WO2024041197A1 - 一种绝缘扁形导线 - Google Patents

一种绝缘扁形导线 Download PDF

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Publication number
WO2024041197A1
WO2024041197A1 PCT/CN2023/104441 CN2023104441W WO2024041197A1 WO 2024041197 A1 WO2024041197 A1 WO 2024041197A1 CN 2023104441 W CN2023104441 W CN 2023104441W WO 2024041197 A1 WO2024041197 A1 WO 2024041197A1
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WIPO (PCT)
Prior art keywords
layer
insulating layer
conductor
tape
thickness
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PCT/CN2023/104441
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English (en)
French (fr)
Inventor
施兴洲
江建龙
郑东辉
肖徽
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河源市可顺绝缘材料有限公司
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Publication of WO2024041197A1 publication Critical patent/WO2024041197A1/zh

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Classifications

    • 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
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame

Definitions

  • the present application relates to the technical field of flat conductors, and in particular to an insulated flat conductor.
  • 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.
  • 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.
  • 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.
  • the main purpose of this application is to provide an insulated flat conductor, aiming to improve the high temperature resistance and insulation performance of the conductor.
  • an insulated flat conductor which includes:
  • the conductor is flat
  • the high temperature resistant flame retardant layer includes a first insulation layer, a second insulation layer and a third insulation layer.
  • the first insulation layer covers the conductor, and the second insulation layer covers the first insulation layer.
  • layer, the third insulating layer covers the second insulating layer; wherein the first insulating layer, the second insulating layer and the third insulating layer are all made of high temperature resistant materials; and
  • a protective layer covers the third insulating layer.
  • the material of the conductor is copper, brass, aluminum or a combination thereof, the width of the conductor is 10 mm to 50 mm, and the thickness is 1.0 mm to 7.0 mm.
  • 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.
  • the first insulating layer includes at least one layer of tape, and the material of the tape is polyimide or ceramic silicon; the thickness of the first insulating layer is 20um ⁇ 300um, and each layer of the tape is The thickness is 10um ⁇ 100um.
  • 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.
  • the material of the mica tape is phlogopite tape, muscovite tape, synthetic mica tape or ceramic composite mica tape.
  • the third insulating layer includes at least one layer of polyimide tape, the thickness of the third insulating layer is 20um-300um, and the thickness of each layer of polyimide tape is 10um-100um.
  • the thickness of the third insulating layer is 40um ⁇ 80um.
  • the number of the protective layers is at least one, and the material of the protective layer is polymer plastic or the protective layer is a heat shrink sleeve, and the thickness of the protective layer is 0.2 mm to 2.0 mm.
  • the polymer plastic is PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI;
  • the heat shrinkable sleeves are fluorine rubber heat shrinkable sleeves, Teflon heat shrinkable sleeves, FEP heat shrinkable sleeves, PTFE heat shrinkable waterproof sleeves, PVDF heat shrinkable sleeves, PET heat shrinkable sleeves, PE heat shrinkable sleeves pipe, PVC heat shrink tubing, polyvinylidene fluoride heat shrink tubing, PTFE heat shrink tubing, silicone heat shrink tubing, chemically cross-linked polyolefin heat shrink tubing or polyester heat shrink tubing.
  • the wire includes a conductor, a high temperature resistant flame retardant layer and a protective layer;
  • the high temperature resistant flame retardant layer includes a first insulating layer, a second insulating layer and a third insulating layer, and the first insulating layer is covered with
  • 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; protection
  • the third insulation layer is coated on the third insulation layer.
  • the outermost 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 flame-retardant layer has strong insulation, high-temperature resistance and resistance.
  • the high-temperature flame-retardant 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 that car drivers are safe under extreme circumstances. personal safety.
  • Figure 1 is an exploded view of an embodiment of the insulated flat conductor of the present application
  • Figure 2 is a schematic structural diagram of an embodiment of the insulated flat conductor of the present application.
  • Figure 3 is a schematic structural diagram of an insulated flat conductor according to an embodiment of the present application when it is in a bent state during a high temperature test.
  • This application proposes an insulated flat conductor, especially a high-temperature resistant insulated flat conductor for automobile power batteries, which is not limited here.
  • the 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 and a second insulating layer 22 and the 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;
  • the protective layer 30 covers the third insulating layer 23 .
  • the conductor 10 may be made of conductive materials such as copper, aluminum, or brass, or a combination of the two materials, and may adopt a copper-clad aluminum structure, which is not limited here.
  • the 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 grade of aluminum conductor material can be Al-1000 series aluminum strip (typical grade 1060) or Al-6000 series aluminum strip (typical grade 6101).
  • the material standard complies with GB/T 3190.
  • 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 a phlogopite tape or a muscovite tape. , synthetic mica tape or ceramic composite mica tape and other high temperature resistant insulating materials, not limited here.
  • the 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; wherein, the first insulating layer 21 , the second insulating layer 22 and the third insulating layer 23 are both made of high temperature resistant materials; the protective layer 30 covers the third insulating layer 23 .
  • the outermost 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 flame retardant layer 20 has strong insulation , high temperature resistance and flame retardant ability.
  • the high temperature resistant flame retardant layer 20 can effectively prevent the insulation failure of the wire 100, improve the high temperature resistance and insulation performance, and play a safety protection role for the battery, thereby ensuring The personal safety of car drivers in extreme situations.
  • 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.
  • the thickness of each layer of tape can be 10um-100um, which is not limited here.
  • 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.
  • the wrapping line speed can be set to 2m/min ⁇ 15m/min, so that the processed semi-finished products meet the quality requirements.
  • the second insulation layer 22 may be at least one layer of mica tape, and the thickness of the mica tape may be 0.10 mm to 1.0 mm. mm, the thickness of each layer of mica tape can be 0.1mm ⁇ 0.5mm, there is no limit here.
  • the material of the mica tape is gilt tape, muscovite tape, synthetic mica tape or ceramic composite mica tape, etc.
  • Typical mica tape structures include PET or PE plus mica paper plus glass fiber reinforced mica tape, double-layer mica tape Paper plus double-layer glass fiber reinforced mica tape is not limited here.
  • the mica tape can also be wrapped on the first insulating layer 21 by using machines such as a horizontal double-head wrapping machine and automatic wrapping.
  • machines such as a horizontal double-head wrapping machine and automatic wrapping.
  • the wrapping machine can also be set to 2m/min ⁇ 15m/min to ensure that the processed semi-finished products meet the quality requirements.
  • the third insulation layer 23 may include at least one layer of polyimide tape, and the thickness of the third insulation layer It can be 20um ⁇ 300um, and the thickness of each layer of polyimide tape can be 10um ⁇ 100um.
  • the flat wire After experimental testing, especially when the thickness of the third insulating layer is 40um to 80um, the flat wire has better high temperature resistance, flame retardant and insulation properties, and the material cost is relatively low.
  • the polyimide tape can be wrapped on the surface of the second insulating layer using automated machine wrapping.
  • Polymer plastic is used for hot-melt extrusion processing on the semi-finished conductor 10 before coating.
  • the processing temperature is based on the melting point of the plastic and the material properties.
  • the temperature range is 150 ⁇ 450°C, assisting the entire pay-off, straightening, pulling, extrusion and cooling. and take-up process, the extrusion line speed can be set to 2m/min ⁇ 15m/min.
  • the second insulating layer 22 is reinforced and wrapped with polyimide tape on both sides. With the advantages of polyimide's high temperature resistance, flame retardancy and high toughness, the second insulating layer 22 is effectively wrapped so that the conductor 10 can When bending, the mica layer at the R corner of the bend spreads and expands with the polyimide in an orderly manner, ensuring the high temperature resistance of the mica. It can withstand temperatures above 800°C for long-term use.
  • the number of protective layers 30 is at least one layer, and the material of the protective layer 30 is polymer plastic or the protective layer 30 is a heat shrink sleeve.
  • the thickness of the protective layer 30 can be 0.2 mm ⁇ 2.0mm.
  • the polymer plastic may be PA11, PA12, PPS, PBT, PET, PEEK, PVC, XLPE, TPU, TPE or PI, etc., and is not limited here.
  • 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.
  • the protective layer 30 on the high-temperature resistant flame-retardant 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 flame retardant layer 20 and avoid insulation failure.
  • 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.
  • the material of the conductor 10 can be copper, brass, aluminum or a combination thereof.
  • the width of the conductor 10 can be 10mm ⁇ 50mm, and the thickness can be 1.0mm ⁇ 7.0mm.
  • the width tolerance of the conductor 10 Can be ⁇ 0.15mm, no limit here.
  • 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.
  • 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.
  • 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.
  • a number of flat insulated flat wires 100 were selected as test samples, and their structures were all composed of a conductor 10, a first insulation layer 21, a second insulation layer 22, a third insulation layer 23 and a protective layer 30.
  • the first insulation layer The material of layer 21 is polyimide, the material of second insulating layer 22 is mica tape, the material of third insulating layer 23 is polyimide, and the material of protective layer 30 is PA12.
  • a number of existing ordinary flat wires were selected as comparison samples. Its structure uses flat conductors, two high-temperature resistant flame-retardant layers and one insulating layer.
  • the high-temperature resistant flame-retardant layers are all made of existing high-temperature resistant and flame-retardant materials, such as mica tape.
  • the bending angle of the sample wire 100 is tested: vertical bending 90°, the bending R angle is equal to the width of the flat wire 100; flat bending 90°, the bending R angle is equal to the thickness of the flat wire 100.
  • the specific test results are as follows in Table 1:
  • the voltage resistance of the bent piece meets the test requirements (3000V, AC, leakage current ⁇ 1mA, water immersion voltage test); the sample wire 100 is used After bending by the bending machine, the bent parts are baked at a high temperature of 400°C for 1 hour, and then are powered on in the oven for dynamic testing or taken out for testing.
  • the leakage current is required to be ⁇ 60mA; in the end, 100pcs of the test samples are tested, and 100pcs of the test samples are OK. All test samples Through testing, high temperature resistance has been significantly improved.

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Abstract

本申请公开了一种绝缘扁形导线，该导线包括导体、耐高温阻燃层和保护层；导体呈扁形；耐高温阻燃层包括第一绝缘层、第二绝缘层和第三绝缘层，第一绝缘层包覆于导体上，第二绝缘层包覆于第一绝缘层上，第三绝缘层包覆于第二绝缘层上；其中，第一绝缘层、第二绝缘层和第三绝缘层均采用耐高温材料；保护层包覆于第三绝缘层上。本申请改进了导线的结构，可以有效地避免绝缘失效，提高了导线的耐高温和绝缘性能。

Description

一种绝缘扁形导线
相关申请的交叉引用
本申请要求在2022年8月25日提交中国专利局、申请号为202211030249.8、发明名称为“一种绝缘扁形导线”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及扁导线技术领域，尤其涉及一种绝缘扁形导线。
背景技术
随着新能源汽车行业的迅猛发展，电池包作为新能源汽车动力输出源，也随之不断发展，其低成本、小体积高输出、安全稳定等要求引领着各种组成零部件的技术革新。
当前，动力电池连接用的导电排应用越来越广泛，应用趋势也朝着一体折弯成型的趋势发展，其优势是加工方便，生产效率高，成本低。目前主流的连接导线是扁导体外部加一层绝缘塑料，如PA塑料，而绝大多数塑料的长期使用温度在125℃以内，这个温度在正常的电池包工作温度区间是足够的，但在一些极端应用场景中，甚至在电池发生失效时，其温度会远远超过125℃而短期达到300～500℃，常规的导电排包覆的塑料在此高温下，会迅速融化而失去绝缘保护能力，因此，保证连接导线在此高温环境下依然保持绝缘不失效，是关乎新能源汽车安全的重要指标。
为解决单层绝缘塑料在短期耐高温的问题，在现有技术中，一些电池连接导电排优化的设计方案是通过在导体上手工缠绕一层云母带进行绝缘，采用云母带可以起到一定的耐高温和绝缘效果。但是，由于云母带处于导线的最外层，在长期使用过程中，导线会出现刮伤、摩擦、以及液体侵蚀，容易导致绝缘失效。
发明内容
本申请的主要目的在于提供一种绝缘扁形导线，旨在提高导线的耐高温和绝缘性能。
为实现上述目的，本申请提出一种绝缘扁形导线，所述导线包括：
导体，所述导体呈扁形；
耐高温阻燃层，包括第一绝缘层、第二绝缘层和第三绝缘层，所述第一绝缘层包覆于所述导体上，所述第二绝缘层包覆于所述第一绝缘层上，所述第三绝缘层，包覆于所述第二绝缘层上；其中，所述第一绝缘层、所述第二绝缘层和所述第三绝缘层均采用耐高温材料；以及
保护层，包覆于所述第三绝缘层上。
可选地，所述导体的材料为铜、黄铜、铝或其组合，所述导体的宽度为10mm～50mm，厚度为1.0mm～7.0mm。
可选地，所述导线还包括电镀于所述导体上的电镀层，所述电镀层的材料为镍、锡、银或铜，所述电镀层的厚度为2um～15um。
可选地，所述第一绝缘层包括至少一层胶带，所述胶带的材料为聚酰亚胺或陶瓷化硅；所述第一绝缘层的厚度为20um～300um，每一层所述胶带的厚度为10um～100um。
可选地，所述第二绝缘层为至少一层云母带，所述第二绝缘层的厚度为0.10mm～1.0mm，每一层所述云母带的厚度为0.1mm～0.5mm。
可选地，所述云母带的材料为金云母带、白云母带、合成云母带或陶瓷化复合云母带。
可选地，所述第三绝缘层包括至少一层聚酰亚胺胶带，所述第三绝缘层的厚度为20um～300um，每一层所述聚酰亚胺胶带的厚度为10um～100um。
可选地，所述第三绝缘层的厚度为40um～80um。
可选地，所述保护层的数量为至少一层，且所述保护层的材料为高分子塑料或所述保护层为热缩套管，所述保护层的厚度为0.2mm～2.0mm。
可选地，所述高分子塑料为PA11、PA12、PPS、PBT、PET、PEEK、PVC、XLPE、TPU、TPE或PI；
所述热缩套管为氟胶热缩套管、特氟龙热缩套管、FEP热缩管、PTFE热收缩防水套管、PVDF热缩套管、PET热缩套管、PE热缩套管、PVC热缩套管、聚偏氟乙烯热缩套管、聚四氟乙烯热缩套管、硅胶热缩套管、化学交联聚烯烃热缩套管或聚酯热缩套管。
在本申请的技术方案中，该导线包括导体、耐高温阻燃层和保护层；耐高温阻燃层包括第一绝缘层、第二绝缘层和第三绝缘层，第一绝缘层包覆于导体上，第二绝缘层包覆于第一绝缘层上，第三绝缘层包覆于第二绝缘层上；第一绝缘层、第二绝缘层和第三绝缘层均采用耐高温材料；保护层包覆于第三绝缘层上。其中，最外层的保护层可以起到防潮、耐刮和一定的绝缘和耐高温性能，满足了电池连接正常的导电绝缘使用，而耐高温阻燃层具有较强的绝缘、耐高温及阻燃能力，当电池工作出现极端状态时，耐高温阻燃层可以有效地避免导线绝缘失效，提高了耐高温和绝缘性能，对电池起到安全防护作用，进而确保了汽车驾驶人在极端情况下的人身安全。
附图说明
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图示出的结构获得其他的附图。
图1为本申请绝缘扁形导线一实施例的分解图；
图2为本申请绝缘扁形导线一实施例的结构示意图；
图3为本申请绝缘扁形导线一实施例在高温测试中处于折弯状态时的结构示意图。
附图标号说明：
100、导线；10、导体；20、耐高温阻燃层；30、保护层；21、第一绝缘
层；22、第二绝缘层；23、第三绝缘层。
本申请目的的实现、功能特点及优点将结合实施例，参照附图做进一步说明。
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请的一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有 作出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
需要说明，若本申请实施例中有涉及方向性指示(诸如上、下、左、右、前、后……)，则该方向性指示仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。
另外，若本申请实施例中有涉及“第一”、“第二”等的描述，则该“第一”、“第二”等的描述仅用于描述目的，而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外，若全文中出现的“和/或”的含义为，包括三个并列的方案，以“A和/或B”为例，包括A方案，或B方案，或A和B同时满足的方案。另外，各个实施例之间的技术方案可以相互结合，但是必须是以本领域普通技术人员能够实现为基础，当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在，也不在本申请要求的保护范围之内。
本申请提出一种绝缘扁形导线，尤其是汽车动力电池用耐高温绝缘扁导线，此处不限。
参照图1及图2，在本申请一实施例中，该导线100包括导体10、耐高温阻燃层20和保护层30；耐高温阻燃层20包括第一绝缘层21、第二绝缘层22和第三绝缘层23，第一绝缘层21包覆于导体10上，第二绝缘层22包覆于第一绝缘层21上，第三绝缘层23包覆于第二绝缘层22上；其中，第一绝缘层21、第二绝缘层22和第三绝缘层23均采用耐高温材料；保护层30包覆于第三绝缘层23上。
本实施例中，导体10的材料可为铜、铝、黄铜等导电材料，也可是两种材料的组合，可以采用铜包铝的结构，此处不限。
其中，铜导体材料可选择牌号T2、TU2，材料标准符合GB/T 5231；或者采用牌号C1100、C1020，材料标准符合JIS H3100，或者采用牌号Cu-ETP(CW004A)、Cu-OF(CW008A)，材料标准符合DIN-EN-13599。铝导体材料可选择材料牌号可为Al-1000系列铝带(典型牌号1060)或Al-6000系列铝带(典型牌号6101)，材料标准符合GB/T 3190。
本实施例中，第一绝缘层21的材料为聚酰亚胺或陶瓷化硅等耐高温的绝缘材料，第二绝缘层22可为云母带，云母带的材料为金云母带、白云母带、合成云母带或陶瓷化复合云母带等耐高温的绝缘材料，此处不限。
在本申请的技术方案中，该导线100包括导体10、耐高温阻燃层20和保护层30；耐高温阻燃层20包括第一绝缘层21、第二绝缘层22和第三绝缘层23，第一绝缘层21包覆于导体10上，第二绝缘层22包覆于第一绝缘层21上，第三绝缘层23包覆于第二绝缘层22上；其中，第一绝缘层21、第二绝缘层22和第三绝缘层23均采用耐高温材料；保护层30包覆于第三绝缘层23上。可以理解的是，最外层的保护层30可以起到防潮、耐刮和一定的绝缘和耐高温性能，满足了电池连接正常的导电绝缘使用，而耐高温阻燃层20具有较强的绝缘、耐高温和阻燃能力，当电池工作出现极端状态时，耐高温阻燃层20可以有效地避免导线100绝缘失效，提高了耐高温和绝缘性能，对电池起到安全防护作用，进而确保了汽车驾驶人在极端情况下的人身安全。
为了进一步地提高导线100的耐高温性、阻燃性和绝缘性，并方便生产制造，参考图1，在一实施例中，第一绝缘层21可包括至少一层胶带，胶带的材料为聚酰亚胺或陶瓷化硅；第一绝缘层21的整体厚度可为20um～300um，此处不做限定。
本实施例中，每一层胶带的厚度可为10um～100um，此处不做限定。
在生产时，可以采用卧式双头绕包机等机器，通过自动化绕包的方式将胶带包覆到导体10上，也可采用挤出方式热压一层聚酰亚胺绝缘层于导体10上，此处不限定具体的包覆方式。其中，在采用卧式双头绕包机时，绕包线速可设置为2m/min～15m/min，以使加工的半成品符合质量要求。
为了进一步地提高导线100的耐高温性、耐火性和绝缘性，参考图1，在一实施例中，第二绝缘层22可为至少一层云母带，云母带的厚度可为0.10mm～1.0mm，每一层云母带的厚度可为0.1mm～0.5mm，此处不做限定。
本实施例中，云母带的材料为金母带、白云母带、合成云母带或陶瓷化复合云母带等，典型云母带结构有PET或PE加云母纸加玻纤增强云母带、双层云母纸加双层玻纤增强云母带，此处不做限定。
本实施例中，云母带也可采用卧式双头绕包机等机器，通过自动绕包的方式将云母带包覆于第一绝缘层21上。其中，在采用卧式双头绕包机时，绕 包线速也可设置为2m/min～15m/min，以使加工的半成品符合质量要求。
为了进一步地提高导线100的耐高温性、耐火性和绝缘性，参考图1，在一实施例中，第三绝缘层23可为包括至少一层聚酰亚胺胶带，第三绝缘层的厚度可为20um～300um，每一层聚酰亚胺胶带的厚度可为10um～100um。
经试验测试，特别是当第三绝缘层的厚度为40um～80um时，该扁形导线的耐高温、阻燃和绝缘性能较佳，且材料成本相对较低。
在生产制造时，可采用机器自动化绕包的方式，将聚酰亚胺胶带包覆到第二绝缘层的表面。采用高分子塑料进行热熔挤出加工包覆前工艺半成品导体10上，加工温度根据塑料熔点和材料性能，温度区间为150～450℃，辅助整个放线、校直、牵引、挤出、冷却和收线工艺，挤出线速可设置为2m/min～15m/min。
需要说明，第二绝缘层22双侧采用聚酰亚胺胶带加强包裹，借助聚酰亚胺高耐温、阻燃及高韧性等优点，有效地包裹住第二绝缘层22，使导体10在折弯时，折弯R角处的云母层随聚酰亚胺有序的均匀分散扩展，保证了云母耐高温的性能，长期使用耐高温800℃以上。
参考图1，在一实施例中，保护层30的数量为至少一层，且保护层30的材料为高分子塑料或保护层30为热缩套管，保护层30的厚度可为0.2mm～2.0mm。
本实施例中，高分子塑料可为PA11、PA12、PPS、PBT、PET、PEEK、PVC、XLPE、TPU、TPE或PI等，此处不限。
本实施例中，热缩套管可为氟胶热缩套管、特氟龙热缩套管、FEP热缩管、PTFE热收缩防水套管、PVDF热缩套管、PET热缩套管、PE热缩套管、PVC热缩套管、聚偏氟乙烯热缩套管、聚四氟乙烯热缩套管、硅胶热缩套管、化学交联聚烯烃热缩套管或聚酯热缩套管等，此处不做限定。
可以理解，通过设置保护层30于耐高温阻燃层20上，能够起到一定的防潮、耐刮、绝缘和耐高温性能，也可避免液体侵蚀耐高温阻燃层20，避免了绝缘失效。
本实施例中，高分子塑料可采用热熔挤出包胶的方式包覆于半成品导线上，加工温度根据塑料熔点和材料性能，温度区间150～450℃，辅助整个放线、校直、牵引、挤出、冷却和收线工艺，挤出线速可设置为2m/min～15m/min。 塑料层可以为单层或多层，此处不限。
参考图1，在一实施例中，导体10的材料可为铜、黄铜、铝或其组合，导体10的宽度可为10mm～50mm，厚度可为1.0mm～7.0mm，导体10的宽度公差可为±0.15mm，此处不限。
可选地，为了提高导体10的防腐蚀性能，并改善导体10导电性能，导线100还可包括电镀于导体10上的电镀层，电镀层的材料可为镍、锡、银或铜等，电镀层的厚度可为2um～15um，此处不限。
在生产制造时，可选用铜杆或铝杆材料，采用挤出机、拉拔机、电镀线等，通过挤压成型方式加工导体10。
此外，在一些实施例中，导体10的两侧边可做倒角处理，可以倒全圆倒角，也可以倒R角，半径大小可为0.5mm～3.5mm，以便于包胶，同时也可避免锋利的边缘割破绝缘层，提高了导线100的使用寿命。
在试验测试中，测试样品选取扁形绝缘扁形导线100若干，其结构均采用导体10、第一绝缘层21、第二绝缘层22、第三绝缘层23和保护层30的组合，其中第一绝缘层21的材料选用聚酰亚胺，第二绝缘层22的材料选用云母带，第三绝缘层23的材料选用聚酰亚胺，保护层30的材料选用PA12。对比样品选取现有普通扁形线材若干，其结构采用扁形导体、二层耐高温阻燃层和一层绝缘层，耐高温阻燃层均采用现有耐高温、阻燃材料，如云母带等。
如图3所示，样品导线100测试折弯角度：立折弯90°，折弯R角等于扁形导线100的宽度；平折弯90°，折弯R角等于扁形导线100的厚度。具体测试结果如下表1：
表1.本申请导线与现有普通导线的对比测试结果

由上可知，样品导线100使用折弯机折弯后，在耐高温测试中，折弯件耐压符合测试要求(3000V,AC,漏电流＜1mA、水浸泡耐压测试)；样品导线100使用折弯机折弯后，折弯件经过高温400℃高温烘烤，1h,在烤箱中通电动态测试或取出测试，要求漏电流＜60mA；最终，测试样件100pcs,测试OK 100pcs，全部测试样品通过测试，耐高温性得到显著提升。
以上所述仅为本申请的可选实施例，并非因此限制本申请的专利范围，凡是在本申请的发明构思下，利用本申请说明书及附图内容所作的等效结构变换，或直接/间接运用在其他相关的技术领域均包括在本申请的专利保护范围内。

Claims (10)

  1. 一种绝缘扁形导线，其特征在于，所述导线包括：
    导体，所述导体呈扁形；
    耐高温阻燃层，包括第一绝缘层、第二绝缘层和第三绝缘层，所述第一绝缘层包覆于所述导体上，所述第二绝缘层包覆于所述第一绝缘层上，所述第三绝缘层，包覆于所述第二绝缘层上；其中，所述第一绝缘层、所述第二绝缘层和所述第三绝缘层均采用耐高温材料；以及
    保护层，包覆于所述第三绝缘层上。
  2. 如权利要求1所述的导线，其特征在于，所述导体的材料为铜、黄铜、铝或其组合，所述导体的宽度为10mm～50mm，厚度为1.0mm～7.0mm。
  3. 如权利要求2所述的导线，其特征在于，所述导线还包括电镀于所述导体上的电镀层，所述电镀层的材料为镍、锡、银或铜，所述电镀层的厚度为2um～15um。
  4. 如权利要求1所述的导线，其特征在于，所述第一绝缘层包括至少一层胶带，所述胶带的材料为聚酰亚胺或陶瓷化硅；所述第一绝缘层的厚度为20um～300um，每一层所述胶带的厚度为10um～100um。
  5. 如权利要求1所述的导线，其特征在于，所述第二绝缘层为至少一层云母带，所述第二绝缘层的厚度为0.10mm～1.0mm，每一层所述云母带的厚度为0.1mm～0.5mm。
  6. 如权利要求5所述的导线，其特征在于，所述云母带的材料为金云母带、白云母带、合成云母带或陶瓷化复合云母带。
  7. 如权利要求1所述的导线，其特征在于，所述第三绝缘层包括至少一层聚酰亚胺胶带，所述第三绝缘层的厚度为20um～300um，每一层所述聚酰 亚胺胶带的厚度为10um～100um。
  8. 如权利要求7所述的导线，其特征在于，所述第三绝缘层的厚度为40um～80um。
  9. 如权利要求1所述的导线，其特征在于，所述保护层的数量为至少一层，且所述保护层的材料为高分子塑料或所述保护层为热缩套管，所述保护层的厚度为0.2mm～2.0mm。
  10. 如权利要求9所述的导线，其特征在于，所述高分子塑料为PA11、PA12、PPS、PBT、PET、PEEK、PVC、XLPE、TPU、TPE或PI；
    所述热缩套管为氟胶热缩套管、特氟龙热缩套管、FEP热缩管、PTFE热收缩防水套管、PVDF热缩套管、PET热缩套管、PE热缩套管、PVC热缩套管、聚偏氟乙烯热缩套管、聚四氟乙烯热缩套管、硅胶热缩套管、化学交联聚烯烃热缩套管或聚酯热缩套管。
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CN215911548U (zh) * 2021-08-31 2022-02-25 宁波峰梅新能源汽车科技有限公司 一种耐电池包热失控的铜排

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CN102097166A (zh) * 2011-03-30 2011-06-15 无锡统力电工有限公司 耐高温、抗电晕绕包铝扁线
US20150221412A1 (en) * 2014-02-05 2015-08-06 Essex Group, Inc. Insulated Winding Wire
CN210295951U (zh) * 2019-08-30 2020-04-10 河南华洋电工科技集团有限公司 一种节能变压器用双玻璃丝绕组线
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