US20190131037A1 - Insulated electric conductor - Google Patents

Insulated electric conductor Download PDF

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Publication number
US20190131037A1
US20190131037A1 US16/089,270 US201716089270A US2019131037A1 US 20190131037 A1 US20190131037 A1 US 20190131037A1 US 201716089270 A US201716089270 A US 201716089270A US 2019131037 A1 US2019131037 A1 US 2019131037A1
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Prior art keywords
electric conductor
insulating layer
layer
insulating
insulated electric
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US16/089,270
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Inventor
Jürgen Hochstöger
Rudolf Schrayvogel
Ewald Koppensteiner
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HPW Metallwerk GmbH
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HPW Metallwerk GmbH
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Assigned to GEBAUER & GRILLER METALLWERK GMBH reassignment GEBAUER & GRILLER METALLWERK GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Hochstöger, Jürgen, KOPPENSTEINER, EWALD, SCHRAYVOGEL, RUDOLF
Publication of US20190131037A1 publication Critical patent/US20190131037A1/en
Assigned to HPW METALLWERK GMBH reassignment HPW METALLWERK GMBH CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: GEBAUER & GRILLER METALLWERK GMBH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/003—Apparatus or processes specially adapted for manufacturing conductors or cables using irradiation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/145—Pretreatment or after-treatment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/301—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen or carbon in the main chain of the macromolecule, not provided for in group H01B3/302
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/307—Other macromolecular compounds
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/42—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
    • H01B3/427—Polyethers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0216—Two layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0225—Three or more layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0291—Disposition of insulation comprising two or more layers of insulation having different electrical properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/305—Polyamides or polyesteramides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/306—Polyimides or polyesterimides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes

Definitions

  • the invention relates to an insulated electric conductor comprising an electric conductor, preferably of copper or aluminum, having an insulating coating, wherein the insulating coating comprises at least one outer insulating layer made of thermoplastic material, and to a method for producing such an insulated electric conductor.
  • Insulated electric conductors are installed in almost any electrical device to conduct electrical current without causing short circuits that may be caused by the contact of non-electrically insulated conductors.
  • Such insulated electric conductors comprise a copper electric conductor and a coating electrically insulating the electric conductor, which usually comprises one or more layers.
  • the insulating coating comprises an insulating layer of thermoplastic material (also called thermoplastic resin, thermoplastic synthetic material or thermoplastic polymer).
  • a round cut is usually carried out on the insulated electric conductor perpendicular to a conductor axis, the electric conductor is stretched by 20% and then the detachment of the insulating coating from the electric conductor is measured. The lower the detachment of the insulating coating from the electric conductor, the better the adhesion.
  • the electric conductor of generic insulated electric conductors consists of copper or an alloy with a high copper content or aluminum or other electrically conductive materials.
  • the electric conductor is understood to mean both a single conductor and a strand containing several individual conductors.
  • the cross-sectional geometry of the electric conductor which is normal to a conductor axis, can have any geometric shape: square, rectangular, circular or elliptical, wherein it is customary to round off any edges, or they are profiled.
  • the insulation of the electric conductor is ensured by the at least one provided insulating layer of thermoplastic material (also called thermoplastic resin, thermoplastic synthetic material or thermoplastic polymer), wherein the at least one insulating layer can advantageously form the outermost layer of the insulating coating.
  • thermoplastic material also called thermoplastic resin, thermoplastic synthetic material or thermoplastic polymer
  • an oxide layer e.g. copper oxide or aluminum oxide
  • the oxide layer has a negative effect on the adhesion properties of a layer of the insulating coating applied to the surface of the electric conductor.
  • the adhesion of the layer of the insulating coating applied to the surface of the electric conductor removed from the oxide layer is significantly improved. It has been shown that the oxide layer can be completely removed by a plasma treatment under an (oxygen-free) protective gas atmosphere, wherein other impurities can be removed by the plasma treatment. It is even possible that the top atomic layers of the electric conductor are removed by the plasma treatment.
  • a gas plasma is generated in the protective gas atmosphere and the electric conductor in the plasma is bombarded with ions of the protective gas in order to remove at least the oxide layer by the ion bombardment.
  • ions of the protective gas for example, nitrogen, argon or hydrogen is suitable as a protective gas or process gas.
  • the plasma treatment has in addition to the removal of the oxide layer further positive effects on the insulated electric conductor: on the one hand, the electric conductor is heated by the impact energy of the ions on the surface and can be annealed during the plasma treatment to recrystallize the structure of the electric conductor; on the other hand, the ion bombardment increases the surface energy of the electric conductor, which additionally improves the adhesion of the insulating coating to the surface of the electric conductor.
  • this is also referred to as an activation of the surface of the electric conductor.
  • Another effect of the plasma treatment is to increase the micro-roughness of the surface of the electric conductor, which also has a positive effect on the adhesion of the insulating coating.
  • At least part of the insulating coating is applied to the surface of the electric conductor under a protective gas atmosphere, preferably under the same protective gas atmosphere under which the plasma treatment is carried out.
  • the insulated electric conductor comprises an electric conductor, preferably of copper or aluminum, with an insulating coating
  • the insulating coating either comprises
  • An insulated electric conductor according to the invention has particularly good adhesion properties by the direct application of a plastic-containing intermediate layer of the insulating coating or by the direct application of the insulating layer of thermoplastic material on the plasma-treated and thus oxide-layer-free surface of the electric conductor: If a circular cut is performed around the insulated electric conductor perpendicular to a conductor axis and the conductor is stretched by 20%, the detachment of the insulating coating from the electric conductor measured in the direction of the conductor axis is only at most 3 mm, preferably at most 2 mm, in particular at most 1 mm.
  • the adhesion effect is thus achieved in both variants in that a plastic layer, which preferably consists of plastic, is applied directly under protective gas atmosphere on the plasma-cleaned and thus oxide layer-free surface of the electric conductor.
  • the plastic layer may directly be the at least one insulating layer made of thermoplastic material if no intermediate layer is provided.
  • the plastic layer can also be a plastic-containing intermediate layer, preferably a plasma polymer layer or at least one fluoropolymer layer. If the insulating coating has a plastic-containing intermediate layer, the at least one insulating layer is preferably applied directly to the plastic-containing intermediate layer. However, it is also conceivable that one or more further intermediate layers are provided between the plastic-containing intermediate layer and the at least one insulating layer.
  • the plastic-containing intermediate layer of the insulating coating is preferably the plasma polymer layer or the at least one fluoropolymer layer.
  • the insulating coating consists of the at least one insulating layer, i.e. it has no further intermediate layers.
  • the detachment of the insulating coating from the electric conductor usually remains far below 1 mm, in particular at most 0.2 mm, preferably at most 0.1 mm, more preferably at most 0.05 mm, particularly preferably at most 0.01 mm, when the at least one insulating layer is applied directly to the surface of the electric conductor.
  • the at least one insulating layer comprises a polyaryletherketone [PAEK], in particular polyetheretherketone (PEEK), or consists of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK].
  • an insulated electric conductor comprising an electric conductor, preferably made of copper or aluminum, having an insulating coating,
  • the insulating coating either comprises
  • An embodiment variant of the invention provides that the electric conductor is arranged continuously under a protective gas atmosphere until the application of the insulating coating in order to prevent the formation of a new oxide layer on the surface of the electric conductor. It is also possible to pass through several protective gas atmospheres in succession, as long as the plasma-treated electric conductor is arranged uninterruptedly under one of the inert gas atmospheres.
  • the gas plasma for bombarding the electric conductor concerns a low-pressure plasma, preferably having a pressure below 80 mbar, which can be produced in a manner known per se.
  • a pressure below 80 mbar which can be produced in a manner known per se.
  • pressures below 50 mbar or even below 20 mbar are conceivable.
  • the insulating coating in particular the at least one insulating layer, has a temperature resistance of at least 180° C., preferably of at least 200° C., in particular of at least 220° C.
  • thermoplastic material of the at least one insulating layer is selected from the group consisting of polyaryletherketone [PAEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS], and combinations thereof.
  • PAEK polyaryletherketone
  • PI polyimide
  • PAI polyamideimide
  • PEI polyetherimide
  • PPS polyphenylene sulfide
  • the thermoplastic material may comprise one or more of the above-mentioned plastics and optionally further constituents, such as fiber material, fillers or other plastics.
  • Polyaryletherketones are composed phenyl groups linked by means of oxygen bridges, i.e. ether or ketone groups, wherein the number and sequence of ether or ketone groups within the polyaryletherketones is variable.
  • Polyimides are plastics whose most important structural feature is the imide group. These include polysuccinimide (PSI), polybismaleimide (PBMI) and polyoxadiazobenzimidazole (PBO), polyimide sulfone (PISO) and polymethacrylimide (PMI).
  • thermoplastic material of the at least one insulating layer is a polyaryletherketone [PAEK] selected from the group consisting of polyetherketone [PEK], polyetheretherketone [PEEK], polyetherketoneketone [PEKK], polyetheretherketoneketone [PEEKK], polyetherketoneetherketoneketone [PEKEKK], and combinations thereof.
  • PAEK polyaryletherketone
  • Polyetheretherketone [PEEK] has proven to be particularly suitable for the at least one insulating layer.
  • the at least one insulating layer has a thickness between 10 and 1000 ⁇ m, preferably between 25 ⁇ m and 750 ⁇ m, particularly preferably between 30 ⁇ m and 500 ⁇ m, in particular between 50 ⁇ m and 250 ⁇ m. It is understood that other layer thicknesses are conceivable, for example 40 ⁇ m, 60 ⁇ m, 80 ⁇ m, 100 ⁇ m or 200 ⁇ m, to name a few possibilities. It is understood that the stated values can relate both to the thickness of a single layer of the insulating layer and also to the total thickness of the insulating layer if the insulating layer comprises more than one layer.
  • the at least one insulating layer can be produced cheaply and quickly if it is applied by an extrusion process, i.e. it is extrusion-coated. Therefore, in a further preferred embodiment variant of the invention, it is provided that the, preferably outer, insulating layer can be produced by means of an extrusion method.
  • the insulating coating consists of the at least one insulating layer and the at least one insulating layer is applied directly to the surface of the electric conductor, a particularly simple and cost-effective production of an insulated electric conductor according to the invention is made possible because the adhesion of the at least one insulating layer to the surface of the electric conductor by the plasma treatment is already so good that no intermediate layers are necessary.
  • the insulating coating consists of the at least one insulating layer and that the intermediate layer which is directly applied to the surface of the electric conductor and contains the plastic is the at least one insulating layer.
  • the particularly preferred embodiment relates to an insulated electric conductor comprising an electric conductor, preferably made of copper or aluminum, having an insulating coating, wherein the insulating coating consists of at least one insulating layer of thermoplastic material, obtainable by a method in which the electric conductor is placed under a protective gas atmosphere and is bombarded with ions of the protective gas in a gas plasma to remove an oxide layer formed on a surface of the electric conductor and/or to increase the surface energy of the electric conductor, and the at least one insulating layer is applied directly to the surface of the electric conductor, the at least one insulating layer is applied to the electric conductor under protective gas atmosphere.
  • the particularly preferred embodiment also relates to an insulated electric conductor comprising an electric conductor, preferably made of copper or aluminum, having an insulating coating, wherein the insulating coating consists of at least one insulating layer of thermoplastic material, wherein according to the invention it is provided that an oxide layer formed on a surface of the electric conductor is removed by bombardment of the electric conductor with ions of a protective gas of a protective gas atmosphere in a gas plasma and subsequently the at least one insulating layer is applied directly to the oxide-layer-free surface of the electric conductor.
  • the insulating coating may, for example, only consist of a single insulating layer, which is applied directly to the surface of the electric conductor in order to allow a particularly simple production.
  • the insulating coating consists of exactly two or more than two, for example, three or four, insulating layers.
  • a lowermost insulating layer is applied directly to the surface of the electric conductor, wherein the further insulating layers are respectively applied to one of the preceding insulating layers. If a defect has occurred in the lowermost insulating layer, i.e.
  • the probability that precisely the defective section of the lowermost insulating layer will not be covered by the subsequent insulating layers will be reduced following an exponential function.
  • all insulating layers are applied under a protective gas atmosphere, so that the adhesion of subsequent insulating layers is ensured in the region of defective sections of the preceding insulating layers.
  • At least one, for example one, two, three or four, further insulating layer of thermoplastic material can be applied to the insulating coating or to the insulating coating consisting of the at least one insulating layer.
  • the at least one further insulating layer is preferably constructed analogously to the at least one insulating layer, so that the thermoplastic material of the at least one further insulating layer is selected from the group consisting of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], polyimide [PI], polyamideimide [PAI], Polyetherimide [PEI], polyphenylene sulfide [PPS], and combinations thereof.
  • the defective sections of the at least one insulating layer are generally relatively small areas, it is also conceivable for at least one further insulating layer to be applied outside the protective gas atmosphere to the insulating coating in order to cover any defective sections of the insulating coating in the region of the defective portions of the insulating coating, so that the adhesion of the further insulating layer is not improved in the region of the defective portions of the insulating coating. It is understood that other insulating layers can be applied, if a greater thickness of the insulation is required.
  • At least one further insulating layer preferably one, two or three thereof, is applied to the insulating coating, wherein the at least one further insulating layer is not applied under a protective gas atmosphere.
  • the insulating coating in order to improve the adhesion of the insulating coating to the surface of the electric conductor, it is provided that the insulating coating has a plasma polymer layer of cross-linked macromolecules of non-uniform chain length applied directly to the surface of the electric conductor, which plasma polymer layer can be produced by polymerization of a gaseous monomer in a gas plasma, preferably in the gas plasma for bombarding the electric conductor.
  • the intermediate layer of the insulating coating which is applied directly to the surface of the electric conductor and contains plastic is the plasma polymer layer in this exemplary embodiment.
  • the plasma polymer layer serves as an intermediate layer and, on the one hand, adheres excellently to the surface of the electric conductor and, on the other hand, enables increased adhesion of the layer of the insulating coating, for example the at least one insulating layer, that is applied to the plasma polymer layer.
  • a further embodiment variant of the first alternative embodiment provides that the plasma polymer layer has a thickness of 1 ⁇ m or less. Thicknesses of up to one hundredth of a micrometer are conceivable as the lower limit. Due to the small layer thickness, the plasma polymer layer has an insignificant effect on the entire thickness of the insulated electric conductor.
  • the monomer for producing the plasma polymer layer is ethylene, buthenol, acetone or tetrafluoromethane [CF 4 ].
  • the plasma polymer layers formed by these monomers in the plasma are distinguished by particularly good adhesion properties.
  • the plasma polymer layer should have similar properties as polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP], CF 4 is suitable as a monomer.
  • the insulating coating has at least one fluoropolymer layer, applied directly to the surface of the electric conductor, preferably comprising polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP].
  • the fluoropolymer layer is also distinguished by excellent adhesion properties, both on the electric conductor and on the layer applied to the fluoropolymer layer, and serves as an intermediate layer of the insulating coating. It is also conceivable that several fluoropolymer layers, for example two, three or four, are applied one above the other to the electric conductor.
  • the thickness of the at least one fluoropolymer layer is between 1 ⁇ m and 120 ⁇ m, preferably between 5 ⁇ m and 100 ⁇ m, particularly preferably between 10 ⁇ m and 80 ⁇ m, in particular between 20 ⁇ m and 50 ⁇ m.
  • the entire insulating coating is applied in a preferred embodiment of the invention under a protective gas atmosphere.
  • the at least one insulating layer is applied directly to the plasma polymer layer or the at least one fluoropolymer layer.
  • the insulating coating consists of at least two layers: the first lower layer applied directly to the electric conductor according to the first or second alternative embodiment variant and the second upper layer in the form of at least one insulating layer of thermoplastic material.
  • the outermost layer of the insulating coating can be formed either by the at least one insulating layer itself or by one or more further layers.
  • the invention further relates to a method for producing an insulated electric conductor, which has the following method steps:
  • the electric conductor preferably made of copper or aluminum, is subjected to the method in the form of a band or a wire.
  • the electric conductor is treated either “in-line”, i.e. directly after the production of the electric conductor (such as by cold forming or extrusion), according to the method according to the invention, or the electric conductor is provided in a wound-up form via a coil outlet.
  • the electric conductor is subjected to a mechanical and/or chemical pre-cleaning before the plasma treatment.
  • the plasma treatment is carried out analogously to the previous embodiments, wherein the electric conductor is continuously conveyed through the plasma treatment unit performing the plasma treatment.
  • the thickness of the layer removed by the plasma treatment from the electric conductor can be adjusted precisely.
  • the insulating coating is applied to the treated surface of the electric conductor.
  • the insulating coating adheres particularly well to the surface of the electric conductor due to the removal of the oxide layer or by the activation of the surface by increasing the surface energy of the electric conductor.
  • either the at least one insulating layer or at least the plastic-containing intermediate layer of the insulating coating i.e. in particular the plasma polymer layer or at least one fluoropolymer layer, is applied under protective gas atmosphere directly to the oxide layer-free surface of the electric conductor.
  • the electric conductor is arranged continuously under a protective gas atmosphere until the application of the insulating coating.
  • thermoplastic material provided that two, three or more insulating layers of thermoplastic material are provided, at least the first of the insulating layers is applied directly to the surface of the electric conductor and the subsequent insulating layers are at least partially applied to the underlying insulating layers.
  • Insulated electric conductors produced in this manner show particularly good adhesion properties as a result of the direct application of a plastic-containing intermediate layer of the insulating coating or by the direct application of at least one insulating layer of thermoplastic material on the plasma-treated, oxide-free surface of the electric conductor: If a circular cut is carried out perpendicular to a conductor axis on the insulated electric conductor and the conductor is stretched by 20%, the detachment of the insulating coating from the electric conductor measured in the direction of the conductor axis is only at most 3 mm, preferably at most 2 mm, in particular at most 1 mm.
  • thermoplastic material of the at least one insulating layer is selected from the group consisting of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.
  • PAEK polyaryletherketone
  • PEEK polyetheretherketone
  • PI polyimide
  • PAI polyamideimide
  • PEI polyetherimide
  • PPS polyphenylene sulfide
  • a variant of the method provides that the at least one insulating layer is extrusion-coated.
  • Extrusion is a cost-effective method for applying the insulating layer and is particularly also suitable for PAEK, in particular PEEK, and PPS.
  • the at least one insulating layer can thus also be applied in a simple manner as the outermost layer of the insulating coating.
  • the electric conductor By preheating the electric conductor, which is particularly advantageous when the at least one insulating layer or the insulating coating is extruded directly onto the surface of the electric conductor, a sudden cooling of the plastic-containing intermediate layer is reduced in contact with the electric conductor and thus negative influences on the adhesion minimized.
  • the electric conductor is cooled before applying the insulating coating in order to prevent excessive heating, such as a melt, of the plastic-containing intermediate layer in contact with the electric conductor. Therefore, it is provided in a further preferred embodiment variant of the method according to the invention that the electric conductor is brought to a temperature of at least 200° C., preferably at least 400° C., prior to the application of the insulating coating.
  • the insulated electric conductor is cooled depending on the strength of the at least one insulating layer to be achieved.
  • the adjustment of the mechanical properties of the at least one insulating layer, in particular the mechanical strength, takes place, inter alia, by the defined cooling of the insulated electric conductor and the consequent adjustment of the degree of crystallization, and is particularly important if the at least one insulating layer is the outermost layer the insulating coating. If, for example, the insulated electric conductor is cooled slowly, for example by cooling in the air, a high degree of crystallinity of the at least one insulating layer is achieved. It is also conceivable to provide quenching in a water bath, therefore an abrupt cooling, or a combination of abrupt and slow cooling.
  • the insulated electric conductor after extruding the at least one insulating layer onto the surface, is guided via rollers, preferably pressure rollers. It is particularly advantageous in this case if the at least one insulating layer forms the outermost layer of the insulating coating. Tight guiding of the insulated electric conductor via the pressure rollers under pressure of the insulated electric conductor leads to a particularly good adhesion of the insulating coating or in particular of the at least one insulating layer on the surface of the electric conductor. In this case, the boundary surfaces of the insulating coating between the individual layers, if several are present, and/or the boundary surfaces of the lowermost layer of the insulating coating and the surface of the electric conductor are pressed together, thus enhancing the adhesion effects.
  • the insulating coating consists of at least one insulating layer and that the at least one insulating layer is applied directly to the surface of the electrical conductor as a plastic-containing intermediate layer of the insulating coating under a protective gas atmosphere. Accordingly, the following method step is carried out:
  • an insulating coating to the surface of the electric conductor, wherein the insulating coating consists of at least one insulating layer of thermoplastic material and wherein the at least one insulating layer is applied under protective gas atmosphere directly to the surface of the electric conductor.
  • the insulating coating consists of at least two, preferably exactly two, insulating layers and the insulating coating is produced by tandem extrusion under a protective gas atmosphere. Due to the tandem extrusion, the at least two insulating layers are produced independently of one another, so that an obstruction of an extrusion tool only causes a defect in one of the insulating layers. As a result, the defective section is covered by the subsequent extrusion steps with high probability.
  • a further embodiment variant of the invention provides that at least one further insulating layer of thermoplastic material is extruded by tandem extrusion onto the insulating coating, wherein the extrusion of the further insulating layer does not take place under a protective gas atmosphere.
  • thermoplastic material of the at least one further insulating layer is selected from the group consisting of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.
  • PAEK polyaryletherketone
  • PEEK polyetheretherketone
  • PI polyimide
  • PAI polyamideimide
  • PEI polyetherimide
  • PPS polyphenylene sulfide
  • the insulating coating comprises at least one fluoropolymer layer, which is applied as a plastic-containing intermediate layer directly to the surface of the electric conductor, the steps required for the production of the insulating coating can be reduced by the fact that the at least one insulating layer and the at least one fluoropolymer layer can be prepared by co-extrusion or tandem extrusion. Thus, both layers can be produced in a single manufacturing step and with an extrusion unit.
  • a plasma polymer layer is applied directly to the surface of the electric conductor by polymerization of a gaseous monomer in a gas plasma as a plastic-containing intermediate layer.
  • an insulated electric conductor according to the invention is used as a winding wire for electrical machines, preferably electric motors or transformers.
  • FIG. 1 shows a schematic representation of a method according to the invention
  • FIG. 2 a shows a first embodiment variant of an insulated electric conductor with a rectangular cross-section
  • FIG. 2 b shows a second embodiment variant of an insulated electric conductor with a rectangular cross-section.
  • FIG. 2 c shows a third embodiment variant of an insulated electric conductor with a rectangular cross-section
  • FIGS. 3 a -3 c show the first to third embodiment variant with a round cross-section.
  • FIG. 1 shows a schematic representation of a method for producing an insulated electric conductor, as shown in FIGS. 2 a to 2 d and 3 a to 3 d .
  • the insulated electric conductor comprises an electric conductor 1 made of copper, wherein other materials such as aluminum are conceivable, and an insulating coating 2 , which has at least one insulating layer 3 made of thermoplastic material (also called thermoplastic resin, thermoplastic synthetic material or thermoplastic polymer), preferably a high-temperature-resistant plastic.
  • the at least one insulating layer 3 is formed as an outer insulating layer 3 and thus forms the outermost layer of the insulating coating 2 . It is understood, however, that in alternative embodiment variants still one or more further layers, preferably insulating layers, may be applied to the insulating layer 3 , which can then form the outermost layer of the insulating coating 2 .
  • the electric conductor 1 is continuously supplied in the illustrated embodiment as a band or wire via a coil outlet 7 to the process and can be prepared for example by means of cold forming processes, such as drawing or rolling, or extrusion, for example by means of Conform® technology. It goes without saying that the method according to the invention can also be carried out “in-line”, i.e. directly connected to the production process.
  • the electric conductor 1 is pre-cleaned mechanically in a pre-cleaning unit 8 , for example by means of a grinding process, or chemically, for example by means of suitable solvents or acids, in order to remove coarse soiling from the electric conductor 1 .
  • the pre-cleaned electric conductor 1 enters a plasma treatment unit 9 in which a protective gas atmosphere of nitrogen, argon or hydrogen is present and a gas plasma in the form of a low-pressure plasma is produced with less than 20 mbar pressure.
  • a low-pressure plasma can already be produced even at a pressure of less than 80 mbar.
  • the surface of the electric conductor 1 is bombarded with ions of the protective gas in order to carry off or remove an oxide layer formed on a surface of the electric conductor 1 .
  • the electric conductor 1 is soft-annealed by the plasma treatment and the surface energy of the electric conductor 1 therefore increases, thus activating the surface.
  • the adhesion between the electric conductor 1 made of copper and the insulating coating 2 applied to the electric conductor 1 can be improved decisively.
  • the insulating coating 2 consists only of an insulating layer 3 .
  • the insulating layer 3 has a temperature resistance of more than 180° C., preferably above 220° C., so that the insulated electric conductor can be used even at high operating temperatures.
  • the outer insulating layer 3 consists of polyetheretherketone [PEEK], which has both high temperature resistance and high resistance to a large number of organic and inorganic substances.
  • the outer insulating layer 3 may also consist of polyphenylene sulfide [PPS] or comprise PEEK and/or PPS.
  • the electric conductor 1 reaches the extrusion unit 11 after passing through the plasma treatment unit 9 , in which the outer insulating layer 3 is extrusion-coated onto the electric conductor 1 .
  • the electric conductor 1 is preheated to a temperature of at least 200° C., preferably at least 300° C.
  • both the extrusion and the transport of the conductor 1 into the extrusion unit 11 takes place under a protective gas atmosphere.
  • An insulated electric conductor produced in this way can be used, for example, as a winding wire, which is also known in English as a “magnet wire”, in an electric machine, such as an electric motor or a transformer.
  • the thickness of the outer insulating layer 3 is about 30 ⁇ m in the present exemplary embodiment.
  • the insulating layer 3 consists of a polyaryletherketone [PAEK], such as polyetheretherketone [PEEK], particularly good adhesion properties are achieved.
  • PAEK polyaryletherketone
  • PEEK polyetheretherketone
  • the detachment of the insulating layer 3 from the electric conductor 1 usually remains well below 1 mm, and is in particular at most 0.2 mm, preferably at most 0.1 mm, more preferably at most 0.05 mm, particularly preferably at most 0.01 mm.
  • the thermoplastic material of the insulating layer 3 is polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS], increased adhesion properties can be achieved.
  • the at least one insulating layer 3 may also comprise two, three, four or more individual insulating layers 3 , all of which are produced under a protective gas atmosphere in the extrusion unit 11 .
  • the probability of defects in the insulating coating 2 can be drastically reduced, since defects in the lowermost of the insulating layers 3 are compensated by subsequent insulating layers 3 . Tandem extrusion processes are particularly suitable for such a preparation.
  • further insulating layers which are preferably constructed analogously to the at least one insulating layer 3 , i.e. in particular of a polyaryletherketone [PAEK] such as polyetheretherketone [PEEK] or another of the aforementioned plastics, are applied to the insulating coating 2 outside the protective gas atmosphere in a further extrusion unit 12 .
  • PAEK polyaryletherketone
  • PEEK polyetheretherketone
  • the insulating coating 2 comprises in the second embodiment shown in FIGS. 2 b and 3 b , in addition to the outer insulating layer 3 made of PEEK or PPS, a plastic-containing intermediate layer in form of a plasma polymer layer 4 .
  • This plasma polymer layer 4 is produced in the method according to the invention in a plasma polymerization unit 10 , which is arranged after the plasma treatment unit 9 and before the extrusion unit 11 . It is also conceivable that the plasma treatment and the plasma polymerization are carried out in a combined device.
  • the plasma polymer layer 4 is formed on the surface of the electric conductor 1 by activating a gaseous monomer such as ethylene, butenol, acetone or tetrafluoromethane [CF 4 ] by the plasma and thereby forming highly cross-linked macromolecules of different chain length and a proportion of free radicals, which deposit as a plasma polymer layer 4 on the surface of the electric conductor 1 .
  • a gaseous monomer such as ethylene, butenol, acetone or tetrafluoromethane [CF 4 ]
  • the resulting plasma polymer layer 4 is less than 1 ⁇ m thick and adheres particularly well to the activated and oxide-free surface of the electric conductor 1 .
  • the outer insulating layer 3 is in turn extruded in the extrusion unit 11 onto the plasma polymer layer 4 as described above, wherein the adhesion between the plasma polymer layer 4 and the outer insulating layer 3 is also high.
  • the insulating coating 2 comprises, in addition to the outer insulating layer 3 made of PEEK, a plastic-containing intermediate layer formed as a fluoropolymer layer 5 of polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP], which is applied directly to the surface of the electric conductor 1 and further improves the adhesion between the electric conductor 1 and the outer insulating layer 3 .
  • the fluoropolymer layer 5 is produced together with the outer insulating layer 3 in the extrusion unit 11 by means of a co-extrusion or tandem extrusion process.
  • the thickness of the fluoropolymer layer 5 is about 30 ⁇ m in the present embodiment.
  • the insulated electric conductor After extrusion-coating the outer insulating layer 3 , the insulated electric conductor is cooled in a controlled manner, for example by air cooling, and passed over a series of pressure rollers which further improve adhesion by applying pressure to the insulated electric conductor. Finally, the insulated electric conductor is wound on a coil winder 13 .
  • the illustrated devices in FIG. 1 concern an overview in which all devices are shown, which are necessary for the production of the individual embodiment variants. While the sequence, from right to left, of the devices passed through are independent of the embodiment variant and in any case the plasma treatment unit 9 and the extrusion unit 11 have to be passed, the plasma polymerization unit 9 and the further extrusion unit 12 are optional devices which are used only in the production of specific design variants. It is understood that instead of a co-extrusion or tandem extrusion process, several individual extrusions can be carried out sequentially.

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  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Manufacturing & Machinery (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • General Health & Medical Sciences (AREA)
  • Laminated Bodies (AREA)
  • Insulated Conductors (AREA)
  • Insulating Of Coils (AREA)
  • Organic Insulating Materials (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)
  • Paints Or Removers (AREA)
  • Physical Vapour Deposition (AREA)
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MX2018011979A (es) 2019-01-15

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