WO2024022020A1

WO2024022020A1 - Insulated wire

Info

Publication number: WO2024022020A1
Application number: PCT/CN2023/104440
Authority: WO
Inventors: 施兴洲; 江建龙; 郑东辉; 肖徽
Original assignee: 河源市可顺绝缘材料有限公司
Priority date: 2022-07-27
Filing date: 2023-06-30
Publication date: 2024-02-01
Also published as: CN117524567A

Abstract

Disclosed in the present invention is an insulated wire. The wire comprises a conductor, a high-temperature-resistant layer and an insulating protective layer, wherein the high-temperature-resistant layer comprises a first insulating layer and/or a second insulating layer, and the conductor is coated with the high-temperature-resistant layer; and the high-temperature-resistant layer is coated with the insulating protective layer. The present application improves the structure of a wire, so that insulation failure can be effectively prevented, and the high-temperature-resistant performance and insulation performance of the wire are improved.

Description

an insulated wire

Cross-references to related applications

This application claims priority to the Chinese patent application filed with the China Patent Office on July 27, 2022, with the application number 202210895228.6 and the invention title "An Insulated Wire", the entire content of which is incorporated into this application by reference.

Technical field

The present application relates to the technical field of flat conductors, and in particular to an insulated conductor.

Background technique

With the rapid development of the new energy vehicle industry, the battery pack, as the power output source of new energy vehicles, has also continued to develop. Its low cost, small size, high output, safety and stability and other requirements are leading the technological innovation of various component parts.

At present, conductive bars for power battery connection are more and more widely used, and the application trend is also developing towards the trend of integrated bending and molding. Its advantages are convenient processing, high production efficiency and low cost. The current mainstream connection wire is a flat conductor with a layer of insulating plastic on the outside, such as PA plastic. The long-term use temperature of most plastics is within 125°C. This temperature is sufficient in the normal battery pack operating temperature range, but in some cases In extreme application scenarios, even when the battery fails, its temperature will far exceed 125°C and reach 300-500°C in a short period of time. At this high temperature, the plastic covering the conventional conductive row will quickly melt and lose its insulation protection ability. Therefore, ensuring that the connecting wires maintain insulation without failure in this high temperature environment is an important indicator related to the safety of new energy vehicles.

In order to solve the problem of short-term high temperature resistance of single-layer insulating plastics, in the existing technology, some optimization design solutions for battery connection conductive bars are to manually wrap a layer of mica tape on the conductor for insulation. The use of mica tape can play a certain role. High temperature resistance and insulation effect. However, since the mica tape is the outermost layer of the wire, during long-term use, the wire will be scratched, rubbed, and eroded by liquid, which can easily lead to insulation failure.

Contents of the invention

The main purpose of this application is to provide an insulated conductor, aiming to improve the high temperature resistance and insulation of the conductor. Fate performance.

In order to achieve the above objectives, this application proposes an insulated conductor, which includes:

conductor;

A high temperature resistant layer, including a first insulating layer and/or a second insulating layer, the high temperature resistant layer covering the conductor; and

An insulating protective layer covers the high temperature resistant layer.

Optionally, the first insulating layer includes at least one layer of tape, the material of the tape is polyimide or ceramic silicon, and the thickness of each layer of the tape is 10um ~ 100um; the first insulating layer The thickness is 20um~300um.

Optionally, the second insulating layer is a mica tape, and the thickness of the mica tape is 0.10 mm to 1.0 mm.

Optionally, the material of the mica tape is phlogopite tape, calcined muscovite tape, coated or gummed mica tape, synthetic mica tape or ceramic composite mica tape.

Optionally, the number of the insulating protective layers is at least one, and the material of the insulating protective layers is polymer plastic or the insulating protective layers are heat shrink sleeves, and the thickness of the insulating protective layers is 0.2 mm. ~2.0mm.

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

Optionally, the heat shrinkable sleeve is fluorine rubber heat shrinkable sleeve, Teflon heat shrinkable sleeve, FEP heat shrinkable sleeve, PTFE heat shrinkable waterproof sleeve, PVDF heat shrinkable sleeve, PET heat shrinkable sleeve , PE heat shrink tubing, PVC heat shrink tubing, polyvinylidene fluoride heat shrink tubing, polytetrafluoroethylene heat shrink tubing, silicone heat shrink tubing, chemically cross-linked polyolefin heat shrink tubing, polyester heat shrink tubing Shrink the sleeve.

Optionally, the conductor is flat; the conductor is made of copper, brass, aluminum or a combination thereof, or the conductor is made of non-metallic conductor, the conductor has a width of 10 mm to 50 mm and a thickness of 1.0 mm～7.0mm.

Optionally, the wire further includes an electroplating layer electroplated on the conductor. The material of the electroplating layer is nickel, tin, silver or copper, and the thickness of the electroplating layer is 2um to 15um.

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

In the technical solution of this application, the wire includes a conductor, a high temperature resistant layer and an insulating protective layer; The high-temperature layer includes a first insulating layer and/or a second insulating layer, the high-temperature resistant layer covers the conductor, and the insulating protective layer covers the high-temperature resistant layer. Among them, the outermost insulating protective layer can be moisture-proof, scratch-resistant and have certain insulation and high-temperature resistance properties, which meets the normal conductive insulation use of battery connections, while the high-temperature-resistant layer has strong insulation, high-temperature resistance and flame retardancy. When the battery is working in extreme conditions, the high-temperature resistant layer can effectively avoid wire insulation failure, improve high-temperature resistance and insulation performance, and play a safety protection role for the battery, thus ensuring the personal safety of car drivers in extreme situations. .

Description of drawings

In order to explain the embodiments of the present application or the technical solutions in the prior art more clearly, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are only These are some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on the structures shown in these drawings without exerting creative efforts.

Figure 1 is a schematic structural diagram of an embodiment of a conductor according to the present application;

FIG. 2 is a schematic structural diagram of an embodiment of the conductor according to the present application when it is in a bent state.

Explanation of reference numbers:
100. Wire; 10. Conductor; 20. High temperature resistant layer; 30. Insulating protective layer; 21. First insulating layer; 22. Second insulating layer.

The realization of the purpose, functional features and advantages of the present application will be further described with reference to the embodiments and the accompanying drawings.

Detailed ways

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of this application.

It should be noted that if there are directional instructions (such as up, down, left, right, front, back...) in the embodiments of the present application, the directional instructions are only used to explain the position of a certain posture (as shown in the accompanying drawings). (display) relative positional relationship, movement, etc. between the components. If the specific posture changes, The directional indication will also change accordingly.

In addition, if there are descriptions involving “first”, “second”, etc. in the embodiments of this application, the descriptions of “first”, “second”, etc. are only for descriptive purposes and shall not be understood as indications or implications. Its relative importance or implicit indication of the number of technical features indicated. Therefore, features defined as "first" and "second" may explicitly or implicitly include at least one of these features. In addition, if "and/or" appears in the full text, it means including three parallel plans, taking "A and/or B" as an example, including plan A, or plan B, or a plan that satisfies both A and B at the same time. . In addition, the technical solutions in various embodiments can be combined with each other, but it must be based on the realization by those of ordinary skill in the art. When the combination of technical solutions is contradictory or cannot be realized, it should be considered that such a combination of technical solutions does not exist. , nor is it within the scope of protection required by this application.

This application proposes an insulated conductor, especially a high-temperature resistant insulated flat conductor for automobile power batteries. It can also be a round conductor and is not limited here.

Referring to Figures 1 and 2, Figure 1 is a schematic structural diagram of an embodiment of the conductor of the present application; Figure 2 is a schematic structural diagram of an embodiment of the conductor of the present application when it is in a bent state. It is a connecting wire 100 for a power battery. The wire 100 is in the shape of Flat setting. Referring mainly to Figure 1, in an embodiment of the present application, the wire 100 includes a conductor 10, a high temperature resistant layer 20 and an insulating protective layer 30; the high temperature resistant layer 20 includes a first insulating layer 21 and/or a second insulating layer 22. The high-temperature layer 20 covers the conductor 10; the insulating protective layer 30 covers the high-temperature resistant layer 20.

In this embodiment, the conductor 10 may be made of conductive materials such as copper, aluminum, brass, graphite or graphene, or a combination of the two materials, and may adopt a copper-clad aluminum structure, which is not limited here.

Among them, copper conductor materials can be selected from grades T2 and TU2, and the material standard complies with GB/T 5231; or the grade C1100, C1020, and the material standard conforms to JIS H3100, or the grade Cu-ETP (CW004A), Cu-OF (CW008A), Material standards comply with DIN-EN-13599. The optional material grades for aluminum conductor materials can be Al-1000 series aluminum strips (typical grade 1060) or Al-6000 series aluminum strips (typical grade 6101). The material standards comply with GB/T 3190.

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 can be a mica tape. The material of the mica tape is phlogopite tape or calcined muscovite mica. Tapes, coated or glued mica tapes, synthetic mica tapes or ceramic composite mica tapes and other high temperature resistant insulating materials are not limited here.

It should be noted 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 solutions: 1. The high temperature resistant layer 20 only includes the first insulating layer 21; 2. The high temperature resistant layer 20 only includes the first insulating layer 21; The layer 20 only includes the second insulating layer 22; 3. The high temperature resistant layer 20 includes the first insulating layer 21 and the second insulating layer 22. When the first insulating layer 21 and the second insulating layer 22 exist at the same time, the coating order can be interchanged. The first insulating layer 21 can be coated first, or the second insulating layer 22 can be coated first.

In the technical solution of the present application, the wire 100 includes a conductor 10, a high temperature resistant layer 20 and an insulating protective layer 30; the high temperature resistant layer 20 includes a first insulating layer 21 and/or a second insulating layer 22, and the high temperature resistant layer 20 covers on the conductor 10; the insulating protective layer 30 covers the high temperature resistant layer 20. It can be understood that the outermost insulating protective layer 30 can be moisture-proof, scratch-resistant and have certain insulation and high-temperature resistance properties, which meets the normal conductive insulation use of battery connections, while the high-temperature resistant layer 20 has strong insulation, High temperature resistance and flame retardant ability. When the battery operates in an extreme state, the high temperature resistance layer 20 can effectively prevent the insulation failure of the wire 100, improve the high temperature resistance and insulation performance, play a safety protection role for the battery, and thus ensure the safety of car drivers. Personal safety in extreme situations.

In order to further improve the high temperature resistance, flame retardancy and insulation of the wire 100 and facilitate production and manufacturing, with reference to Figure 1, in one embodiment, the first insulation layer 21 may include at least one layer of tape, and the material of the tape is polyethylene. Imide or ceramic silicon; the overall thickness of the first insulating layer 21 can be 20um ~ 300um, which is not limited here.

In this embodiment, the thickness of each layer of tape can be 10um-100um, which is not limited here.

During production, machines such as a horizontal double-head wrapping machine can be used to wrap the tape on the conductor 10 through automatic wrapping, or an extrusion method can be used to hot-press a layer of polyimide insulation layer on the conductor 10 , the specific coating method is not limited here. Among them, when using a horizontal double-head wrapping machine, the wrapping line speed can be set to 2m/min ~ 15m/min, so that the processed semi-finished products meet the quality requirements.

In order to further improve the high temperature resistance, fire resistance and insulation of the conductor 100, referring to FIG. 1, in one embodiment, the second insulation layer 22 may be a mica tape, and the thickness of the mica tape may be 0.10 mm to 1.0 mm. There are no restrictions anywhere.

In this embodiment, the material of the mica tape is gold mother tape, synthetic mica tape, ceramic composite mica tape, etc., which is not limited here.

In this embodiment, the mica tape can also be wrapped on the conductor 10 or the first insulating layer 21 by using a machine such as a horizontal double-head wrapping machine. Among them, when using a horizontal double-head wrapping machine, the wrapping line speed can also be set to 2m/min ~ 15m/min, so that the processed semi-finished products meet the quality requirements. quantity requirements.

Referring to FIG. 1 , in one embodiment, the number of the insulating protective layer 30 is at least one layer, and the material of the insulating protective layer 30 is polymer plastic or the insulating protective layer 30 is a heat shrink sleeve. The thickness of the insulating protective layer 30 can be 0.2mm～2.0mm.

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

In this embodiment, the heat shrinkable sleeve can be a fluorine rubber heat shrinkable sleeve, a Teflon heat shrinkable sleeve, a FEP heat shrinkable sleeve, a PTFE heat shrinkable waterproof sleeve, a PVDF heat shrinkable sleeve, a PET heat shrinkable sleeve, PE heat shrink tubing, PVC heat shrink tubing, polyvinylidene fluoride heat shrink tubing, polytetrafluoroethylene heat shrink tubing, silicone heat shrink tubing, chemically cross-linked polyolefin heat shrink tubing or polyester heat shrink tubing Casings, etc. are not limited here.

It can be understood that by disposing the insulating protective layer 30 on the high-temperature resistant layer 20, it can achieve certain moisture-proof, scratch-resistant, insulating and high-temperature-resistant properties, and can also prevent liquid from eroding the high-temperature resistant layer 20 and avoid insulation failure.

In this embodiment, the polymer plastic can be coated on the semi-finished conductor by hot-melt extrusion coating. The processing temperature is based on the melting point of the plastic and the material properties. The temperature range is 150-450°C to assist the entire wiring, straightening, and pulling. , extrusion, cooling and take-up process, the extrusion line speed can be set to 2m/min~15m/min. The plastic layer can be a single layer or multiple layers, and is not limited here.

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 a non-metal conductor, such as graphite or graphene. The width of the conductor 10 can be 10mm~50mm, the thickness can be 1.0mm~7.0mm, and the width tolerance of the conductor 10 can be ±0.15mm, which is not limited here.

Optionally, in order to improve the anti-corrosion performance of the conductor 10 and improve the electrical conductivity of the conductor 10, the conductor 100 may also include an electroplating layer electroplated on the conductor 10. The material of the electroplating layer may be nickel, tin, silver or copper, etc., and the electroplating layer The thickness of the layer can range from 2um to 15um, and is not limited here.

During production and manufacturing, copper rod or aluminum rod materials can be used, and the conductor 10 can be processed by extrusion molding using an extruder, drawing machine, electroplating line, etc.

In addition, in some embodiments, both sides of the conductor 10 can be chamfered, either by full-circle chamfering or R-angle chamfering, and the radius can be 0.5 mm to 3.5 mm to facilitate encapsulation, and at the same time, It can prevent sharp edges from cutting the insulation layer and improve the service life of the conductor 100.

In the comparative test, a number of flat conductors 100 were selected as test samples, and their structures were all made of conductors 10, A combination of the first insulating layer 21, the second insulating layer 22 and the insulating protective layer 30, wherein the material of the first insulating layer 21 is polyimide or ceramic silicon, and the material of the second insulating layer 22 is mica tape. A number of existing ordinary flat wires are selected as comparison samples. The structure adopts a flat conductor and a single insulation layer, or an insulating combination of a flat conductor and a layer of mica tape. The specific test results are as follows in Table 1:

Table 1. Comparative test results of the wires of this application and existing ordinary wires

Through comparative tests, it can be seen that compared with existing ordinary wires, the conductor 100 of the present application has higher flame retardancy, temperature resistance and water resistance than the comparative sample. Among them, the flame retardant level can reach UL94-V0; under the test condition of 500℃, after 1h high temperature test, the insulation withstand voltage test passed; the surface of conductor 10 is water-resistant, and after immersion test for 1h, the insulation withstand voltage test in water qualified.

The above are only optional embodiments of the present application, and are not intended to limit the patent scope of the present application. Under the inventive concept of the present application, any equivalent structural transformation made by using the contents of the description and drawings of the present application, or direct/indirect Application in other related technical fields is included in the scope of patent protection of this application.

Claims

An insulated conductor, characterized in that the conductor includes:

conductor;

A high temperature resistant layer, including a first insulating layer and/or a second insulating layer, the high temperature resistant layer covering the conductor; and

An insulating protective layer covers the high temperature resistant layer.
The wire according to claim 1, wherein the first insulation layer includes at least one layer of tape, the material of the tape is polyimide or ceramic silicon, and the thickness of each layer of tape is 10um. ~100um; the thickness of the first insulating layer is 20um ~ 300um.
The conductor according to claim 1, wherein the second insulation layer is a mica tape, and the thickness of the mica tape is 0.10 mm to 1.0 mm.
The conductor according to claim 3, characterized in that the material of the mica tape is phlogopite tape, calcined muscovite tape, coated or gummed mica tape, synthetic mica tape or ceramic composite mica tape.
The wire according to claim 4, wherein the number of the insulating protective layers is at least one layer, and the material of the insulating protective layers is polymer plastic or the insulating protective layers are heat shrinkable sleeves, so The thickness of the insulating protective layer is 0.2mm~2.0mm.
The wire according to claim 5, wherein the polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI.
The wire according to claim 5, wherein the heat shrinkable sleeve is a fluorine rubber heat shrinkable sleeve, a Teflon heat shrinkable sleeve, a FEP heat shrinkable sleeve, a PTFE heat shrinkable waterproof sleeve, or a PVDF heat shrinkable sleeve. Sleeves, PET heat shrinkable sleeves, PE heat shrinkable sleeves, PVC heat shrinkable sleeves, polyvinylidene fluoride heat shrinkable sleeves, polytetrafluoroethylene heat shrinkable sleeves, silicone heat shrinkable sleeves, chemically cross-linked polyolefin Heat shrink tubing or polyester heat shrink tubing.
The conductor according to any one of claims 1 to 7, characterized in that the conductor is flat; the conductor is made of copper, brass, aluminum or a combination thereof, or the conductor is made of non-metallic conductor , the width of the conductor is 10mm~50mm, and the thickness is 1.0mm~7.0mm.
The wire according to claim 8, characterized in that the wire further includes an electroplating layer electroplated on the conductor, the material of the electroplating layer is nickel, tin, silver or copper, and the thickness of the electroplating layer is 2um～15um.
The conductor according to claim 8, wherein both sides of the conductor are provided with chamfers, and the chamfers are full-circle chamfers or chamfers with a radius of 0.5 mm to 3.5 mm.