Insulated flat conductor

Abstract

This application discloses an insulated flat conductor wire, the conductor wire including a conductor, a high-temperature resistant flame-retardant layer, and a protective layer, the conductor is flat, the high-temperature resistant flame-retardant layer includes a first insulating layer, a second insulating layer, and a third insulating layer, the first insulating layer covers the conductor, the second insulating layer covers the first insulating layer, the third insulating layer covers the second insulating layer, the first insulating layer, the second insulating layer, and the third insulating layer are all made of high-temperature resistant materials, and the protective layer covers the third insulating layer. By improving the structure of the conductor wire, this application can effectively avoid insulation failure and improve the high-temperature resistance and insulation properties of the conductor wire.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority from a Chinese patent application filed with the China Patent Office on August 25, 2022, bearing application number 202211030249.8 and entitled "Insulated Flat Conductor Wire," the entire contents of which are incorporated herein by reference.

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

[0003] With the rapid development of the new energy automobile industry, the battery pack, which is the power output source of new energy automobiles, is also continuing to develop. Its requirements of low cost, small volume, high power output, safety, stability and so on are leading to technological innovation of various components.

[0004] Currently, busbars for connecting power batteries are becoming increasingly widespread, with a trend toward one-piece bending molding, which offers the advantages of easy processing, high production efficiency, and low costs. Currently, the mainstream connecting wires are flat conductors coated with a single layer of insulating plastic, such as PA plastic. The long-term operating temperature of most plastics is below 125°C, which is sufficient for the normal operating temperature range of battery packs. However, in some extreme applications, even in the event of a battery failure, the temperature can far exceed 125°C, reaching 300-500°C in the short term. At such high temperatures, the plastic coating of conventional busbars quickly melts and loses its insulating protection capability. Therefore, ensuring that connecting wires can insulate without failure in such high-temperature environments is an important indicator of the safety of new energy vehicles.

[0005] To solve the short-term high-temperature resistance problem of single-layer insulating plastic, the optimized design of some battery busbars in the prior art involves manually wrapping a layer of mica tape around the conductor to provide insulation. However, because the mica tape is the outermost layer of the conductor, scratches, friction, and liquid erosion can occur on the conductor over long-term use, leading to insulation failure. Summary of the Invention [Problem to be solved by the invention]

[0006] The primary objective of the present application is to provide an insulated flat conductor wire for improving the high temperature resistance and insulating properties of the conductor wire. [Means for solving the problem]

[0007] In order to achieve the above object, the present application A flat conductor; a high-temperature resistant, flame-retardant layer including a first insulating layer, a second insulating layer, and a third insulating layer, wherein the first insulating layer covers the conductor, the second insulating layer covers the first insulating layer, and the third insulating layer covers the second insulating layer, and the first insulating layer, the second insulating layer, and the third insulating layer are all made of a high-temperature resistant material; and a protective layer covering the third insulating layer.

[0008] Optionally, the material of the conductor is copper, brass, aluminum or a combination thereof, and the width of the conductor is 10mm to 50mm, and the thickness is 1.0mm to 7.0mm.

[0009] Optionally, the conductive wire further includes an electroplating layer electroplated on the conductor, the material of the electroplating layer being nickel, tin, silver or copper, and the thickness of the electroplating layer being 2 um to 15 um.

[0010] 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 the first insulating layer is 20um to 300um, and the thickness of each layer of the adhesive tape is 10um to 100um.

[0011] Optionally, the second insulating layer is at least one layer of mica tape, the thickness of the second insulating layer is 0.10mm to 1.0mm, and the thickness of each layer of the mica tape is 0.1mm to 0.5mm.

[0012] Optionally, the material of the mica tape is phlogopite tape, muscovite tape, synthetic mica tape or ceramic composite mica tape.

[0013] Optionally, the third insulating layer includes at least one layer of polyimide adhesive tape, the thickness of the third insulating layer is 20 um to 300 um, and the thickness of each layer of the polyimide adhesive tape is 10 um to 100 um.

[0014] Optionally, the third insulating layer has a thickness of 40 um to 80 um.

[0015] Optionally, the number of the protective layer is at least one, the material of the protective layer is polymer plastic, or the protective layer is a heat shrinkable tube, and the thickness of the protective layer is 0.2 mm to 2.0 mm.

[0016] Optionally, the polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE, or PI; The heat shrink tube is a fluororubber heat shrink tube, a Teflon heat shrink tube, an FEP heat shrink tube, a PTFE heat shrink waterproof tube, a PVDF heat shrink tube, a PET heat shrink tube, a PE heat shrink tube, a PVC heat shrink tube, a polyvinylidene fluoride heat shrink tube, a polytetrafluoroethylene heat shrink tube, a silica gel heat shrink tube, a chemically crosslinked polyolefin heat shrink tube, or a polyester heat shrink tube.

[0017] In the technical solution of the present application, the lead wire includes a conductor, a high-temperature-resistant flame-retardant layer, and a protective layer, the high-temperature-resistant flame-retardant layer including first, second, and third insulating layers, the first insulating layer covering the conductor, the second insulating layer covering the first insulating layer, and the third insulating layer covering the second insulating layer, the first, second, and third insulating layers all being made of high-temperature-resistant materials, and the protective layer covering the third insulating layer. The outermost protective layer provides moisture-proofing, scratch resistance, and a certain degree of insulation and high-temperature resistance, fulfilling the purpose of conductive insulation during normal battery connection, while the high-temperature-resistant flame-retardant layer has high insulation, high-temperature resistance, and flame retardancy, and can effectively prevent insulation failure of the lead wire when the battery operates under extreme conditions, improving high-temperature resistance and insulation, thereby fulfilling the role of battery safety protection and ensuring the personal safety of vehicle drivers in extreme situations. [Brief explanation of the drawings]

[0018] In order to more clearly describe the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce 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 any creative work.

[0019] [Figure 1] 1 is an exploded view of an embodiment of an insulated flat conductor according to the present invention; [Figure 2] 1 is a structural schematic diagram of an embodiment of an insulated flat conductor according to the present invention; [Figure 3] 1 is a structural schematic diagram of an embodiment of the insulated flat conductor of the present invention in a bent state during a high-temperature test.

[0020] The realization of the object, features and advantages of the function of the present application will be further explained with reference to the examples and drawings. DETAILED DESCRIPTION OF THE INVENTION

[0021] Hereinafter, the technical solutions of the embodiments of the present application will be clearly and completely described with reference to the drawings of the embodiments of the present application, and it is obvious that the described embodiments are only some of the embodiments of the present application, and not all of the embodiments. Based on the embodiments of the present application, all other embodiments that a person skilled in the art can obtain without creative work fall within the scope of protection of the present application.

[0022] In addition, when directional indications (e.g., up, down, left, right, front, back, etc.) are mentioned in the embodiments of the present application, the directional indications are used only to interpret the relative positional relationships and movement situations between each component in a specific posture (see illustration), and when the specific posture changes, the directional indications also change accordingly.

[0023] Furthermore, when a description in the embodiments of the present application includes "first," "second," etc., it should be understood that the description "first," "second," etc. is used for descriptive purposes only and does not indicate or imply the relative importance or the number of technical features indicated. Therefore, a feature defined by "first" or "second" may explicitly or implicitly include at least one of the feature. Furthermore, the meaning of "and / or" appearing throughout the specification includes three parallel schemes. For example, "A and / or B" includes scheme A, scheme B, or a scheme where both A and B are satisfied simultaneously. Furthermore, to the extent feasible by a person skilled in the art, the technical solutions in each embodiment can be combined with each other. However, if a combination of technical solutions is mutually contradictory or infeasible, the combination of technical solutions shall be deemed not to exist and not within the scope of protection claimed by the present application.

[0024] The present application proposes an insulated flat conductor, particularly, but not limited to, a high-temperature resistant insulated flat conductor for an automobile power battery.

[0025] As shown in Figures 1 and 2, in one embodiment of the present application, the conductive wire 100 includes a conductor 10, a high-temperature-resistant flame-retardant layer 20, and a protective layer 30, wherein the high-temperature-resistant flame-retardant layer 20 includes a first insulating layer 21, a second insulating layer 22, and a third insulating layer 23, wherein the first insulating layer 21 covers the conductor 10, the second insulating layer 22 covers the first insulating layer 21, and the third insulating layer 23 covers the second insulating layer 22, wherein the first insulating layer 21, the second insulating layer 22, and the third insulating layer 23 are all made of high-temperature-resistant materials, and the protective layer 30 covers the third insulating layer 23.

[0026] In this embodiment, the material of the conductor 10 may be a conductive material such as copper, aluminum, brass, etc., or may be a combination of two materials, or may adopt a copper-clad aluminum structure, and is not limited here.

[0027] Copper conductor materials can be selected from grades T2 and TU2, conforming to GB / T 5231, or grades C1100 and C1020, conforming to JIS H3100, or grades Cu-ETP (CW004A) and Cu-OF (CW008A), conforming to DIN-EN-13599. Aluminum conductor materials can be selected from Al-1000 series aluminum strip (typically grade 1060) or Al-6000 series aluminum strip (typically grade 6101), conforming 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, and the second insulating layer 22 may be mica tape, which may be a high-temperature resistant insulating material such as phlogopite tape, muscovite tape, synthetic mica tape, or ceramic composite mica tape, and is not limited thereto.

[0029] In the technical solution of the present application, the conductive wire 100 includes a conductor 10, a high-temperature resistant flame-retardant layer 20, and a protective layer 30, the high-temperature resistant flame-retardant layer 20 includes a first insulating layer 21, a second insulating layer 22, and a third insulating layer 23, the first insulating layer 21 covers the conductor 10, the second insulating layer 22 covers the first insulating layer 21, and the third insulating layer 23 covers the second insulating layer 22, the first insulating layer 21, the second insulating layer 22, and the third insulating layer 23 are all made of high-temperature resistant materials, and the protective layer 30 covers the third insulating layer 23. As can be seen, the outermost protective layer 30 can exhibit moisture-proof, scratch-resistant, and certain insulating properties and high-temperature resistance, thereby meeting the conductive insulation requirements when the battery is normally connected; on the other hand, the high-temperature-resistant and flame-retardant layer 20 has high insulating properties, high-temperature resistance and flame retardancy, and when the battery operates under extreme conditions, the high-temperature-resistant and flame-retardant layer 20 can effectively prevent insulation failure of the conductor 100, improve high-temperature resistance and insulating properties, play a role in protecting the safety of the battery, and further ensure the personal safety of the vehicle driver in extreme situations.

[0030] In order to further improve the high temperature resistance, flame retardancy and insulating properties of the conductive wire 100 and to facilitate production and manufacturing, in one embodiment, as shown in FIG. 1, the first insulating layer 21 may include at least one layer of adhesive tape, and the material of the adhesive tape may be polyimide or ceramic silicon, and the entire thickness of the first insulating layer 21 may be 20 um to 300 um, and is not limited thereto.

[0031] In this embodiment, the thickness of each layer of adhesive tape may be 10 um to 100 um, and is not limited thereto.

[0032] During production, machines such as a horizontal double-head wrapping machine can be used to cover the conductor 10 with adhesive tape using an automatic wrapping method, and then a polyimide insulating layer can be hot-pressed onto the conductor 10 using an extrusion method; the specific wrapping method is not limited here. When using a horizontal double-head wrapping machine, the wrapping speed can be set to 2 m / min to 15 m / min to ensure that the processed semi-finished product meets quality requirements.

[0033] In order to further improve the high temperature resistance, fire resistance and insulation properties of the conductive wire 100, in one embodiment, as shown in FIG. 1, the second insulating layer 22 may be at least one layer of mica tape, the thickness of the mica tape may be 0.10 mm to 1.0 mm, and the thickness of each layer of mica tape may be 0.1 mm to 0.5 mm, and is not limited thereto.

[0034] In this embodiment, the material of the mica tape may be phlogopite tape, muscovite tape, synthetic mica tape, ceramic composite mica tape, etc., and typical mica tape structures include PET or PE + mica paper + glass fiber reinforced mica tape, double-layer mica paper + double-layer glass fiber reinforced mica tape, and are not limited thereto.

[0035] In this embodiment, the mica tape can also be wrapped using a machine such as a horizontal double-head wrapping machine, and the first insulating layer 21 is covered with the mica tape using an automatic wrapping method. When using a horizontal double-head wrapping machine, the wrapping speed can be set to 2 m / min to 15 m / min to ensure that the processed semi-finished product meets the quality requirements.

[0036] In order to further improve the high temperature resistance, fire resistance and insulating properties of the conductive wire 100, in one embodiment, as shown in FIG. 1, the third insulating layer 23 may include at least one layer of polyimide adhesive tape, the thickness of the third insulating layer may be 20 um to 300 um, and the thickness of each layer of polyimide adhesive tape may be 10 um to 100 um.

[0037] Tests have shown that, particularly when the thickness of the third insulating layer is 40 um to 80 um, the flat conductor wire has excellent high temperature resistance, flame retardancy and insulation properties, and the material cost is relatively low.

[0038] In production and manufacturing, the surface of the second insulating layer is coated with polyimide adhesive tape by an automated wrapping method using a machine. A polymer plastic is used to coat the semi-finished conductor 10 from the previous process using a hot melt extrusion process. Depending on the melting point of the plastic and the properties of the material, the processing temperature ranges from 150 to 450°C. The entire process of unwinding, aligning, pulling, extruding, cooling, and winding is assisted, and the extrusion speed can be set to 2 m / min to 15 m / min.

[0039] In addition, both sides of the second insulating layer 22 are reinforced and wrapped with polyimide adhesive tape, which effectively wraps the second insulating layer 22 by taking advantage of the advantages of polyimide, such as high temperature resistance, flame retardancy, and high toughness. When the conductor 10 is bent, the mica layer at the bent corners is uniformly and evenly dispersed together with the polyimide, expanding, ensuring the high temperature resistance of the mica. With long-term use, it can withstand temperatures of over 800°C.

[0040] As shown in FIG. 1, in one embodiment, the number of protective layers 30 is at least one, the material of the protective layer 30 is polymer plastic, or the protective layer 30 is a heat shrink tube, and the thickness of the protective layer 30 may be 0.2 mm to 2.0 mm.

[0041] In this embodiment, the polymer plastic may be PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE, or PI, etc., but is not limited thereto.

[0042] In this embodiment, the heat shrink tube may be a fluororubber heat shrink tube, a Teflon heat shrink tube, an FEP heat shrink tube, a PTFE heat shrink waterproof tube, a PVDF heat shrink tube, a PET heat shrink tube, a PE heat shrink tube, a PVC heat shrink tube, a polyvinylidene fluoride heat shrink tube, a polytetrafluoroethylene heat shrink tube, a silica gel heat shrink tube, a chemically cross-linked polyolefin heat shrink tube, or a polyester heat shrink tube, etc., and is not limited thereto.

[0043] As can be understood, by placing the protective layer 30 on the high-temperature resistant flame-retardant layer 20, it can provide certain moisture-proof, scratch-resistant, insulating and high-temperature resistant properties, and can also prevent liquid erosion of the high-temperature resistant flame-retardant layer 20, thereby avoiding insulation failure.

[0044] In this embodiment, the polymer plastic can be coated on the semi-finished conductor wire by hot-melt extrusion coating. Depending on the melting point of the plastic and the properties of the material, the processing temperature range is 150-450°C, and the entire process of unwinding, aligning, pulling, extruding, cooling, and winding can be assisted, and the extrusion speed can be set to 2m / min-15m / min. The plastic layer can be single-layered or multi-layered, and is not limited here.

[0045] As shown in FIG. 1, in one embodiment, the material of the conductor 10 may be copper, brass, aluminum, or a combination thereof, the width of the conductor 10 may be 10 mm to 50 mm, the thickness may be 1.0 mm to 7.0 mm, and the tolerance of the width of the conductor 10 may be ±0.15 mm, which is not limited here.

[0046] Optionally, in order to improve the corrosion resistance and conductivity of the conductor 10, the conductive wire 100 may further include an electroplating layer electroplated on the conductor 10, the material of which may be nickel, tin, silver, copper, etc., and the thickness of the electroplating layer may be 2 um to 15 um, and is not limited thereto.

[0047] In the production and manufacturing, copper rod or aluminum rod material is used, and the conductor 10 can be processed by extrusion molding using an extruder, a drawing machine, an electroplating line, etc.

[0048] In some embodiments, both side edges of the conductor 10 may be chamfered, rounded, or rounded, with a radius of 0.5 mm to 3.5 mm, which facilitates coating and prevents sharp edges from cutting the insulating layer, thereby extending the service life of the conductor 100.

[0049] In the test, multiple insulated flat conductors 100 were selected as test samples, each of which was structured using a combination of a conductor 10, a first insulating layer 21, a second insulating layer 22, a third insulating layer 23, and a protective layer 30, with the first insulating layer 21 made of polyimide, the second insulating layer 22 made of mica tape, the third insulating layer 23 made of polyimide, and the protective layer 30 made of PA12. Multiple conventional flat wire materials were selected as comparison samples, each of which was structured using a flat conductor, two high-temperature flame-retardant layers, and one insulating layer, with the high-temperature flame-retardant layers all made of conventional high-temperature flame-retardant materials such as mica tape.

[0050] As shown in Figure 3, the bending angles of the sample conductor 100 during testing were: vertical bending at 90°, with the bending R angle equal to the width of the flat conductor 100; horizontal bending at 90°, with the bending R angle equal to the thickness of the flat conductor 100. Specific test results are shown in Table 1.

[0051] [Table 1]

[0052] As can be seen from the above, after the sample conductor 100 was bent using a bending machine, the high temperature resistance test showed that the pressure resistance of the bent sample met the test requirements (3000V, AC, leakage current <1mA, water immersion pressure test). After the sample conductor 100 was bent using a bending machine, the bent sample was baked at a high temperature of 400°C for 1 hour, and then dynamically tested by applying electricity in an oven or removed and tested, requiring a leakage current of <60mA. Finally, out of 100 test samples, 100 passed the test, meaning that all test samples passed the test and the high temperature resistance was greatly improved.

[0053] The above are merely optional embodiments of the present application and do not limit the patent scope of the present application. Any equivalent structural modifications made using the contents of the specification and drawings of the present application without departing from the inventive concept of the present application, or direct or indirect applications in other related technical fields, are all included in the patent protection scope of the present application. [Explanation of symbols]

[0054] 100, conducting wire, 10, conductor, 20, high-temperature resistant flame-retardant layer, 30, protective layer, 21, first insulating layer, 22, second insulating layer, 23, third insulating layer.

Claims

1. An insulated flat conductor, the conductor comprising: A flat conductor; a high-temperature resistant flame-retardant layer including a first insulating layer, a second insulating layer, and a third insulating layer, wherein the first insulating layer covers the conductor, the second insulating layer covers the first insulating layer, and the third insulating layer covers the second insulating layer, and the first insulating layer, the second insulating layer, and the third insulating layer are all made of a high-temperature resistant material; a protective layer covering the third insulating layer.

2. 2. The conductor wire according to claim 1, wherein the conductor material is copper, brass, aluminum, or a combination thereof, and the conductor has a width of 10 mm to 50 mm and a thickness of 1.0 mm to 7.0 mm.

3. The conductor wire according to claim 2, further comprising an electroplating layer electroplated on the conductor, the material of the electroplating layer being nickel, tin, silver or copper, and the thickness of the electroplating layer being 2 um to 15 um.

4. The conductor according to claim 1, wherein 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 the first insulating layer is 20 μm to 300 μm, and the thickness of each layer of the adhesive tape is 10 μm to 100 μm.

5. The conductor of claim 1, wherein the second insulating layer is at least one layer of mica tape, the thickness of the second insulating layer is 0.10 mm to 1.0 mm, and the thickness of each layer of mica tape is 0.1 mm to 0.5 mm.

6. 6. The conductor wire according to claim 5, wherein the material of the mica tape is a phlogopite tape, a muscovite tape, a synthetic mica tape, or a ceramic composite mica tape.

7. 2. The conductor according to claim 1, wherein the third insulating layer comprises at least one layer of polyimide adhesive tape, the thickness of the third insulating layer is 20 μm to 300 μm, and the thickness of each layer of the polyimide adhesive tape is 10 μm to 100 μm.

8. The conductor according to claim 7, wherein the third insulating layer has a thickness of 40 um to 80 um.

9. The conductor wire according to claim 1, characterized in that the number of the protective layers is at least one, the material of the protective layer is a polymer plastic or the protective layer is a heat-shrinkable tube, and the thickness of the protective layer is 0.2 mm to 2.0 mm.

10. The polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI; 10. The conductor wire according to claim 9, wherein the heat shrinkable tube is a fluororubber heat shrinkable tube, a Teflon 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, or a polyester heat shrinkable tube.

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