps, and straps.

[0038] The unique structural design of flat cable assemblies is key to achieving these significant weight reductions. With traditional round cable, any size reduction is limited by the fact that the individual cables and their terminations must be able to withstand any stress or deformation experienced at the connection points and in the harness. In contrast, flat cables are constructed from multiple layers, a structure that not only provides strain relief but also ensures secure termination connections—enabling the use of smaller conductors in many applications.

[0039] Compared to round conductors, flat cables exhibit superior thermal performance. Specifically, flat cables have a larger surface area for a given volume, effectively facilitating heat dissipation, allowing the same conductor volume to carry higher currents.

[0040] Flat cable assemblies are particularly well-suited for applications with planar structures, such as those built into battery modules. Their high flexibility makes them ideal for applications with motion or small bend radii, such as in steering wheel airbags. Flat cable assemblies are secured with adhesives, eliminating the need for mechanical clamps and requiring no additional tape or protective layers, which are typically required to protect traditional wiring harnesses. In a vehicle, most devices require both power and signal connections. It is also possible to integrate power and signal lines into a single flat cable, serving as the "backbone" connecting the main computing devices in an intelligent vehicle architecture.

[0041] Flat cable assemblies offer a stable, fixed geometry and robust design, making them particularly well-suited for automated applications. This structure facilitates conductor handling and termination, particularly when inserting terminal plugs into connectors or soldering to pre-assembled terminals. Flat cables excel in modular connection systems and can effectively leverage the advantages of automation within such systems. Using a pressure-sensitive adhesive, flat cables can be precisely secured in place by robots.

[0042] Flat cable assemblies can also have various shapes, such as thin cylindrical, rectangular, special-shaped, etc., to adapt to different applications.

[0043] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A flat cable assembly with a function of rapid heat transfer, characterized in that: include: Several parallel arranged flat cable conductors, a main insulating film layer of polyimide-fluoropolymer and a fast thermal conductive layer. The main insulating film layer of polyimide-fluoropolymer is laminated on the surface of each flat cable conductor and between each flat cable conductor. The fast thermal conductive layer is arranged on the heat dissipation path of the main insulating film layer and is laminated and connected to the main insulating film layer to quickly conduct heat away from the flat cable conductor.

2. The flat cable assembly with rapid heat transfer function according to claim 1, characterized in that: The main insulating film layer of polyimide-fluoropolymer includes an upper film layer and a lower film layer arranged relative to the conductor. The upper film layer and the lower film layer are fixedly connected by a welding layer to form a main insulating film layer covering the surface of each flat cable conductor and between each flat cable conductor.

3. The flat cable assembly with a rapid heat transfer function according to claim 1, characterized in that: The rapid heat-conducting layer is a graphene rapid heat-conducting layer, which is laminated and connected to the main insulating film layer via a heat-conducting pressure-sensitive adhesive layer.

4. The flat cable assembly with rapid heat transfer function according to claim 1, characterized in that: The rapid heat-conducting layer quickly conducts heat away from the conductor through the heat sink or the heat-conducting housing.

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