Flexible mica composite strip for wire harness wrapping

Abstract

The utility model relates to the technical field of new energy automobile thermal runaway protection mica materials, in particular to a flexible mica composite strip for wire harness wrapping. The flexible mica composite strip for wire harness wrapping comprises a plurality of phlogopite tapes, and the plurality of phlogopite tapes are hot-pressed to form a flexible mica composite base band; a PI film is compounded on the surface of the flexible mica composite base band; carbon fiber gridding cloth is compounded in the flexible mica composite base band; the carbon fiber gridding cloth is positioned between the adjacent phlogopite tapes; an adhesive layer and a release film layer are sequentially compounded on the surface, back on to the PI film, of the flexible mica composite base band outwards. The flexible mica composite strip has good wear resistance, chemical solvent resistance, insulation breakdown resistance, flame retardance, fire resistance and electromagnetic interference resistance, thermal runaway protection performance, NVH performance and signal transmission stability performance of the new energy automobile can be improved, and meanwhile the wire harness wrapping cost of the new energy automobile is reduced.

Description

Technical Field

[0001] This application relates to the field of mica materials for thermal runaway protection in new energy vehicles, and in particular to a flexible mica composite tape for wire harness wrapping. Background Technology

[0002] Wire harness wrapping materials are mainly used for wrapping and assembling electrical wiring in automobiles. They maintain the cylindrical shape of the wires, prevent loosening, ensure the cables do not deform after cabling, enhance the cables' resistance to pressure, tension, and torsion, improve insulation performance, effectively prevent current leakage, and enhance cable safety. Traditional wire harness wrapping materials, such as nylon cable ties, PVC tape, and rubber tape (black tape), are suitable for conventional gasoline vehicles. However, for new energy vehicles with numerous cables and a wider range of electrical signal frequencies, traditional wrapping materials are insufficient. The wrapping environment of new energy vehicles places higher demands on wire harness wrapping materials, going beyond basic insulation functions to include thermal runaway protection, electromagnetic interference resistance, and especially flame retardant properties.

[0003] Emerging flexible mica tape can meet the insulation, flame retardant, and fireproofing requirements of wiring harness wrapping materials for new energy vehicles, and has already been applied to instrument panel wiring harness wrapping and battery module wiring harness wrapping in new energy vehicles. The flexible mica tape shell plays a role in insulation and flame retardancy in battery module wiring harness wrapping, and has been accepted by major new energy vehicle manufacturers. However, while flexible mica tape itself has good insulation and anti-electrical breakdown performance, its electromagnetic interference resistance and wave absorption performance are poor. In practice, traditional black tape is often used for initial wrapping, followed by reinforcement wrapping with flexible mica tape, which prolongs the battery module wiring harness wrapping process, increases wiring harness wrapping costs, and consequently raises the production cost of new energy vehicles.

[0004] In addition, flexible mica tape has poor wear resistance. When used for wrapping, friction between wire harnesses can easily cause powder shedding. This not only causes abnormal noise due to friction, leading to a decrease in the NVH performance of new energy vehicles, but also causes protective defects in the friction parts of the mica wire harness wrapping material, resulting in a decrease in mechanical properties and flame retardant and fireproof performance. Furthermore, the powder shedding due to friction can affect the heat dissipation environment of the battery cell module, leading to a decrease in the overall thermal runaway protection performance. Utility Model Content

[0005] To address the issues of deviations in electromagnetic interference resistance and wear resistance of existing flexible mica tapes, this application provides a flexible mica composite tape for wire harness wrapping.

[0006] The flexible mica composite tape for wire harness wrapping provided in this application is achieved through the following solution:

[0007] A flexible mica composite tape for wire harness wrapping includes several phlogopite mica tapes, which are hot-pressed to form a flexible mica composite base tape. A PI film is laminated on the surface of the flexible mica composite base tape. A carbon fiber mesh is laminated inside the flexible mica composite base tape. The carbon fiber mesh is located between adjacent phlogopite mica tapes. An adhesive layer and a release film layer are laminated sequentially outward on the surface of the flexible mica composite base tape facing away from the PI film.

[0008] The flexible mica composite tape in this application has good wear resistance, chemical solvent resistance, insulation and breakdown resistance, flame retardancy and fire resistance and electromagnetic interference resistance. It can improve the thermal runaway protection performance, NVH performance and signal transmission stability of new energy vehicles, while reducing the wiring harness wrapping cost of new energy vehicles.

[0009] Preferably, the thickness of the phlogopite tape is 75-80 μm or 150-160 μm.

[0010] In this application, the use of commercially available 75-80μm or 150-160μm phlogopite tape can reduce the overall production cost of flexible mica composite tape.

[0011] Preferably, the PI film thickness is 20 μm, 25 μm, 40 μm, or 50 μm.

[0012] The use of commercially available standard-thickness PI film in this application ensures the overall flame retardant and fireproof performance, tensile mechanical strength, tear strength, and abrasion resistance of the flexible mica composite tape.

[0013] Preferably, the carbon fiber mesh is a plain weave with a mesh size of 0.5mm*0.5mm, 1mm*1mm, 2mm*2mm, 3mm*3mm, 4mm*4mm, or 5mm*5mm.

[0014] The carbon fiber mesh fabric with a mesh structure in this application ensures the overall flame burn-through resistance, electromagnetic interference resistance, tensile mechanical strength, tear strength, and abrasion resistance of the flexible mica composite tape, while also ensuring the interlayer bonding strength and bonding stability between the carbon fiber mesh fabric and the phlogopite tape.

[0015] Preferably, the warp and weft threads in the carbon fiber mesh are both 1K T300 carbon fiber yarn.

[0016] More preferably, the outer wall of the 1K T300 carbon fiber yarn is formed with an aluminum plating layer of 20-500nm thickness by electroplating, plasma spraying, chemical vapor deposition, or vacuum evaporation.

[0017] More preferably, the outer wall of the 1K T300 carbon fiber yarn is formed with a copper plating layer of 20-500nm thickness by electroplating, plasma spraying, chemical vapor deposition, or vacuum evaporation.

[0018] More preferably, the outer wall of the 1K T300 carbon fiber yarn is formed with a nickel plating layer of 20-500nm thickness by electroplating nickel, plasma spraying nickel plating, chemical vapor deposition, or vacuum evaporation.

[0019] The aforementioned aluminum-plated 1K T300 carbon fiber yarn, copper-plated 1K T300 carbon fiber yarn, and nickel-plated 1K T300 carbon fiber yarn can further improve the overall electromagnetic interference resistance of the flexible mica composite strip.

[0020] More preferably, the thickness of the phlogopite tape is 75-80 μm; the thickness of the PI film is 40 μm; the flexible mica composite base tape is formed by hot pressing n phlogopite tapes, where n is 2, 3, or 4; the flexible mica composite base tape contains n-1 carbon fiber mesh fabrics hot-pressed together, the mesh size of which is 1 mm * 1 mm; each carbon fiber mesh fabric is composited between adjacent phlogopite tapes.

[0021] Preferably, the thickness of the adhesive layer is 5-50 μm.

[0022] Preferably, the adhesive layer is a silicone pressure-sensitive adhesive layer, which can ensure the overall heat resistance and flame retardancy, and reduce the friction noise between the wire harness and the adhesive layer, thus playing a role in buffering and shock absorption and protecting the wrapped wire harness.

[0023] In summary, this application has the following advantages:

[0024] 1. The flexible mica composite tape in this application has good wear resistance, chemical solvent resistance, insulation and breakdown resistance, flame retardancy and fire resistance and electromagnetic interference resistance, which can improve the thermal runaway protection performance, NVH performance and signal transmission stability of new energy vehicles.

[0025] 2. The flexible mica composite tape in this application can be wound and formed in one step, which can reduce the cost of wire harness wrapping.

[0026] 3. The carbon fiber mesh fabric introduced in this application can not only improve the electromagnetic interference resistance, but also improve the overall mechanical properties, flexibility and flame burn-through resistance of the flexible mica composite strip, which can further enhance the thermal runaway protection performance of new energy vehicles.

[0027] 4. The adhesive layer in this application preferably uses silicone pressure-sensitive adhesive, which can ensure the overall heat resistance and flame retardancy, and reduce the friction noise between the wire harness and the adhesive layer, thereby playing a role in buffering and shock absorption and protecting the wrapped wire harness. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the flexible mica composite tape used for wire harness wrapping in Example 1.

[0029] Figure 2 This is a schematic diagram of the structure of aluminum-plated 1K T300 carbon fiber yarn in the embodiment.

[0030] Figure 3 This is a schematic diagram of the structure of copper-plated 1K T300 carbon fiber yarn in the embodiment.

[0031] Figure 4 This is a schematic diagram of the structure of nickel-plated 1K T300 carbon fiber yarn in the embodiment.

[0032] Figure 5 This is a schematic diagram of the overall structure of the flexible mica composite tape used for wire harness wrapping in Example 2.

[0033] In the figure, 1 is phlogopite mica tape; 10 is flexible mica composite base tape; 2 is PI film; 3 is carbon fiber mesh cloth; 30 is 1K T300 carbon fiber yarn; 301 is aluminum plating layer; 302 is copper plating layer; 303 is nickel plating layer; 4 is adhesive layer; and 5 is release film layer. Detailed Implementation

[0034] The present application will be further described in detail below with reference to the accompanying drawings and embodiments.

[0035] Example: Refer to Figure 1 A flexible mica composite tape for wire harness wrapping includes several phlogopite mica tapes 1, a PI film 2, and a carbon fiber mesh 3. The phlogopite mica tapes 1 are hot-pressed to form a flexible mica composite base tape 10, and the carbon fiber mesh 3 is hot-pressed onto adjacent phlogopite mica tapes 1 within the flexible mica composite base tape 10. The PI film 2 is laminated to one surface of the flexible mica composite base tape 10, and an adhesive layer 4 and a release film layer 5 are sequentially laminated to the other surface of the flexible mica composite base tape 10.

[0036] Phlogopite tape 1 comes in two thicknesses: one is 75-80μm thick, and the other is 150-160μm thick. Both of these thicknesses are commercially available standard products and can reduce the overall production cost of flexible mica composite tapes.

[0037] Commercially available polyimide (PI) films are available in thicknesses of 5.0 μm, 7.5 μm, 13 μm, 20 μm, 25 μm, 40 μm, 50 μm, 75 μm, 100 μm, and 125 μm. However, PI films with thicknesses of 75 μm, 100 μm, and 125 μm can negatively impact the overall thickness of the flexible mica composite tape and are also more expensive. Therefore, the thickness of the PI film 2 (polyimide film) in this application is selected as 20 μm, 25 μm, 40 μm, or 50 μm. Preferably, the PI film 2 has a thickness of 40 μm, and such films are sold by companies such as Suzhou Jiusimeng Electronic Materials Co., Ltd., Shenzhen Ruihuatai Thin Film Technology Co., Ltd., and Zhuzhou Shidai Huaxin New Material Technology Co., Ltd.

[0038] Carbon fiber mesh fabric 3 is a plain weave carbon fiber mesh fabric woven from 1K T300 carbon fiber yarn 30 as warp and weft threads using a carbon fiber braiding machine. The mesh size of this carbon fiber mesh fabric 3 is 0.5mm*0.5mm, 1mm*1mm, 2mm*2mm, 3mm*3mm, 4mm*4mm, or 5mm*5mm. It should be noted that a smaller mesh size results in relatively lower bonding strength and stability between the carbon fiber mesh fabric 3 and the phlogopite mica tape 1, but it can impart relatively better electromagnetic interference resistance to the flexible mica composite tape. Considering all factors, a 1mm*1mm mesh size for the fiber mesh fabric 3 is preferable.

[0039] 1K T300 carbon fiber yarn 30 can be selected from 1K T300 carbon fiber yarn sold in Toray Industries.

[0040] refer to Figure 2 In order to obtain better electromagnetic interference resistance, 1K T300 carbon fiber yarn 30 is formed with an aluminum coating layer 301 of varying thickness from 20 to 500 nm by existing aluminum plating processes such as electroplating, plasma spraying, chemical vapor deposition, or vacuum evaporation. The resulting carbon fiber yarn is aluminum-plated 1K T300 carbon fiber yarn.

[0041] refer to Figure 3 In order to obtain better electromagnetic interference resistance, 1K T300 carbon fiber yarn 30 is formed with a copper plating layer 302 of varying thickness from 20 to 500 nm by existing copper plating processes such as electroplating, plasma spraying, chemical vapor deposition, or vacuum evaporation. The resulting carbon fiber yarn is copper-plated 1K T300 carbon fiber yarn.

[0042] refer to Figure 4 In order to obtain better electromagnetic interference resistance, 1K T300 carbon fiber yarn 30 is formed with a nickel plating layer 303 of varying thickness from 20 to 500 nm by existing nickel plating processes such as electroplating nickel, plasma spraying nickel plating, chemical vapor deposition or vacuum evaporation. The resulting carbon fiber yarn is nickel-plated K T300 carbon fiber yarn.

[0043] To achieve better electromagnetic interference resistance, the warp and weft threads in the carbon fiber mesh fabric 3 can be selected from commercially available nickel composite carbon fiber, copper composite carbon fiber, and copper-nickel composite carbon fiber. The aforementioned nickel composite carbon fiber, copper composite carbon fiber, and copper-nickel composite carbon fiber are all available in specific models from the Advanced Institute of Technology (Shenzhen).

[0044] For the adhesive layer 4, either acrylic pressure-sensitive adhesive or silicone pressure-sensitive adhesive can be used, with silicone pressure-sensitive adhesive being preferred. On the one hand, it has better adhesion to phlogopite tape, and on the other hand, it can reduce friction noise between the wire harness and the adhesive layer while ensuring overall heat resistance and flame retardancy, thus playing a role in buffering, shock absorption, and protecting the wrapped wire harness.

[0045] When the thickness of the phlogopite tape 1 is 75-80 μm and the thickness of the PI film 2 is 40 μm, the flexible mica composite base tape 10 is formed by hot pressing n phlogopite tapes 1, where n is 2, 3, or 4. The flexible mica composite base tape 10 also contains n-1 carbon fiber mesh fabrics 3, or at least one type of carbon fiber mesh fabric 3. The mesh size of the carbon fiber mesh fabric 3 is 1 mm * 1 mm. The carbon fiber mesh fabric 3 is a plain weave carbon fiber mesh fabric woven from 1KT300 carbon fiber yarn 30 as warp and weft threads using a carbon fiber weaving machine. A single carbon fiber mesh fabric 3 is composited between adjacent phlogopite tapes 1.

[0046] Example 1: Reference Figure 1 When the thickness of the phlogopite tape 1 is 75-80 μm and the thickness of the PI film 2 is 40 μm, the flexible mica composite base tape 10 is formed by hot pressing three phlogopite tapes 1. Two carbon fiber mesh fabrics 3 are hot-pressed into the flexible mica composite base tape 10. The mesh size of the carbon fiber mesh fabric 3 is 1 mm * 1 mm. The carbon fiber mesh fabric 3 is a plain weave carbon fiber mesh fabric woven with 1K T300 carbon fiber yarn 30 as warp and weft threads using a carbon fiber braiding machine. A single carbon fiber mesh fabric 3 is composited between adjacent phlogopite tapes 1. The structure of the prepared flexible mica composite tape for wire harness wrapping is as follows: PI film 2 / phlogopite tape 1 / carbon fiber mesh fabric 3 / phlogopite tape 1 / carbon fiber mesh fabric 3 / phlogopite tape 1 / adhesive layer 4 / release film layer 5.

[0047] The difference between Example 2 and Example 1 is that: (Refer to...) Figure 5When the thickness of the phlogopite tape 1 is 150-160 μm and the thickness of the PI film 2 is 40 μm, the flexible mica composite base tape 10 is formed by hot pressing two phlogopite tapes 1. A carbon fiber mesh 3 is hot-pressed into the flexible mica composite base tape 10. The carbon fiber mesh 3 has a mesh size of 1 mm * 1 mm and is a plain weave carbon fiber mesh 3 woven from aluminum-coated 1K T300 carbon fiber yarn as warp and weft threads using a carbon fiber braiding machine. A single carbon fiber mesh 3 is composited between adjacent phlogopite tapes 1. The structure of the prepared flexible mica composite tape for wire harness wrapping is as follows: PI film 2 / phlogopite tape 1 / carbon fiber mesh 3 / phlogopite tape 1 / adhesive layer 4 / release film layer 5.

[0048] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A flexible mica composite tape for harness wrap-around, characterized by: The system includes several phlogopite mica strips (1), which are hot-pressed to form a flexible mica composite substrate (10); the surface of the flexible mica composite substrate (10) is coated with a PI film (2); the flexible mica composite substrate (10) is coated with a carbon fiber mesh (3); the carbon fiber mesh (3) is located between adjacent phlogopite mica strips (1); the surface of the flexible mica composite substrate (10) facing away from the PI film (2) is coated with an adhesive layer (4) and a release film layer (5) sequentially coated outwards.

2. A flexible mica composite tape for wire harness wrapping as claimed in claim 1, wherein: The thickness of the phlogopite tape (1) is 75-80 μm or 150-160 μm.

3. A flexible mica composite tape for wire harness wrapping as claimed in claim 1, wherein: The thickness of the PI film (2) is 20 μm, 25 μm, 40 μm, or 50 μm.

4. The flexible mica composite tape for wire harness wrapping of claim 1, wherein: The carbon fiber mesh (3) is a plain weave with mesh sizes of 0.5mm*0.5mm, 1mm*1mm, 2mm*2mm, 3mm*3mm, 4mm*4mm, or 5mm*5mm.

5. A flexible mica composite tape for use in wiring harness wrap according to claim 4, characterized in that: The warp and weft threads in the carbon fiber mesh fabric (3) are both 1K T300 carbon fiber yarn (30).

6. A flexible mica composite tape for wire harness wrapping according to claim 5, characterized in that: The outer wall of the 1KT300 carbon fiber yarn (30) is formed with an aluminum layer (301) with a thickness of 20-500nm by electroplating aluminum, plasma spraying aluminum, chemical vapor deposition or vacuum evaporation.

7. A flexible mica composite tape for wire harness wrapping as claimed in claim 5, wherein: The outer wall of the 1KT300 carbon fiber yarn (30) is formed with a copper plating layer (302) with a thickness of 20-500nm by electroplating copper, plasma spraying copper plating, chemical vapor deposition or vacuum evaporation.

8. A flexible mica composite tape for loom wrapping according to any one of claims 5-7, characterized in that: The thickness of the phlogopite tape (1) is 75-80μm; the thickness of the PI film (2) is 40μm; the flexible mica composite base tape (10) is formed by hot pressing n phlogopite tapes (1), where n is 2, 3 or 4; the flexible mica composite base tape (10) contains n-1 carbon fiber mesh fabrics (3) hot-pressed in it, and the mesh size of the carbon fiber mesh fabrics (3) is 1mm*1mm; a single carbon fiber mesh fabric (3) is composited between adjacent phlogopite tapes (1).

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