Insulated wire

Abstract

This application discloses an insulated wire, which includes a conductor, a high-temperature resistant layer, and an insulating protection layer. The high-temperature resistant layer includes a first insulating layer and / or a second insulating layer. The high-temperature resistant layer covers the conductor, and the insulating protection layer covers the high-temperature resistant layer. By improving the structure of the wire, this application can effectively avoid insulation failures and improve the high-temperature resistance and insulation of the wire.

Description

Cross - reference to related applications

[0001] This application claims the priority of a Chinese patent application with the application number 202210895228.6 and the invention title "Insulated Conductor", which was filed with the Chinese Patent Office on July 27, 2022, and the entire content of which is incorporated herein by reference.

Technical field

[0002] This application relates to the technical field of flat conductors, and particularly to insulated conductors.

Background art

[0003] With the rapid development of the new - energy vehicle industry, the battery pack, which is the power output source of new - energy vehicles, has also been continuously developing. Its requirements for low cost, small volume, high power, safety, stability, etc. have led to technological innovations in various components.

[0004] Currently, busbars for power battery connection are being more and more widely applied, and the application trend is also developing towards the trend of integral bending and forming. Its advantages are easy processing, high production efficiency, and low cost. Currently, the mainstream connecting conductors are those with the outside of flat conductors coated with a single - layer insulating plastic such as PA plastic. The long - term use temperature of most plastics is 125°C or lower. This temperature is sufficient within the normal operating temperature range of battery packs. However, in some extreme application scenarios, and ultimately when the battery fails, the temperature far exceeds 125°C and reaches 300 - 500°C in the short term. The plastic coating the conventional busbar will quickly melt and lose its insulation protection ability at this high temperature. Therefore, ensuring that the connecting conductor can be insulated without failure in this high - temperature environment is an important indicator related to the safety of new - energy vehicles.

[0005] In order to solve the problem of short-term high-temperature resistance of single-layer insulating plastic, in the prior art, some design proposals for optimizing busbars for battery connection are to insulate by manually winding one layer of mica tape on the conductor. By using mica tape, certain high-temperature resistance and insulation effect can be achieved. However, since the mica tape is on the outermost layer of the conductor, during long-term use, scratches, friction and liquid erosion may occur on the conductor, which easily leads to insulation failure.

Summary of the Invention

Problems to be Solved by the Invention

[0006] The main object of the present application is to provide an insulated wire for improving the high-temperature resistance and insulation of the conductor.

Means for Solving the Problems

[0007] To achieve the above object, the present application provides a conductor, a high-temperature resistant layer having a first insulating layer and / or a second insulating layer and covering the conductor, and an insulating protection layer covering the high-temperature resistant layer, and provides an insulated wire.

[0008] Optionally, the first insulating layer includes at least one layer of adhesive tape, the material of the adhesive tape is polyimide or ceramic silicon, the thickness of each layer of the adhesive tape is 10um - 100um, and the thickness of the first insulating layer is 20um - 300um.

[0009] Optionally, the second insulating layer is a mica tape, and the thickness of the mica tape is 0.10mm - 1.0mm.

[0010] Optionally, the material of the mica tape is phlogopite tape, fired muscovite tape, coated or gel mica tape, synthetic mica tape or ceramic composite mica tape.

[0011] Optionally, the number of the insulating protection layers is at least one layer, the material of the insulating protection layer is a polymer plastic, or the insulating protection layer is a heat-shrinkable tube, and the thickness of the insulating protection layer is 0.2 mm to 2.0 mm.

[0012] Optionally, the polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI.

[0013] Optionally, the heat-shrinkable tube is a fluororubber heat-shrinkable tube, a Teflon (registered trademark) heat-shrinkable tube, an FEP heat-shrinkable tube, a PTFE heat-shrinkable waterproof tube, a PVDF heat-shrinkable tube, a PET heat-shrinkable tube, a PE heat-shrinkable tube, a PVC heat-shrinkable tube, a polyvinylidene fluoride heat-shrinkable tube, a polytetrafluoroethylene heat-shrinkable tube, a silica gel heat-shrinkable tube, a chemically cross-linked polyolefin heat-shrinkable tube, a polyester heat-shrinkable tube.

[0014] Optionally, the conductor is flat, the material of the conductor is copper, brass, aluminum or a combination thereof, or the material of the conductor is a non-metal conductor, the width of the conductor is 10 mm to 50 mm, and the thickness is 1.0 mm to 7.0 mm.

[0015] Optionally, the conductor further includes an electroplated layer electroplated on the conductor, the material of the electroplated layer is nickel, tin, silver or copper, and the thickness of the electroplated layer is 2 μm to 15 μm.

[0016] Optionally, chamfers are provided on both sides of the conductor, and the chamfers are full-circle chamfers or chamfers with a radius of 0.5 mm to 3.5 mm.

[0017] In the technical solution of the present application, the conducting wire includes a conductor, a high-temperature resistant layer, and an insulating protection layer. The high-temperature resistant layer includes a first insulating layer and / or a second insulating layer. The high-temperature resistant layer covers the conductor, and the insulating protection layer covers the high-temperature resistant layer. Among them, the outermost insulating protection layer can exhibit moisture-proof, scratch-resistant, and certain insulating and high-temperature resistant properties, meeting the conductive insulation requirements during normal connection of the battery. On the other hand, the high-temperature resistant layer has high insulation, high-temperature resistance, and flame retardancy. When the battery operates in an extreme state, the high-temperature resistant layer can effectively avoid insulation failures of the conducting wire, improve high-temperature resistance and insulation, play a role in protecting the battery, and further ensure the personal safety of the driver of the vehicle in extreme situations.

[0018] To more clearly explain the technical solutions in the embodiments or the prior art of the present application, the following briefly introduces the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present application, and those skilled in the art can also obtain other drawings based on the structures shown in these drawings without creative labor.

Brief Description of the Drawings

[0019]

Figure 1

Figure 2

[0020] The realization of the object, functional features, and advantages of the present application will be further described with reference to the embodiments and the drawings.

Modes for Carrying Out the Invention

[0021] Hereinafter, with reference to the drawings of the embodiments of the present application, the technical solutions of the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are some embodiments of the present application, not all embodiments. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative labor belong to the protection scope of the present application.

[0022] In addition, when the embodiments of the present application mention direction indications (for example, up, down, left, right, front, back...), the direction indications are only used to interpret the relative positional relationship between each member and the movement situation in a specific posture (refer to the illustration). When the specific posture changes, the direction indications will change accordingly.

[0023] Also, in the embodiments of the present application, when there are descriptions including "first", "second", etc., it should be understood that the descriptions such as "first" and "second" are only used for the purpose of description, and do not indicate or imply their relative importance or implicitly indicate the number of technical features indicated. Therefore, the features limited by "first" and "second" may explicitly or implicitly include at least one of the features. Also, the meaning of "and / or" that appears throughout the specification is to include three parallel schemes. Taking "A and / or B" as an example, it includes the A scheme, or the B scheme, or the scheme where A and B are satisfied simultaneously. Also, as long as those skilled in the art can achieve it, the technical solutions of each embodiment can be combined with each other. However, when the combinations of technical solutions conflict with each other or cannot be realized, such combinations of technical solutions do not exist and are considered not within the protection scope claimed by the present application.

[0024] The present application proposes an insulated wire, and in particular, a high-temperature resistant insulated flat wire for an automotive power battery, which may be a round wire and is not limited here.

[0025] Referring to FIGS. 1 and 2, FIG. 1 is a schematic structural diagram of a wire in an embodiment of the present application, and FIG. 2 is a schematic structural diagram of the wire in a bent state in an embodiment of the present application. It is a connecting wire 100 for a power battery, and the wire 100 is provided in a flat shape. Mainly referring to FIG. 1, in an embodiment of the present application, the wire 100 includes a conductor 10, a high-temperature resistant layer 20, and an insulating protection layer 30. The high-temperature resistant layer 20 includes a first insulating layer 21 and / or a second insulating layer 22. The high-temperature resistant layer 20 covers the conductor 10, and the insulating protection layer 30 covers the high-temperature resistant layer 20.

[0026] In this embodiment, the material of the conductor 10 may be a conductive material such as copper, aluminum, brass, graphite, or graphene, or a combination of two materials, or a structure of copper-coated aluminum may be adopted, without limitation here.

[0027] For the copper conductor material, grades T2 and TU2 can be selected, and the material standard shall conform to GB / T 5231, or grades C1100 and C1020 can be adopted, and the material standard shall conform to JIS H3100, or grades Cu-ETP (CW004A) and Cu-OF (CW008A) can be adopted, and the material standard shall conform to DIN-EN-13599. For the aluminum conductor material, the material grade can be an aluminum strip of the Al-1000 series (typical grade 1060) or an aluminum strip of the Al-6000 series (typical grade 6101), and the material standard shall conform to GB / T 3190.

[0028] In this embodiment, the material of the first insulating layer 21 is a high-temperature resistant insulating material such as polyimide or ceramic silicon. The second insulating layer 22 may be a mica tape, and the material of the mica tape may be a high-temperature resistant insulating material such as a phlogopite tape, a fired muscovite tape, a coated or gel mica tape, a synthetic mica tape, or a ceramic composite mica tape, without limitation here.

[0029] Note that the high-temperature resistant layer 20 may include the first insulating layer 21 and / or the second insulating layer 22. That is, this embodiment has three types of solutions: 1. The high-temperature resistant layer 20 includes only the first insulating layer 21. 2. The high-temperature resistant layer 20 includes only the second insulating layer 22. 3. The high-temperature resistant layer 20 includes the first insulating layer 21 and the second insulating layer 22. Among them, when the first insulating layer 21 and the second insulating layer 22 exist simultaneously, the coating order is exchangeable, and the first insulating layer 21 may be coated first, or the second insulating layer 22 may be coated first.

[0030] In the technical solution of the present application, the conductor wire 100 includes a conductor 10, a high-temperature resistant layer 20, and an insulating protection layer 30. The high-temperature resistant layer 20 includes a first insulating layer 21 and / or a second insulating layer 22. The high-temperature resistant layer 20 covers the conductor 10, and the insulating protection layer 30 covers the high-temperature resistant layer 20. As can be understood, the outermost insulating protection layer 30 can exhibit moisture resistance, scratch resistance, and certain insulation and high-temperature resistance, satisfying the conductive insulation application during normal connection of the battery. On the other hand, the high-temperature resistant layer 20 has high insulation, high-temperature resistance, and flame retardancy. When the battery operates in an extreme state, the high-temperature resistant layer 20 can effectively avoid insulation failure of the conductor wire 100, improve high-temperature resistance and insulation, play a role in protecting the safety of the battery, and further ensure the personal safety of the driver of the vehicle in extreme situations.

[0031] To further improve the high-temperature resistance, flame retardancy, and insulation of the conductor wire 100 and facilitate production and manufacturing, referring to FIG. 1, in one embodiment, the first insulating layer 21 may include at least one layer of adhesive tape. The material of the adhesive tape is polyimide or ceramic silicon. The total thickness of the first insulating layer 21 may be 20um to 300um, which is not limited herein.

[0032] In this embodiment, the thickness of each layer of adhesive tape may be 10um to 100um, which is not limited herein.

[0033] During production, machines such as a horizontal double-head lapping machine can be employed. The conductor 10 can be covered with adhesive tape by an automatic lapping method, and a layer of polyimide insulating layer can be hot-pressed onto the conductor 10 by an extrusion method. The specific coating method is not limited herein. When a horizontal double-head lapping machine is employed, the lapping speed may be set to 2m / min to 15m / min to ensure that the processed semi-finished product meets the quality requirements.

[0034] To further improve the high-temperature resistance, fire resistance, and insulation of the conductor wire 100, referring to FIG. 1, in one embodiment, the second insulating layer 22 may be mica tape. The thickness of the mica tape may be 0.10mm to 1.0mm, which is not limited herein.

[0035] In this embodiment, the material of the mica tape may be phlogopite tape, synthetic mica tape, ceramic composite mica tape, etc., and is not limited herein.

[0036] In this embodiment, a machine such as a horizontal double-head wrapping machine can also be adopted for the mica tape, and the conductor 10 or the first insulating layer 21 is coated with the mica tape by an automatic wrapping method. Among them, when a horizontal double-head wrapping machine is adopted, the wrapping speed may be set to 2 m / min to 15 m / min in order for the processed semi-finished product to meet the quality requirements.

[0037] Referring to FIG. 1, in the embodiment, the number of the insulating protection layers 30 is at least one layer, the material of the insulating protection layer 30 is a polymer plastic, or the insulating protection layer 30 is a heat-shrinkable tube, and the thickness of the insulating protection layer 30 may be 0.2 mm to 2.0 mm.

[0038] In this embodiment, the polymer plastic may be PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE, PI, etc., and is not limited herein.

[0039] In this embodiment, the heat-shrinkable tube may be a fluororubber heat-shrinkable tube, a Teflon (registered trademark) heat-shrinkable tube, an FEP heat-shrinkable tube, a PTFE heat-shrinkable waterproof tube, a PVDF heat-shrinkable tube, a PET heat-shrinkable tube, a PE heat-shrinkable tube, a PVC heat-shrinkable tube, a polyvinylidene fluoride heat-shrinkable tube, a polytetrafluoroethylene heat-shrinkable tube, a silica gel heat-shrinkable tube, a chemically cross-linked polyolefin heat-shrinkable tube, a polyester heat-shrinkable tube, etc., and is not limited herein.

[0040] As can be understood, by providing the insulating protection layer 30 on the high-temperature resistant layer 20, certain moisture-proof, scratch resistance, insulation and high-temperature resistance can be exerted, liquid erosion to the high-temperature resistant layer 20 can also be avoided, thereby avoiding insulation failure.

[0041] In this embodiment, the polymer plastic can coat the semi-finished conductor wire by the hot melt extrusion coding method. According to the melting point of the plastic and the properties of the material, the temperature range of the processing temperature is 150~450°C, and it can assist the entire process of unwinding, aligning, pulling, extruding, cooling and winding. The extrusion speed may be set to 2m / min~15m / min. The plastic layer may be single-layer or multi-layer, and is not limited here.

[0042] Referring to FIG. 1, in one embodiment, the material of the conductor 10 may be a metal conductor such as copper, brass, aluminum or a combination thereof, or may be a non-metal conductor such as graphite or graphene. The width of the conductor 10 may be 10mm~50mm, the thickness may be 1.0mm~7.0mm, and the tolerance of the width of the conductor 10 may be ±0.15mm, and is not limited here.

[0043] Optionally, in order to improve the corrosion resistance of the conductor 10 and improve the conductivity of the conductor 10, the wire 100 may further include an electroplated layer electroplated on the conductor 10. The material of the electroplated layer may be nickel, tin, silver or copper, etc. The thickness of the electroplated layer may be 2um~15um, and is not limited here.

[0044] In production and manufacturing, copper rod or aluminum rod materials can be used, and an extruder, a stretcher, an electroplating line, etc. can be adopted, and the conductor 10 can be processed by the extrusion molding method.

[0045] Also, in some embodiments, the two side edges of the conductor 10 may be chamfered, may be rounded chamfered, or may be R chamfered, and the radius may be 0.5mm~3.5mm. Thereby, the coding becomes easy, and it is also possible to avoid the sharp edge from cutting the insulating layer, and the service life of the wire 100 is extended.

[0046] In the comparative test, multiple flat conductors 100 were selected as test samples. All of their structures adopted the combination of a conductor 10, a first insulating layer 21, a second insulating layer 22, and an insulating protection layer 30. Among them, the material of the first insulating layer 21 was selected from polyimide or ceramic silicon, and the material of the second insulating layer 22 was selected as mica tape. Multiple conventional general flat wire materials were selected as comparative samples, and their structures consisted of a flat conductor and a single insulating layer, or an insulating combination of a flat conductor and a layer of mica tape. The specific test results are as shown in Table 1 below.

[0047]

Table 1

[0048] As can be seen from the comparative test, compared with conventional general wire materials, the conductor 100 of the present application has higher flame retardancy, heat resistance, and water resistance than the comparative samples. Among them, the flame retardancy level can reach UL94-V0. Under the test conditions of a temperature of 500 °C, after a 1-hour high-temperature test, it passed the insulation withstand voltage test. The surface of the conductor 10 can withstand water, and after a 1-hour immersion test, it passed the underwater insulation withstand voltage test.

[0049] The above are only selectable embodiments of the present application and do not limit the patent scope of the present application. Without departing from the inventive concept of the present application, equivalent structural deformations made using the content of the specification and drawings of the present application, or direct / indirect applications in other related technical fields are all included in the patent protection scope of the present application.

Description of Reference Numerals

[0050] 100 Conductor 10 Conductor 20 High-temperature resistant layer 30 Insulating protection layer 21 First insulating layer 22 Second insulating layer

Claims

1. An insulated wire, comprising: a conductor; a high-temperature resistant layer provided with a first insulating layer and / or a second insulating layer and covering the conductor; an insulating protective layer covering the high-temperature resistant layer. The insulated wire is characterized by the above.

2. The first insulating layer includes at least one layer of adhesive tape. The material of the adhesive tape is polyimide or ceramic silicon. The thickness of each layer of the adhesive tape is 10 μm to 100 μm, and the thickness of the first insulating layer is 20 μm to 300 μm. The wire according to claim 1, characterized by the above.

3. The second insulating layer is a mica tape, and the thickness of the mica tape is 0.10 mm to 1.0 mm. The wire according to claim 1, characterized by the above.

4. The material of the mica tape is phlogopite tape, fired muscovite tape, coated or gel mica tape, synthetic mica tape or ceramic composite mica tape. The wire according to claim 3, characterized by the above.

5. The number of the insulating protective layers is at least one layer. The material of the insulating protective layer is a polymer plastic, or the insulating protective layer is a heat shrinkable tube. The thickness of the insulating protective layer is 0.2 mm to 2.0 mm. The wire according to claim 4, characterized by the above.

6. The polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI. The wire according to claim 5, characterized by the above.

7. The heat shrinkable tube is a fluororubber heat shrinkable tube, Teflon (registered trademark) heat shrinkable tube, FEP heat shrinkable tube, PTFE heat shrinkable waterproof tube, PVDF heat shrinkable tube, PET heat shrinkable tube, PE heat shrinkable tube, PVC heat shrinkable tube, polyvinylidene fluoride heat shrinkable tube, polytetrafluoroethylene heat shrinkable tube, silica gel heat shrinkable tube, chemically cross-linked polyolefin heat shrinkable tube or polyester heat shrinkable tube. The wire according to claim 5, characterized by the above.

8. The wire is flat. The material of the conductor is copper, brass, aluminum or a combination thereof, or the material of the conductor is a non-metal conductor. The width of the conductor is 10 mm to 50 mm, and the thickness is 1.0 mm to 7.0 mm. The wire according to any one of claims 1 to 7, characterized by the above.

9. The conductor further includes an electroplated layer electroplated on the conductor, the material of the electroplated layer is nickel, tin, silver or copper, and the thickness of the electroplated layer is 2 μm to 15 μm. The conductor according to claim 8, characterized in that.

10. Chamfers are provided on both sides of the conductor, and the chamfers are full-round chamfers or chamfers with a radius of 0.5 mm to 3.5 mm. The conductor according to claim 8, characterized in that.

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