EP3441986B1 - Insulated electrical conductor - Google Patents

Insulated electrical conductor Download PDF

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Publication number
EP3441986B1
EP3441986B1 EP18191902.8A EP18191902A EP3441986B1 EP 3441986 B1 EP3441986 B1 EP 3441986B1 EP 18191902 A EP18191902 A EP 18191902A EP 3441986 B1 EP3441986 B1 EP 3441986B1
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EP
European Patent Office
Prior art keywords
layer
electrical conductor
electric conductor
insulating coating
insulating
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Application number
EP18191902.8A
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German (de)
French (fr)
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EP3441986B8 (en
EP3441986A1 (en
Inventor
Jürgen Hochstöger
Rudolf Schrayvogel
Ewald Koppensteiner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
HPW Metallwerk GmbH
Original Assignee
Gebauer and Griller Metallwerk GmbH
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Application filed by Gebauer and Griller Metallwerk GmbH filed Critical Gebauer and Griller Metallwerk GmbH
Priority to PL18191902T priority Critical patent/PL3441986T3/en
Priority to RS20211525A priority patent/RS62697B1/en
Publication of EP3441986A1 publication Critical patent/EP3441986A1/en
Application granted granted Critical
Publication of EP3441986B1 publication Critical patent/EP3441986B1/en
Publication of EP3441986B8 publication Critical patent/EP3441986B8/en
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    • 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
    • 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
    • H01B13/003—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
    • H01B13/141—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
    • H01B13/06—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
    • H01B3/303—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
    • H01B3/307—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
    • H01B3/306—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 electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating comprising at least one outer insulating layer made of thermoplastic material, and to a method for producing such an insulated electrical conductor.
  • Insulated electrical conductors are installed in almost every electrical device in order to conduct electrical current without causing short circuits, which can be caused by the contact of non-electrically insulated conductors.
  • Such insulated electrical conductors comprise an electrical conductor made of copper and a coating which electrically insulates the electrical conductor and usually has one or more layers.
  • the insulating coating comprises an insulating layer made of thermoplastic material.
  • an all-round cut is usually made on the insulated electrical conductor perpendicular to a conductor axis, the electrical conductor is stretched by 20% and then the detachment of the insulating coating from the electrical conductor is measured. The less the insulating coating detaches from the electrical conductor, the better the adhesion.
  • JP2003031061A discloses the production of an insulated electrical conductor comprising an electrical conductor with an insulating coating, the insulating coating comprising an insulating layer made of thermoplastic material (EVA or PE).
  • the electrical conductor of the generic insulated electrical conductor consists of copper or an alloy with a high copper content or aluminum or other electrically conductive materials.
  • the electrical conductor is understood to mean both a single conductor and a stranded wire containing a plurality of individual conductors.
  • the cross-sectional geometry of the electrical conductor which is normal to a conductor axis, can have any geometric shape: square, rectangular, circular or elliptical, whereby it Any edges are usually rounded or profiled.
  • the insulation of the electrical conductor is ensured by the provided at least one insulation layer made of thermoplastic material, wherein the at least one insulation layer can advantageously form the outermost layer of the insulating coating. However, it is also conceivable that one or more further insulation layers are applied to the at least one insulation layer.
  • oxide layer for example made of copper oxide or aluminum oxide
  • the oxide layer has a negative effect on the adhesive properties of a layer of the insulating coating applied to the surface of the electrical conductor.
  • the adhesion of the layer of the insulating coating applied to the surface of the electrical conductor from which the oxide layer has been removed 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, with other impurities also being able to be removed by the plasma treatment. It is even possible that the plasma treatment removes the top atomic layers of the electrical conductor.
  • a gas plasma is generated in the protective gas atmosphere and the electrical 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.
  • Suitable protective gas or process gas are, for example, nitrogen, argon or hydrogen.
  • the plasma treatment has other positive effects on the insulated electrical conductor: on the one hand, the electrical conductor is heated by the impact energy of the ions on the surface and can be annealed during the plasma treatment
  • the surface energy of the electrical conductor can be increased by ion bombardment, which additionally improves the adhesion of the insulating coating to the surface of the electrical conductor.
  • Another effect of the plasma treatment is the increase in the micro-roughness of the surface of the electrical 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 electrical conductor in a protective gas atmosphere, preferably in the same protective gas atmosphere under which the plasma treatment is carried out.
  • An insulated electrical conductor according to the invention has particularly good adhesion properties due to the direct application of a plastic-containing intermediate layer of the insulating coating or the direct application of the insulating layer made of thermoplastic material to the plasma-treated and thus oxide-layer-free surface of the electrical conductor: If a circumferential cut on the insulated electrical conductor is perpendicular carried out to a conductor axis and the conductor stretched by 20%, the detachment of the insulating coating from the electrical conductor measured in the direction of the conductor axis is only a maximum of 3 mm, preferably a maximum of 2 mm, in particular a maximum of 1 mm.
  • the adhesion effect is thus achieved in both variants in that a plastic layer, which is preferably made of plastic, is applied under a protective gas atmosphere directly to the surface of the electrical conductor, which is preferably plasma-cleaned and thus oxide layer-free.
  • the plastic layer can be the at least one insulating layer made of thermoplastic plastic if no intermediate layer is provided.
  • the plastic layer can also be an intermediate layer containing plastic, preferably a plasma polymer layer or at least one fluoropolymer layer. If the insulating coating has an intermediate layer containing plastic, the at least one insulating layer is preferably applied directly to the intermediate layer containing plastic. However, it is also conceivable that one or more further intermediate layers are provided between the intermediate layer containing plastic and the at least one insulation 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 insulation layer, that is to say has no further intermediate layers.
  • the detachment of the insulating coating from the electrical conductor usually remains far below 1 mm, in particular a maximum of 0.2 mm, preferably a maximum of 0.1 mm, preferably a maximum of 0.05 mm, particularly preferably a maximum 0.01 mm, if the at least one insulation layer is applied directly to the surface of the electrical conductor.
  • the at least one insulation layer comprises a polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], or consists of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK].
  • One embodiment variant of the invention provides that the electrical conductor is arranged continuously under a protective gas atmosphere until the insulating coating is applied in order to prevent the formation of a new oxide layer on the surface of the electrical conductor. It is also possible to run through several protective gas atmospheres one after the other, as long as the plasma-treated electrical conductor is arranged uninterruptedly under one of the protective gas atmospheres.
  • the gas plasma for bombarding the electrical conductor is a low-pressure plasma, preferably with 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 insulation layer is selected from the group consisting of polyaryletherketone [PAEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.
  • PAEK polyaryletherketone
  • PAI polyamideimide
  • PEI polyetherimide
  • PPS polyphenylene sulfide
  • the thermoplastic material can comprise one or more of the plastics mentioned above and, if appropriate, further components, such as fiber material, fillers or further plastics.
  • Polyaryletherketones are made up of phenyl groups linked by means of oxygen bridges, i.e. ether or ketone groups, the number and sequence of the ether or ketone groups within the polyaryletherketones being variable.
  • Polyimides are plastics whose most important structural feature is the imide group. These include polysuccinimide (PSI), Polybismaleimide (PBMI) and polyoxadiazobenzimidazole (PBO), polyimidesulfone (PISO) and polymethacrylimide (PMI).
  • thermoplastic of the at least one insulation layer is a polyaryletherketone [PAEK] selected from the group consisting of polyetherketone [PEK], polyetheretherketone [PEEK], polyetherketoneketone [PEKK ], Polyether ether ketone ketone [PEEKK], polyether ketone ether ketone ketone [PEKEKK], and combinations thereof.
  • PAEK polyaryletherketone
  • Polyetheretherketone [PEEK] has proven to be particularly well suited for the at least one insulation layer.
  • the at least one insulation 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.
  • other layer thicknesses are also conceivable, for example 40 ⁇ m, 60 ⁇ m, 80 ⁇ m, 100 ⁇ m or 200 ⁇ m, to name a few possibilities.
  • the specified values can relate both to the thickness of an individual layer of the insulation layer and to the total thickness of the insulation layer if the insulation layer comprises more than one layer.
  • the at least one insulation layer can be produced inexpensively and quickly if it is applied by an extrusion process, that is to say it is extruded on. Therefore, in a further preferred embodiment of the invention, it is provided that the, preferably outer, insulation layer can be produced by means of an extrusion process.
  • 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 electrical conductor, one becomes special enables simple and inexpensive production of an insulated electrical conductor according to the invention, since the adhesion of the at least one insulation layer to the surface of the electrical conductor as a result of 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 plastic-containing intermediate layer applied directly to the surface of the electrical conductor is the at least one insulating layer.
  • the particularly preferred embodiment relates to an insulated electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating consisting of at least one insulating layer made of thermoplastic material, obtainable by a method in which the electrical conductor is under a protective gas atmosphere in a gas plasma is bombarded with ions of the protective gas in order to remove an oxide layer formed on a surface of the electrical conductor and / or to increase the surface energy of the electrical conductor, and the at least one insulation layer is applied directly to the surface of the electrical conductor is, the at least one insulation layer is applied to the electrical conductor in a protective gas atmosphere.
  • the particularly preferred embodiment also relates to an insulated electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating consisting of at least one insulating layer made of thermoplastic material, the invention providing that an oxide layer formed on a surface of the electrical conductor by bombarding the electrical conductor with ions of a Protective gas of a protective gas atmosphere is removed in a gas plasma and subsequently the at least one insulation layer is applied directly to the oxide-layer-free surface of the electrical conductor.
  • the insulating coating can consist, for example, of only a single insulating layer which is applied directly to the surface of the electrical conductor in order to enable particularly simple manufacture.
  • a further particularly preferred embodiment of the invention provides that the insulating Coating consists of exactly two or more than two, for example three or four, insulation layers.
  • a lowermost insulation layer is applied directly to the surface of the electrical conductor, the further insulation layers each being applied to one of the preceding insulation layers. If a fault has occurred in the lowest insulation layer, i.e.
  • the subsequent insulation layers increase the likelihood that the faulty section of the lowest insulation layer will not be covered by the following insulation layers either, reduced following an exponential function.
  • all insulation layers are applied in a protective gas atmosphere, so that the adhesion of subsequent insulation layers in the area of defective sections of the preceding insulation layers is improved.
  • At least one, that is to say for example one, two, three or four, further insulation layer made 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 insulation layer is preferably constructed analogously to the at least one insulation layer, so that the thermoplastic plastic of the at least one further insulation 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.
  • At least one further insulation layer is applied to the insulating coating outside the protective gas atmosphere in order to cover any defective sections of the insulating coating, so that the adhesion of the further insulation layer is not improved in the area of the defective sections of the insulating coating.
  • further insulation layers can also be applied if a greater thickness of the insulation is required. Therefore, in a further embodiment of the invention it is provided that at least one, preferably one, two or three, further insulation layer is applied to the insulating coating, the at least one further insulation layer not being applied in a protective gas atmosphere.
  • the insulating coating has a plasma polymer layer of crosslinked macromolecules of non-uniform chain length, which plasma polymer layer is applied directly to the surface of the electrical conductor by polymerizing a gaseous monomer in a gas plasma, preferably in a gas plasma for bombarding the electrical conductor, can be produced.
  • the plastic-containing intermediate layer of the insulating coating applied directly to the surface of the electrical conductor in this exemplary embodiment is the plasma polymer layer.
  • the plasma polymer layer serves as an intermediate layer and, on the one hand, adheres excellently to the surface of the electrical conductor and, on the other hand, enables increased adhesion of the layer of the insulating coating applied to the plasma polymer layer, for example the at least one insulating layer.
  • the plasma polymer layer has a thickness of 1 ⁇ m or less. Thicknesses of up to a hundredth of a micrometer are conceivable as the lower limit. Due to the small layer thickness, the plasma polymer layer has only a negligible effect on the entire thickness of the insulated electrical 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 characterized by particularly good adhesion properties.
  • the plasma polymer layer is to have properties similar to those of polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP], CF 4 is the ideal monomer.
  • the insulating coating has at least one fluoropolymer layer applied directly to the surface of the electrical conductor, preferably comprising polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP].
  • the fluoropolymer layer is also characterized by excellent adhesive properties, both on the electrical conductor and on the layer applied to the fluoropolymer layer, and serves as an intermediate layer insulating coating. It is also conceivable that several fluoropolymer layers, for example two, three or four, are applied to the electrical conductor on top of one another.
  • 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.
  • a further embodiment of the invention provides that the at least one insulation 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 electrical conductor in accordance with the first or second alternative embodiment variant and the second upper layer in the form of the at least one insulating layer made of thermoplastic material.
  • the outermost layer of the insulating coating can either be formed by the at least one insulating layer itself or by one or more further layers.
  • the electrical conductor preferably made of copper or aluminum, is subjected to the process in the form of a tape or a wire.
  • the electrical conductor is either treated "inline", i.e. directly after the production of the electrical conductor (for example by cold forming or extrusion), in accordance with the method according to the invention, or the electrical conductor is made available in wound form via a coil payout.
  • the electrical conductor becomes one more before the plasma treatment mechanical and / or chemical pre-cleaning.
  • the plasma treatment is carried out analogously to the previous explanations, the electrical conductor being continuously conveyed through the plasma treatment unit carrying out the plasma treatment.
  • the thickness of the layer removed from the electrical conductor by the plasma treatment can be precisely adjusted by a suitable choice of the process parameters.
  • the temperature for the soft annealing and the associated recrystallization of the structure of the electrical conductor can also be defined.
  • the insulating coating is applied to the treated surface of the electrical conductor.
  • the insulating coating adheres particularly well to the surface of the electrical conductor due to the removal of the oxide layer or the activation of the surface by increasing the surface energy of the electrical conductor.
  • either the at least one insulation layer or at least the plastic-containing intermediate layer of the insulating coating i.e. in particular the plasma polymer layer or the at least one fluoropolymer layer, applied directly to the oxide layer-free surface of the electrical conductor in a protective gas atmosphere. It is particularly advantageous if the electrical conductor is arranged continuously under a protective gas atmosphere until the insulating coating is applied. It goes without saying that, if two, three or more insulation layers made of thermoplastic material are provided, in any case the first of the insulation layers is applied directly to the surface of the electrical conductor and the subsequent ones Insulation layers are at least partially applied to the underlying insulation layers.
  • Insulated electrical conductors produced in this way have particularly good adhesion properties through the direct application of an intermediate layer of the insulating coating containing plastic or through the direct application of the at least one insulating layer made of thermoplastic material to the plasma-treated, oxide-free surface of the electrical conductor: If an all-round cut is made on the insulated electrical conductor carried out perpendicular to a conductor axis and the conductor stretched by 20%, the detachment of the insulating coating from the electrical conductor measured in the direction of the conductor axis is only a maximum of 3 mm, preferably a maximum of 2 mm, in particular a maximum of 1 mm.
  • thermoplastic of the at least one insulation 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
  • Extrusion is a cost-effective method for applying the insulation layer and is also particularly suitable for PAEK, in particular PEEK, and PPS.
  • the at least one insulation layer can thus also be applied in a simple manner as the outermost layer of the insulating coating.
  • the electrical conductor By preheating the electrical conductor, which is particularly advantageous if the at least one insulation layer or the insulating coating is extruded directly onto the surface of the electrical conductor, a sudden cooling of the plastic-containing intermediate layer on contact with the electrical conductor is reduced and thus negative influences on adhesion are minimized.
  • the electrical conductor is cooled before the application of the insulating coating in order to prevent excessive heating, for example a melt, of the plastic-containing intermediate layer upon contact with the electrical conductor. Therefore, in a further preferred embodiment of the method, it is provided that the electrical conductor is brought to a temperature of at least 200 ° C., preferably at least 400 ° C., before the insulating coating is applied.
  • the insulated electrical conductor is cooled after the at least one insulation layer has been extruded on, depending on the strength of the at least one insulation layer to be achieved.
  • the setting of the mechanical properties of the at least one insulation layer takes place, among other things, through the defined cooling of the insulated electrical conductor and the resulting setting of the degree of crystallization and is particularly important if the at least one insulation layer is the outermost layer the insulating coating. If the insulated electrical conductor is cooled slowly, for example, by cooling in air, the result is a high degree of crystallinity of the at least one insulation layer. Quenching in a water bath, i.e. abrupt cooling, or a combination of abrupt and slow cooling is also conceivable.
  • the insulated electrical conductor is guided over rollers, preferably pressure rollers, after the at least one insulation layer has been extruded on. It is particularly advantageous if the at least one insulation layer forms the outermost layer of the insulating coating. Closely guiding the insulated electrical conductor over the pressure rollers while applying pressure to the insulated electrical conductor leads to particularly good adhesion of the insulating coating or in particular of the at least one insulation layer on the surface of the electrical conductor.
  • the interfaces of the insulating coating between the individual layers, if several are present, and / or the interface of the lowest layer of the insulating coating and the surface of the electrical conductor are pressed against one another, thus increasing the adhesion effects.
  • the insulating coating consists of at least two, preferably exactly two, insulating layers and the insulating coating is produced by means of tandem extrusion under a protective gas atmosphere.
  • the tandem extrusion the at least two insulation layers are produced independently of one another, so that a clogging of an extrusion tool only causes a defect in one of the insulation layers.
  • the defective section is covered with a high degree of probability by the subsequent extrusion steps.
  • a further embodiment of the invention provides that at least one further insulating layer made of thermoplastic material is applied to the insulating material by means of tandem extrusion Coating is extruded on, the extrusion of the further insulation layer not taking place under a protective gas atmosphere.
  • thermoplastic of the at least one further insulation layer is preferably 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 steps required to produce 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 produced by means of co- or tandem extrusion. So both layers can be in can only be produced in a single production step and with an extrusion unit.
  • a further embodiment variant provides that a plasma polymer layer containing plastic is applied directly to the surface of the electrical conductor by polymerizing a gaseous monomer in a gas plasma.
  • an insulated electrical conductor according to the invention is used as a winding wire for electrical machines, preferably electrical motors or transformers.
  • FIG. 11 shows a schematic representation of a method for producing an insulated electrical conductor as shown in FIG Figures 2a to 2d or 3a to 3d is shown.
  • the insulated electrical conductor comprises an electrical conductor 1 made of copper, other materials such as aluminum are also conceivable, and an insulating coating 2, which has at least one insulating layer 3 made of thermoplastic, preferably high-temperature-resistant plastic.
  • the at least one insulation layer 3 is designed as an outer insulation layer 3 and thus forms the outermost layer of the insulating coating 2.
  • one or more additional layers, preferably Insulation layers can be applied, which can then form the outermost layer of the insulating coating 2.
  • the electrical conductor 1 is continuously fed to the process as a strip or wire via a coil payout 7 and can be produced using cold forming processes, such as drawing or rolling, or extrusion, for example using Conform® technology. It goes without saying that the method according to the invention can also be carried out “in-line”, that is to say directly following the manufacturing process.
  • the electrical conductor 1 is pre-cleaned mechanically, for example by means of a grinding process, or chemically, for example by means of suitable solvents or acids, in a pre-cleaning unit 8, in order to remove coarse dirt from the electrical conductor 1.
  • the pre-cleaned electrical conductor 1 arrives in a plasma treatment unit 9 in which a protective gas atmosphere of nitrogen, argon or hydrogen prevails and a gas plasma is produced in the form of a low-pressure plasma with a pressure of less than 20 mbar.
  • a low-pressure plasma can also be used at a pressure of less than 80 mbar can be produced.
  • the surface of the electrical conductor 1 is bombarded with ions of the protective gas in order to ablate or remove an oxide layer formed on a surface of the electrical conductor 1.
  • the electrical conductor 1 is annealed soft by the plasma treatment and the surface energy of the electrical conductor 1 increases, so the surface is activated.
  • the insulating coating 2 consists of only one insulation layer 3.
  • the insulation layer 3 has a temperature resistance of over 180 ° C., preferably over 220 ° C., so that the insulated electrical conductor can also be used at high operating temperatures.
  • the outer insulation 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 insulation layer 3 can also consist of polyphenylene sulfide [PPS] or comprise PEEK and / or PPS.
  • the electrical conductor 1 In order to achieve increased adhesion between the electrical conductor 1 and the outer insulation layer 3, the electrical conductor 1, after passing through the plasma treatment unit 9, enters the extrusion unit 11 in which the outer insulation layer 3 is extruded onto the electrical conductor 1 will.
  • the electrical conductor 1 is preheated to a temperature of at least 200.degree. C., preferably at least 300.degree.
  • both the extrusion and the transport of the conductor 1 into the extrusion unit 11 take place under a protective gas atmosphere.
  • An insulated electrical conductor produced in this way can be used, for example, as a winding wire, also known as "magnet wire" in English, in an electrical machine, such as an electric motor or a transformer.
  • the thickness of the outer insulation layer 3 is approximately 30 ⁇ m in the present exemplary embodiment.
  • the insulation layer 3 consists of a polyaryletherketone [PAEK] such as polyetheretherketone [PEEK], particularly good adhesion properties are achieved as a result.
  • the separation of the insulation layer 3 from the electrical conductor 1 usually remains far below 1 mm, and is in particular a maximum of 0.2 mm, preferably a maximum of 0.1 mm, preferably a maximum of 0.05 mm, particularly preferably a maximum of 0.01 mm.
  • the thermoplastic of the insulation layer 3 is polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS], increased adhesion properties can be achieved.
  • the at least one insulation layer 3 can also comprise two, three, four or more individual insulation layers 3, all of which are produced in the extrusion unit 11 under a protective gas atmosphere. This allows the probability of defects in the insulating coating 2 to be drastically reduced, since defects in the lowest of the insulation layers 3 are compensated for by subsequent insulation layers 3. Tandem extrusion processes are particularly suitable for such a production.
  • further insulation layers which are preferably constructed analogously to the at least one insulation layer 3, that is to say in particular made of a polyaryletherketone [PAEK] such as Polyetheretherketone [PEEK] or another of the aforementioned plastics, are applied to the insulating coating 2 in a further extrusion unit 12 outside the protective gas atmosphere.
  • PAEK polyaryletherketone
  • PEEK Polyetheretherketone
  • the insulating coating 2 comprises in FIG Figures 2b and 3b
  • an intermediate layer containing plastic in the form of a plasma polymer layer 4 is shown in addition to the second embodiment variant the extrusion unit 11 is arranged. 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 in the plasma polymerization unit 10 on the surface of the electrical conductor 1 by adding a gaseous monomer such as ethylene, buthenol, acetone or tetrafluoromethane [CF 4 ] is activated by means of the plasma and, as a result, highly crosslinked macromolecules of different chain lengths and a proportion of free radicals are formed, which are deposited as a plasma polymer layer 4 on the surface of the electrical conductor 1.
  • the plasma polymer layer 4 produced in this way is less than 1 ⁇ m thick and adheres particularly well to the activated and oxide-free surface of the electrical conductor 1.
  • the outer insulation layer 3 is in turn extruded onto the plasma polymer layer 4 in the extrusion unit 11 as described above, the adhesion between the plasma polymer layer 4 and the outer insulation layer 3 also being high.
  • the insulating coating 2 comprises, in addition to the outer insulating layer 3 made of PEEK, a fluoropolymer layer 5 made of polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP] plastic-containing intermediate layer which is applied directly to the surface of the electrical conductor 1 and further improves the adhesion between the electrical conductor 1 and the outer insulation layer 3.
  • the fluoropolymer layer 5 is produced together with the outer insulation layer 3 in the extrusion unit 11 by means of a co- or tandem extrusion process.
  • the thickness of the fluoropolymer layer 5 is approximately 30 ⁇ m in the present exemplary embodiment.
  • the insulated electrical conductor is cooled in a controlled manner, for example by air cooling, and passed over a series of pressure rollers which further improve the adhesion by exerting pressure on the insulated electrical conductor. Finally, the insulated electrical conductor is wound onto a reel winder 13.
  • Fig. 1 it is an overview in which all facilities are shown that are necessary for the production of the individual design variants. While the sequence, from right to left, of the devices passed through is independent of the embodiment variant and in any case the plasma treatment unit 9 and the extrusion unit 11 must be passed through, the plasma polymerization unit 9 and the further extrusion unit 12 are involved about optional equipment that is only used in the manufacture of specific design variants. It goes without saying that instead of a co- or tandem extrusion process, several individual extrusions can also be carried out sequentially.

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Description

GEBIET DER ERFINDUNGFIELD OF THE INVENTION

Die Erfindung betrifft einen isolierten elektrischen Leiter umfassend einen elektrischen Leiter, vorzugsweise aus Kupfer oder Aluminium, mit einer isolierenden Beschichtung, wobei die isolierende Beschichtung zumindest eine äußere Isolationsschicht aus thermoplastischem Kunststoff umfasst, sowie auf ein Verfahren zur Herstellung eines solchen isolierten elektrischen Leiters.The invention relates to an insulated electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating comprising at least one outer insulating layer made of thermoplastic material, and to a method for producing such an insulated electrical conductor.

STAND DER TECHNIKSTATE OF THE ART

Isolierte elektrische Leiter werden in nahezu jedem elektrischen Gerät verbaut, um elektrischen Strom zu leiten ohne dabei Kurzschlüsse zu verursachen, die durch den Kontakt von nicht elektrisch isolierten Leitern verursacht werden können.Insulated electrical conductors are installed in almost every electrical device in order to conduct electrical current without causing short circuits, which can be caused by the contact of non-electrically insulated conductors.

Derartige isolierte elektrische Leiter umfassen einen elektrischen Leiter aus Kupfer und eine den elektrischen Leiter elektrisch isolierenden Beschichtung, die üblicher Weise eine oder mehrere Schichten aufweist. Um die Isolierung des elektrischen Leiters sicherzustellen umfasst die isolierende Beschichtung eine Isolationsschicht aus thermoplastischem Kunststoff.Such insulated electrical conductors comprise an electrical conductor made of copper and a coating which electrically insulates the electrical conductor and usually has one or more layers. In order to ensure the insulation of the electrical conductor, the insulating coating comprises an insulating layer made of thermoplastic material.

Während es in vielen Anwendungsgebieten vorteilhaft ist, wenn die Haftung der isolierenden Beschichtung am elektrischen Leiter schwach ausgebildet ist, um ein leichtes Abisolieren des elektrischen Leiters zu ermöglichen, ist es in anderen Anwendungsgebieten erwünscht, eine möglichst große Haftung sicherzustellen. Solche Anwendungsgebiete finden sich beispielsweise im Elektromaschinenbau und insbesondere bei Elektromotoren oder Transformatoren, wo die isolierten elektrischen Leiter auch einer erhöhten Temperatur ausgesetzt sind. Die Verarbeitbarkeit der isolierten elektrischen Leiter erfordert dabei oftmals eine erhöhte Haftung der isolierenden Beschichtung am elektrischen Leiter, teilweise auch bei hohen Betriebstemperaturen.While it is advantageous in many fields of application if the adhesion of the insulating coating to the electrical conductor is weak in order to allow easy stripping of the electrical conductor, in other fields of application it is desirable to ensure the greatest possible adhesion. Such areas of application can be found, for example, in electrical engineering and in particular in electric motors or transformers, where the insulated electrical conductors are also exposed to an elevated temperature. The processability of the insulated electrical conductor often requires increased adhesion of the insulating coating to the electrical conductor, sometimes even at high operating temperatures.

Um die Haftung zu überprüfen wird üblicher Weise ein Rundumschnitt am isolierten elektrischen Leiter senkrecht zu einer Leiterachse durchgeführt, der elektrische Leiter um 20% gedehnt und danach die Ablösung der isolierenden Beschichtung vom elektrischen Leiter gemessen. Desto geringer die Ablösung der isolierenden Beschichtung vom elektrischen Leiter ist, desto besser ist die Haftung.To check the adhesion, an all-round cut is usually made on the insulated electrical conductor perpendicular to a conductor axis, the electrical conductor is stretched by 20% and then the detachment of the insulating coating from the electrical conductor is measured. The less the insulating coating detaches from the electrical conductor, the better the adhesion.

In herkömmlichen isolierten elektrischen Leiter die eine isolierende Beschichtung mit einer, vorzugsweise hochtemperaturbeständigen, Isolationsschicht aufweisen, ist die Haftung zwischen dem elektrischen Leiter, insbesondere aus Kupfer, und der isolierenden Beschichtung, insbesondere der Isolationsschicht, eher gering, da die Haftung eines Kunststoffs am elektrischen Leiter aufgrund der Oberflächeneigenschaften gering ist. JP2003031061A offenbart die Herstellung eines isolierten elektrischen Leiters umfassend einen elektrischen Leiter mit einer isolierenden Beschichtung, wobei die isolierende Beschichtung eine Isolationsschicht aus thermoplastischem Kunststoff (EVA oder PE) umfasst.In conventional insulated electrical conductors that have an insulating coating with a preferably high-temperature-resistant insulating layer, the adhesion between the electrical conductor, in particular made of copper, and the insulating coating, in particular the insulating layer, is rather low, since the adhesion of a plastic to the electrical conductor is rather low is low due to the surface properties. JP2003031061A discloses the production of an insulated electrical conductor comprising an electrical conductor with an insulating coating, the insulating coating comprising an insulating layer made of thermoplastic material (EVA or PE).

AUFGABE DER ERFINDUNGOBJECT OF THE INVENTION

Es ist daher eine Aufgabe der Erfindung einen isolierten elektrischen Leiter vorzuschlagen, welcher die Nachteile des Stands der Technik überwindet und eine gute Haftung zwischen der isolierenden Beschichtung und dem elektrischen Leiter gewährleistet.It is therefore an object of the invention to propose an insulated electrical conductor which overcomes the disadvantages of the prior art and ensures good adhesion between the insulating coating and the electrical conductor.

DARSTELLUNG DER ERFINDUNGDISCLOSURE OF THE INVENTION

Der elektrische Leiter gattungsgemäßer isolierter elektrischer Leiter besteht aus Kupfer oder einer Legierung mit einem hohen Kupferanteil oder Aluminium oder sonstigen elektrisch leitfähigen Materialien. Unter dem elektrischen Leiter wird dabei sowohl ein Einzelleiter als auch eine mehrere Einzelleiter enthaltende Litze verstanden. Die Querschnittsgeometrie des elektrischen Leiters, welche normal auf eine Leiterachse steht, kann dabei eine beliebige geometrische Form aufweisen: quadratisch, rechteckig, kreisrund oder elliptisch, wobei es üblich ist etwaige Kanten abzurunden, bzw. profiliert. Die Isolation des elektrischen Leiters wird durch die vorgesehene zumindest eine Isolationsschicht aus thermoplastischem Kunststoff sichergestellt, wobei die zumindest eine Isolationsschicht vorteilhafter Weise die äußerste Schicht der isolierenden Beschichtung ausbilden kann. Es ist aber auch denkbar, dass auf der zumindest einen Isolationsschicht eine oder mehrere weitere Isolationsschichten aufgetragen sind.The electrical conductor of the generic insulated electrical conductor consists of copper or an alloy with a high copper content or aluminum or other electrically conductive materials. The electrical conductor is understood to mean both a single conductor and a stranded wire containing a plurality of individual conductors. The cross-sectional geometry of the electrical conductor, which is normal to a conductor axis, can have any geometric shape: square, rectangular, circular or elliptical, whereby it Any edges are usually rounded or profiled. The insulation of the electrical conductor is ensured by the provided at least one insulation layer made of thermoplastic material, wherein the at least one insulation layer can advantageously form the outermost layer of the insulating coating. However, it is also conceivable that one or more further insulation layers are applied to the at least one insulation layer.

Durch den Kontakt mit Sauerstoff, der unausweichlich ist sofern der elektrische Leiter der Atmosphäre ausgesetzt ist, bildet sich eine Oxidschicht, beispielsweise aus Kupferoxid oder Aluminiumoxid, an der Oberfläche des elektrischen Leiters aus. Umfassende Versuchsreihen haben gezeigt, dass sich die Oxidschicht negativ auf die Haftungseigenschaften einer auf die Oberfläche des elektrischen Leiters aufgebrachten Schicht der isolierenden Beschichtung auswirkt.Contact with oxygen, which is inevitable if the electrical conductor is exposed to the atmosphere, forms an oxide layer, for example made of copper oxide or aluminum oxide, on the surface of the electrical conductor. Comprehensive series of tests have shown that the oxide layer has a negative effect on the adhesive properties of a layer of the insulating coating applied to the surface of the electrical conductor.

Wenn jedoch die Oxidschicht entfernt wird, verbessert sich die Haftung der auf der von der Oxidschicht befreiten Oberfläche des elektrischen Leiters aufgebrachten Schicht der isolierenden Beschichtung maßgeblich. Es hat sich gezeigt, dass die Oxidschicht durch eine Plasmabehandlung unter einer - sauerstofffreien - Schutzgasatmosphäre vollständig entfernt werden kann, wobei auch sonstige Verunreinigungen durch die Plasmabehandlung entfernt werden können. Es ist sogar möglich, dass durch die Plasmabehandlung die obersten Atomschichten des elektrischen Leiters abgetragen werden.If, however, the oxide layer is removed, the adhesion of the layer of the insulating coating applied to the surface of the electrical conductor from which the oxide layer has been removed 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, with other impurities also being able to be removed by the plasma treatment. It is even possible that the plasma treatment removes the top atomic layers of the electrical conductor.

Bei der Plasmabehandlung wird ein Gas-Plasma in der Schutzgasatmosphäre erzeugt und der elektrische Leiter im Plasma mit Ionen des Schutzgases beschossen, um zumindest die Oxidschicht durch den Ionenbeschuss abzutragen. Als Schutzgas bzw. Prozessgas eignen sich beispielsweise Stickstoff, Argon oder Wasserstoff. Die Plasmabehandlung hat neben der Entfernung der Oxidschicht noch weitere positive Effekte auf den isolierten elektrischen Leiter: einerseits wird der elektrische Leiter durch die Aufprallenergie der Ionen auf der Oberfläche erhitzt und kann während der Plasmabehandlung weichgeglüht werden, um das Gefüge des elektrischen Leiters zu rekristallisieren andererseits kann durch den Ionenbeschuss die Oberflächenenergie des elektrischen Leiters erhöht werden, was die Haftung der isolierenden Beschichtung an der Oberfläche des elektrischen Leiters zusätzlich verbessert. Man spricht in diesem Zusammenhang auch von einer Aktivierung der Oberfläche des elektrischen Leiters. Ein weiterer Effekt der Plasmabehandlung ist die Erhöhung der Mikrorauigkeit der Oberfläche des elektrischen Leiters, welches sich ebenfalls positiv auf die Haftung der isolierenden Beschichtung auswirkt.During the plasma treatment, a gas plasma is generated in the protective gas atmosphere and the electrical 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. Suitable protective gas or process gas are, for example, nitrogen, argon or hydrogen. In addition to removing the oxide layer, the plasma treatment has other positive effects on the insulated electrical conductor: on the one hand, the electrical conductor is heated by the impact energy of the ions on the surface and can be annealed during the plasma treatment On the other hand, to recrystallize the structure of the electrical conductor, the surface energy of the electrical conductor can be increased by ion bombardment, which additionally improves the adhesion of the insulating coating to the surface of the electrical conductor. In this context, one speaks of an activation of the surface of the electrical conductor. Another effect of the plasma treatment is the increase in the micro-roughness of the surface of the electrical conductor, which also has a positive effect on the adhesion of the insulating coating.

Um die erneute Ausbildung einer Oxidschicht an der Oberfläche des elektrischen Leiters zu verhindern, wird zumindest ein Teil der isolierenden Beschichtung unter Schutzgasatmosphäre, vorzugsweise unter derselben Schutzgasatmosphäre unter der die Plasmabehandlung durchgeführt wird, auf die Oberfläche des elektrischen Leiters aufgebracht wird.In order to prevent the renewed formation of an oxide layer on the surface of the electrical conductor, at least part of the insulating coating is applied to the surface of the electrical conductor in a protective gas atmosphere, preferably in the same protective gas atmosphere under which the plasma treatment is carried out.

Um die eingangs gestellte Aufgabe zu lösen, ist in einem isolierten elektrischen Leiter umfassend einen elektrischen Leiter, vorzugsweise aus Kupfer oder Aluminium, mit einer isolierenden Beschichtung

  • wobei die isolierende Beschichtung entweder
    zumindest eine Isolationsschicht aus thermoplastischem Kunststoff umfasst
  • oder
    zumindest eine Isolationsschicht aus thermoplastischem Kunststoff und eine Kunststoff enthaltende Zwischenschicht, vorzugsweise eine Plasmapolymer-Schicht oder zumindest eine Fluoropolymer-Schicht, umfasst,
  • daher erfindungsgemäß vorgesehen, dass eine auf einer Oberfläche des elektrischen Leiters ausgebildete Oxidschicht, vorzugsweise durch Beschuss des elektrischen Leiters mit Ionen eines Schutzgases einer Schutzgasatmosphäre in einem Gas-Plasma, entfernt ist
  • und nachfolgend entweder
    die zumindest eine Isolationsschicht unmittelbar auf die oxidschicht-freie Oberfläche des elektrischen Leiters aufgebracht ist
  • oder, im dem Fall, dass die Beschichtung die Kunststoff enthaltende Zwischenschicht umfasst,
    zumindest die Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung unmittelbar auf die oxidschicht-freie Oberfläche des elektrischen Leiters aufgebracht ist.
In order to achieve the object set at the beginning, an insulated electrical conductor comprises an electrical conductor, preferably made of copper or aluminum, with an insulating coating
  • being the insulating coating either
    comprises at least one insulation layer made of thermoplastic material
  • or
    at least one insulation layer made of thermoplastic and an intermediate layer containing plastic, preferably a plasma polymer layer or at least one fluoropolymer layer,
  • Therefore, the invention provides that an oxide layer formed on a surface of the electrical conductor is removed, preferably by bombarding the electrical conductor with ions of a protective gas of a protective gas atmosphere in a gas plasma
  • and subsequently either
    the at least one insulation layer is applied directly to the oxide layer-free surface of the electrical conductor
  • or, in the case that the coating comprises the intermediate layer containing plastic,
    at least the plastic-containing intermediate layer of the insulating coating is applied directly to the oxide layer-free surface of the electrical conductor.

Ein erfindungsgemäßer isolierter elektrischer Leiter weist durch die unmittelbare Aufbringung einer Kunststoff enthaltenden Zwischenschicht der isolierenden Beschichtung oder durch die unmittelbare Aufbringung der Isolationsschicht aus thermoplastischem Kunststoff auf die plasmabehandelte und dadurch oxidschichtfreie Oberfläche des elektrischen Leiters besonders gute Haftungseigenschaften auf: Wird ein Rundumschnitt am isolierten elektrischen Leiter senkrecht zu einer Leiterachse durchgeführt und der Leiter um 20% gedehnt so beträgt die Ablösung der isolierenden Beschichtung vom elektrischen Leiter in Richtung der Leiterachse gemessen lediglich maximal 3 mm, vorzugsweise maximal 2 mm, insbesondere maximal 1 mm.An insulated electrical conductor according to the invention has particularly good adhesion properties due to the direct application of a plastic-containing intermediate layer of the insulating coating or the direct application of the insulating layer made of thermoplastic material to the plasma-treated and thus oxide-layer-free surface of the electrical conductor: If a circumferential cut on the insulated electrical conductor is perpendicular carried out to a conductor axis and the conductor stretched by 20%, the detachment of the insulating coating from the electrical conductor measured in the direction of the conductor axis is only a maximum of 3 mm, preferably a maximum of 2 mm, in particular a maximum of 1 mm.

Der Haftungseffekt wird also bei beiden Varianten dadurch erreicht, dass eine Kunststoffschicht, welche vorzugsweise aus Kunststoff besteht, unter Schutzgasatmosphäre unmittelbar auf die, vorzugsweise plasmagereinigte und dadurch, oxidschichtfreie Oberfläche des elektrischen Leiters aufgetragen wird. Einerseits kann es sich bei der Kunststoffschicht unmittelbar um die zumindest eine Isolationsschicht aus thermoplastischem Kunststoff handeln, wenn keine Zwischenschicht vorgesehen ist. Andererseits kann es sich bei der Kunststoffschicht auch um eine Kunststoff enthaltende Zwischenschicht, vorzugsweise eine Plasmapolymer-Schicht oder um zumindest eine Fluoropolymer-Schicht, handeln. Wenn die isolierende Beschichtung eine Kunststoff enthaltende Zwischenschicht aufweist, ist die zumindest eine Isolationsschicht bevorzugt unmittelbar auf die Kunststoff enthaltende Zwischenschicht aufgebracht. Es ist jedoch auch denkbar, dass eine oder mehrere weitere Zwischenschichten zwischen der Kunststoff enthaltenden Zwischenschicht und der zumindest einen Isolationsschicht vorgesehen sind.The adhesion effect is thus achieved in both variants in that a plastic layer, which is preferably made of plastic, is applied under a protective gas atmosphere directly to the surface of the electrical conductor, which is preferably plasma-cleaned and thus oxide layer-free. On the one hand, the plastic layer can be the at least one insulating layer made of thermoplastic plastic if no intermediate layer is provided. On the other hand, the plastic layer can also be an intermediate layer containing plastic, preferably a plasma polymer layer or at least one fluoropolymer layer. If the insulating coating has an intermediate layer containing plastic, the at least one insulating layer is preferably applied directly to the intermediate layer containing plastic. However, it is also conceivable that one or more further intermediate layers are provided between the intermediate layer containing plastic and the at least one insulation layer.

Wenngleich eine Vielzahl von unterschiedlichen Kunststoffen denkbar ist, die als Material für die Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung geeignet sind, handelt es sich bei der Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung vorzugsweise um die Plasmapolymer-Schicht oder um die zumindest eine Fluoropolymer-Schicht.Although a large number of different plastics are conceivable which are suitable as material for the plastic-containing intermediate layer of the insulating coating, the plastic-containing intermediate layer of the insulating coating is preferably the plasma polymer layer or the at least one fluoropolymer layer.

Wenn keine Kunststoff enthaltende Zwischenschicht vorgesehen ist und die Isolationsschicht unmittelbar auf die Oberfläche des elektrischen Leiters aufgetragen ist, ist es besonders bevorzugt, wenn die isolierende Beschichtung aus der zumindest einen Isolationsschicht besteht, also keine weiteren Zwischenschichten aufweist.If no intermediate layer containing plastic is provided and the insulation layer is applied directly to the surface of the electrical conductor, it is particularly preferred if the insulating coating consists of the at least one insulation layer, that is to say has no further intermediate layers.

Überraschenderweise hat sich im Rahmen von Testreihen herausgestellt, dass die Ablösung der isolierenden Beschichtung vom elektrischen Leiter üblicher Weise weit unter 1 mm bleibt, insbesondere maximal 0,2 mm, vorzugsweise maximal 0,1 mm, bevorzugt maximal 0,05 mm, besonders bevorzugt maximal 0,01 mm, beträgt, wenn die zumindest eine Isolationsschicht unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird. Besonders vorteilhafte Effekte können dadurch erreicht werden, dass die zumindest eine Isolationsschicht ein Polyaryletherketon [PAEK], insbesondere Polyetheretherketon [PEEK], umfasst oder aus Polyaryletherketon [PAEK], insbesondere Polyetheretherketon [PEEK], besteht.Surprisingly, it has been found in the course of test series that the detachment of the insulating coating from the electrical conductor usually remains far below 1 mm, in particular a maximum of 0.2 mm, preferably a maximum of 0.1 mm, preferably a maximum of 0.05 mm, particularly preferably a maximum 0.01 mm, if the at least one insulation layer is applied directly to the surface of the electrical conductor. Particularly advantageous effects can be achieved in that the at least one insulation layer comprises a polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], or consists of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK].

Eine Ausführungsvariante der Erfindung sieht vor, dass der elektrische Leiter bis zum Aufbringen der isolierenden Beschichtung durchgehend unter Schutzgasatmosphäre angeordnet ist, um die Ausbildung einer neuen Oxidschicht auf der Oberfläche des elektrischen Leiters zu verhindern. Es können auch mehrere Schutzgasatmosphären hintereinander durchlaufen werden, solange der plasmabehandelte elektrische Leiter ununterbrochen unter einer der Schutzgasatmosphären angeordnet ist.One embodiment variant of the invention provides that the electrical conductor is arranged continuously under a protective gas atmosphere until the insulating coating is applied in order to prevent the formation of a new oxide layer on the surface of the electrical conductor. It is also possible to run through several protective gas atmospheres one after the other, as long as the plasma-treated electrical conductor is arranged uninterruptedly under one of the protective gas atmospheres.

In einer weiteren Ausführungsvariante der Erfindung ist vorgesehen, dass es sich bei dem Gas-Plasma zum Beschießen des elektrischen Leiters um ein Niederdruckplasma, vorzugsweise mit einem Druck unter 80 mbar, handelt, welches sich in an sich bekannter Weise herstellen lässt. Beispielsweise sind Drücke unter 50 mbar oder sogar unter 20 mbar denkbar.In a further embodiment of the invention it is provided that the gas plasma for bombarding the electrical conductor is a low-pressure plasma, preferably with a pressure below 80 mbar, which can be produced in a manner known per se. For example, pressures below 50 mbar or even below 20 mbar are conceivable.

Um den Einsatz des isolierten elektrischen Leiters in einer Umgebung mit erhöhter Temperatur, beispielsweise in Elektromaschinen mit erhöhter Betriebstemperatur, zu ermöglichen, ist in einer weiteren Ausführungsvariante der Erfindung vorgesehen, dass die isolierende Beschichtung, insbesondere die zumindest eine Isolationsschicht, eine Temperaturbeständigkeit von zumindest 180°C, vorzugsweise von zumindest 200°C, insbesondere von zumindest 220°C, aufweist.In order to enable the use of the insulated electrical conductor in an environment with increased temperature, for example in electrical machines with increased operating temperature, a further embodiment of the invention provides that 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.

Besonders gute Eigenschaften hinsichtlich der Temperaturbeständigkeit und der Beständigkeit gegen eine Vielzahl an organischen und chemischen Lösungsmittel, insbesondere auch gegen Hydrolyse, werden in einer bevorzugten Ausführungsvariante des erfindungsgemäßen isolierten elektrischen Leiters und des erfindungsgemäßen Verfahrens dadurch erreicht, dass der thermoplastische Kunststoff der zumindest einen Isolationsschicht ausgewählt ist aus der Gruppe bestehend aus Polyaryletherketon [PAEK], Polyimid [PI], Polyamidimid [PAI], Polyetherimid [PEI], Polyphenylensulfid [PPS] und Kombinationen davon. Es versteht sich dabei von selbst, dass der thermoplastische Kunststoff einen oder mehrere der oben genannten Kunststoffe sowie gegebenenfalls weitere Bestandteile, wie beispielsweise Fasermaterial, Füllstoffe oder weitere Kunststoffe, umfassen kann.Particularly good properties in terms of temperature resistance and resistance to a large number of organic and chemical solvents, in particular also to hydrolysis, are achieved in a preferred embodiment of the insulated electrical conductor according to the invention and the method according to the invention in that the thermoplastic material of the at least one insulation layer is selected from the group consisting of polyaryletherketone [PAEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof. It goes without saying that the thermoplastic material can comprise one or more of the plastics mentioned above and, if appropriate, further components, such as fiber material, fillers or further plastics.

Polyaryletherketone setzen sich aus mittels Sauerstoffbrücken, also Ether- oder Ketongruppen, verbundenen Phenylgruppen zusammen, wobei die Anzahl und Abfolge der Ether- bzw. Ketongruppen innerhalb der Polyaryletherketone variabel ist. Polyimide sind Kunststoffe, deren wichtigstes Strukturmerkmal die Imidgruppe ist. Dazu gehören u. a. Polysuccinimid (PSI), Polybismaleinimid (PBMI) und Polyoxadiazobenzimidazol (PBO), Polyimidsulfon (PISO) und Polymethacrylimid (PMI).Polyaryletherketones are made up of phenyl groups linked by means of oxygen bridges, i.e. ether or ketone groups, the number and sequence of the ether or ketone groups within the polyaryletherketones being variable. Polyimides are plastics whose most important structural feature is the imide group. These include polysuccinimide (PSI), Polybismaleimide (PBMI) and polyoxadiazobenzimidazole (PBO), polyimidesulfone (PISO) and polymethacrylimide (PMI).

Entsprechend ist in einer besonders bevorzugten Ausführungsvariante des erfindungsgemäßen isolierten elektrischen Leiters und des erfindungsgemäßen Verfahrens vorgesehen, dass der thermoplastische Kunststoff der zumindest einen Isolationsschicht ein Polyaryletherketon [PAEK] ausgewählt aus der Gruppe bestehend aus Polyetherketon [PEK], Polyetheretherketon [PEEK], Polyetherketonketon [PEKK], Polyetheretherketonketon [PEEKK], Polyetherketon-etherketonketon [PEKEKK] und Kombinationen davon ist. Als besonders gut geeignet für die zumindest eine Isolationsschicht hat sich Polyetheretherketon [PEEK] erwiesen.Accordingly, in a particularly preferred embodiment of the insulated electrical conductor according to the invention and the method according to the invention, it is provided that the thermoplastic of the at least one insulation layer is a polyaryletherketone [PAEK] selected from the group consisting of polyetherketone [PEK], polyetheretherketone [PEEK], polyetherketoneketone [PEKK ], Polyether ether ketone ketone [PEEKK], polyether ketone ether ketone ketone [PEKEKK], and combinations thereof. Polyetheretherketone [PEEK] has proven to be particularly well suited for the at least one insulation layer.

In einer weiteren Ausführungsvariante der Erfindung ist vorgesehen, dass die zumindest eine Isolationsschicht eine Dicke zwischen 10 und bis 1000 µm, vorzugsweise zwischen 25 µm und 750 µm, besonders bevorzugt zwischen 30 µm und 500 µm, insbesondere zwischen 50 µm und 250 µm, aufweist. Es versteht sich von selbst, dass auch andere Schichtdicken denkbar sind, beispielsweise 40 µm, 60 µm, 80 µm, 100 µm oder 200 µm, um einige Möglichkeiten zu nennen. Es versteht sich von selbst, dass sich die angegebenen Werte sowohl auf die Dicke einer einzelnen Schicht der Isolationsschicht als auch auf die Gesamtdicke der Isolationsschicht beziehen kann, wenn die Isolationsschicht mehr als eine Schicht umfasst.In a further embodiment of the invention it is provided that the at least one insulation layer has a thickness between 10 and 1000 µm, preferably between 25 µm and 750 µm, particularly preferably between 30 µm and 500 µm, in particular between 50 µm and 250 µm. It goes without saying that other layer thicknesses are also conceivable, for example 40 μm, 60 μm, 80 μm, 100 μm or 200 μm, to name a few possibilities. It goes without saying that the specified values can relate both to the thickness of an individual layer of the insulation layer and to the total thickness of the insulation layer if the insulation layer comprises more than one layer.

Die zumindest eine Isolationsschicht lässt sich kostengünstig und schnell herstellen, wenn sie durch ein Extrusionsverfahren aufgebracht wird also aufextrudiert ist. Daher ist in einer weiteren bevorzugten Ausführungsvariante der Erfindung vorgesehen, dass die, vorzugsweise äußere, Isolationsschicht mittels eines Extrusions-Verfahrens herstellbar ist.The at least one insulation layer can be produced inexpensively and quickly if it is applied by an extrusion process, that is to say it is extruded on. Therefore, in a further preferred embodiment of the invention, it is provided that the, preferably outer, insulation layer can be produced by means of an extrusion process.

Wenn die isolierende Beschichtung aus der zumindest einen Isolationsschicht besteht und die zumindest eine Isolationsschicht unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird, wird eine besonders einfache und kostengünstige Herstellung eines erfindungsgemäßen isolierten elektrischen Leiters ermöglicht, da die Haftung der zumindest einen Isolationsschicht an der Oberfläche des elektrischen Leiters durch die Plasmabehandlung bereits so gut ist, dass keine Zwischenschichten notwendig sind.If 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 electrical conductor, one becomes special enables simple and inexpensive production of an insulated electrical conductor according to the invention, since the adhesion of the at least one insulation layer to the surface of the electrical conductor as a result of the plasma treatment is already so good that no intermediate layers are necessary.

Daher ist in einer weiteren besonders bevorzugten Ausführungsvariante der Erfindung vorgesehen, dass die isolierende Beschichtung aus der zumindest einen Isolationsschicht besteht und dass es sich bei der unmittelbar auf die Oberfläche des elektrischen Leiters aufgebrachten, Kunststoff enthaltenden Zwischenschicht um die zumindest eine Isolationsschicht handelt.Therefore, in a further particularly preferred embodiment of the invention, it is provided that the insulating coating consists of the at least one insulating layer and that the plastic-containing intermediate layer applied directly to the surface of the electrical conductor is the at least one insulating layer.

Somit betrifft die besonders bevorzugte Ausführungsvariante einen isolierten elektrischen Leiter umfassend einen elektrischen Leiter, vorzugsweise aus Kupfer oder Aluminium, mit einer isolierenden Beschichtung, wobei die isolierende Beschichtung aus zumindest einer Isolationsschicht aus thermoplastischem Kunststoff besteht, erhältlich durch ein Verfahren, in dem der elektrische Leiter unter einer Schutzgasatmosphäre in einem Gas-Plasma mit Ionen des Schutzgases beschossen wird, um eine auf einer Oberfläche des elektrischen Leiters ausgebildete Oxidschicht zu entfernen und/oder die Oberflächenenergie des elektrischen Leiters zu erhöhen, und die zumindest eine Isolationsschicht unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird, die zumindest eine Isolationsschicht unter Schutzgasatmosphäre auf den elektrischen Leiter aufgebracht wird.Thus, the particularly preferred embodiment relates to an insulated electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating consisting of at least one insulating layer made of thermoplastic material, obtainable by a method in which the electrical conductor is under a protective gas atmosphere in a gas plasma is bombarded with ions of the protective gas in order to remove an oxide layer formed on a surface of the electrical conductor and / or to increase the surface energy of the electrical conductor, and the at least one insulation layer is applied directly to the surface of the electrical conductor is, the at least one insulation layer is applied to the electrical conductor in a protective gas atmosphere.

In gleiche Art und Weise betrifft die besonders bevorzugte Ausführungsvariante auch einen isolierte elektrischer Leiter umfassend einen elektrischen Leiter, vorzugsweise aus Kupfer oder Aluminium, mit einer isolierenden Beschichtung, wobei die isolierende Beschichtung aus zumindest einer Isolationsschicht aus thermoplastischem Kunststoff besteht, wobei erfindungsgemäß vorgesehen ist, dass eine auf einer Oberfläche des elektrischen Leiters ausgebildete Oxidschicht durch Beschuss des elektrischen Leiters mit Ionen eines Schutzgases einer Schutzgasatmosphäre in einem Gas-Plasma entfernt ist und nachfolgend die zumindest eine Isolationsschicht unmittelbar auf die oxidschicht-freie Oberfläche des elektrischen Leiters aufgebracht ist.In the same way, the particularly preferred embodiment also relates to an insulated electrical conductor comprising an electrical conductor, preferably made of copper or aluminum, with an insulating coating, the insulating coating consisting of at least one insulating layer made of thermoplastic material, the invention providing that an oxide layer formed on a surface of the electrical conductor by bombarding the electrical conductor with ions of a Protective gas of a protective gas atmosphere is removed in a gas plasma and subsequently the at least one insulation layer is applied directly to the oxide-layer-free surface of the electrical conductor.

Die isolierende Beschichtung kann beispielsweise nur aus einer einzigen Isolationsschicht bestehen, welche unmittelbar auf der Oberfläche des elektrischen Leiters aufgebracht ist, um eine besonders einfache Herstellung zu ermöglichen.The insulating coating can consist, for example, of only a single insulating layer which is applied directly to the surface of the electrical conductor in order to enable particularly simple manufacture.

Um jedoch die Wahrscheinlichkeit eines Fehlers in der isolierenden Beschichtung, beispielsweise einen nicht mit der isolierenden Beschichtung versehenen Abschnitt des elektrischen Leiters bedingt durch einen Fehler im Herstellungsverfahren einer Isolationsschicht, drastisch zu verringern, ist in einer weiteren besonders bevorzugten Ausführungsvariante der Erfindung vorgesehen, dass die isolierende Beschichtung aus genau zwei oder aus mehr als zwei, beispielsweise aus drei oder vier, Isolationsschichten besteht. Dabei ist jedenfalls eine unterste Isolationsschicht unmittelbar auf der Oberfläche des elektrischen Leiters aufgebracht, wobei die weiteren Isolationsschichten jeweils auf einer der vorhergehenden Isolationsschichten aufgebracht sind. Sollte in der untersten Isolationsschicht ein Fehler aufgetreten sein, also ein Abschnitt des elektrischen Leiters nicht von der untersten Isolationsschicht abgedeckt sein, so wird durch die nachfolgenden Isolationsschichten die Wahrscheinlichkeit, dass genau der fehlerhafte Abschnitt der untersten Isolationsschicht auch von den nachfolgenden Isolationsschichten nicht abgedeckt wird, einer Exponentialfunktion folgend reduziert. Desto höher die Anzahl der Isolationsschichten, desto geringer die Wahrscheinlichkeit, dass ein Abschnitt des elektrischen Leiters gar keine isolierende Beschichtung aufweist. Um die verbesserte Haftung der nachfolgenden Isolationsschichten am elektrischen Leiter zu erreichen, werden alle Isolationsschichten unter Schutzgasatmosphäre aufgebracht, sodass die Haftung nachfolgender Isolationsschichten im Bereich von fehlerhaften Abschnitten der vorhergehenden Isolationsschichten verbessert ist.However, in order to drastically reduce the probability of a fault in the insulating coating, for example a section of the electrical conductor not provided with the insulating coating due to a fault in the manufacturing process of an insulating layer, a further particularly preferred embodiment of the invention provides that the insulating Coating consists of exactly two or more than two, for example three or four, insulation layers. In any case, a lowermost insulation layer is applied directly to the surface of the electrical conductor, the further insulation layers each being applied to one of the preceding insulation layers. If a fault has occurred in the lowest insulation layer, i.e. a section of the electrical conductor is not covered by the lowest insulation layer, the subsequent insulation layers increase the likelihood that the faulty section of the lowest insulation layer will not be covered by the following insulation layers either, reduced following an exponential function. The higher the number of insulation layers, the lower the probability that a section of the electrical conductor has no insulating coating at all. In order to achieve improved adhesion of the subsequent insulation layers to the electrical conductor, all insulation layers are applied in a protective gas atmosphere, so that the adhesion of subsequent insulation layers in the area of defective sections of the preceding insulation layers is improved.

Grundsätzlich kann auf der isolierenden Beschichtung bzw. auf der aus der zumindest einen Isolationsschicht bestehenden isolierenden Beschichtung zumindest eine, also beispielsweise eine, zwei, drei oder vier, weitere Isolationsschicht aus thermoplastischem Kunststoff aufgebracht werden. Die zumindest eine weitere Isolationsschicht ist dabei vorzugsweise analog zur zumindest einen Isolationsschicht aufgebaut, sodass der thermoplastische Kunststoff der zumindest einen weiteren Isolationsschicht ausgewählt ist aus der Gruppe bestehend aus Polyaryletherketon [PAEK], insbesondere Polyetheretherketon [PEEK], Polyimid [PI], Polyamidimid [PAI], Polyetherimid [PEI], Polyphenylensulfid [PPS] und Kombinationen davon.In principle, at least one, that is to say for example one, two, three or four, further insulation layer made 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 insulation layer is preferably constructed analogously to the at least one insulation layer, so that the thermoplastic plastic of the at least one further insulation 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.

Da es sich bei den fehlerhaften Abschnitten der zumindest einen Isolationsschicht in der Regel um verhältnismäßig kleine Flächen handelt, ist es auch denkbar, dass zumindest eine weitere Isolationsschicht außerhalb der Schutzgasatmosphäre auf die isolierende Beschichtung aufgebracht werden, um etwaige fehlerhafte Abschnitte der isolierenden Beschichtung abzudecken, sodass im Bereich der fehlerhaften Abschnitte der isolierenden Beschichtung die Haftung der weiteren Isolationsschicht nicht verbessert ist. Natürlich können auch weitere Isolationsschichten aufgebracht werden, wenn eine größere Dicke der Isolierung erforderlich ist. Daher ist in einer weiteren Ausführungsvariante der Erfindung vorgesehen, dass zumindest eine, vorzugsweise eine, zwei oder drei, weitere Isolationsschicht auf der isolierenden Beschichtung aufgebracht ist, wobei die zumindest eine weitere Isolationsschicht nicht unter Schutzgasatmosphäre aufgebracht wird.Since the defective sections of the at least one insulation layer are usually relatively small areas, it is also conceivable that at least one further insulation layer is applied to the insulating coating outside the protective gas atmosphere in order to cover any defective sections of the insulating coating, so that the adhesion of the further insulation layer is not improved in the area of the defective sections of the insulating coating. Of course, further insulation layers can also be applied if a greater thickness of the insulation is required. Therefore, in a further embodiment of the invention it is provided that at least one, preferably one, two or three, further insulation layer is applied to the insulating coating, the at least one further insulation layer not being applied in a protective gas atmosphere.

In einer ersten alternativen Ausführungsvariante der Erfindung ist zur Verbesserung der Haftung der isolierenden Beschichtung an der Oberfläche des elektrischen Leiters vorgesehen, dass die isolierende Beschichtung eine unmittelbar auf die Oberfläche des elektrischen Leiters aufgebrachte Plasmapolymer-Schicht aus vernetzten Makromolekülen uneinheitlicher Kettenlänge aufweist, welche Plasmapolymer-Schicht durch Polymerisation eines gasförmigen Monomers in einem Gas-Plasma, vorzugsweise im Gas-Plasma zum Beschießen des elektrischen Leiters, herstellbar ist. In anderen Worten handelt es sich bei der unmittelbar auf die Oberfläche des elektrischen Leiters aufgebrachten, Kunststoff enthaltenden Zwischenschicht der isolierenden Beschichtung in diesem Ausführungsbeispiel um die Plasmapolymer-Schicht. Die Plasmapolymer-Schicht dient als Zwischenschicht und haftet einerseits ausgezeichnet an der Oberfläche des elektrischen Leiters und ermöglich andererseits eine erhöhte Haftung der auf die Plasmapolymer-Schicht aufgetragenen Schicht der isolierenden Beschichtung, beispielsweise der zumindest einen Isolationsschicht.In a first alternative embodiment of the invention, in order to improve the adhesion of the insulating coating to the surface of the electrical conductor, it is provided that the insulating coating has a plasma polymer layer of crosslinked macromolecules of non-uniform chain length, which plasma polymer layer is applied directly to the surface of the electrical conductor by polymerizing a gaseous monomer in a gas plasma, preferably in a gas plasma for bombarding the electrical conductor, can be produced. In other words, the plastic-containing intermediate layer of the insulating coating applied directly to the surface of the electrical conductor in this exemplary embodiment is the plasma polymer layer. The plasma polymer layer serves as an intermediate layer and, on the one hand, adheres excellently to the surface of the electrical conductor and, on the other hand, enables increased adhesion of the layer of the insulating coating applied to the plasma polymer layer, for example the at least one insulating layer.

Eine weitere Ausführungsvariante der ersten alternativen Ausführungsvariante sieht vor, dass die Plasmapolymer-Schicht eine Dicke von 1 µm oder weniger aufweist. Denkbar sind dabei Dicken bis zu einem Hundertstel eines Mikrometers als Untergrenze. Durch die geringe Schichtdicke wirkt sich die Plasmapolymer-Schicht nur unwesentlich auf die gesamte Dicke des isolierten elektrischen Leiters aus.Another embodiment of the first alternative embodiment provides that the plasma polymer layer has a thickness of 1 μm or less. Thicknesses of up to a hundredth of a micrometer are conceivable as the lower limit. Due to the small layer thickness, the plasma polymer layer has only a negligible effect on the entire thickness of the insulated electrical conductor.

Gemäß einer weiteren Ausführungsvariante der ersten alternativen Ausführungsvariante handelt es sich bei dem Monomer zur Herstellung der Plasmapolymer-Schicht um Ethylen, Buthenol, Aceton oder Tetrafluormethan [CF4]. Die durch diese Monomere im Plasma gebildeten Plasmapolymer-Schichten zeichnen sich durch besonders gute Haftungseigenschaften aus. Insbesondere wenn die Plasmapolymer-Schicht ähnliche Eigenschaften wie Polytetrafluorethylen [PTFE] oder Perfluorethylenpropylen [FEP] aufweisen soll, bietet sich CF4 als Monomer an.According to a further variant of the first alternative variant, 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 characterized by particularly good adhesion properties. In particular, if the plasma polymer layer is to have properties similar to those of polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP], CF 4 is the ideal monomer.

In einer zweiten alternativen Ausführungsvariante ist vorgesehen, dass die isolierende Beschichtung zumindest eine unmittelbar auf die Oberfläche des elektrischen Leiters aufgebrachte, vorzugsweise Polytetrafluorethylen [PTFE] oder Perfluorethylenpropylen [FEP] umfassende, Fluoropolymer-Schicht aufweist. Auch die Fluoropolymer-Schicht zeichnet sich durch hervorragende Haftungseigenschaften, sowohl am elektrischen Leiter als auch an der auf der Fluoropolymer-Schicht aufgetragenen Schicht, aus und dient als Zwischenschicht der isolierenden Beschichtung. Es ist auch denkbar, dass mehrere Fluoropolymer-Schichten, beispielsweise zwei drei oder vier, übereinander auf den elektrischen Leiter aufgebracht werden. Besonders vorteilhafte Haftungseigenschaften werden dadurch erreicht, dass die die Dicke der zumindest einen Fluoropolymer-Schicht zwischen 1 µm und 120 µm, vorzugsweise zwischen 5 µm und 100 µm, besonders bevorzugt zwischen 10 µm und 80 µm, insbesondere zwischen 20 µm und 50 µm, beträgt.In a second alternative embodiment it is provided that the insulating coating has at least one fluoropolymer layer applied directly to the surface of the electrical conductor, preferably comprising polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP]. The fluoropolymer layer is also characterized by excellent adhesive properties, both on the electrical conductor and on the layer applied to the fluoropolymer layer, and serves as an intermediate layer insulating coating. It is also conceivable that several fluoropolymer layers, for example two, three or four, are applied to the electrical conductor on top of one another. Particularly advantageous adhesion properties are achieved in that the thickness of the at least one fluoropolymer layer is between 1 μm and 120 μm, preferably between 5 μm and 100 μm, particularly preferably between 10 μm and 80 μm, in particular between 20 μm and 50 μm .

Um die zuvor beschrieben verbesserten Haftungseigenschaften für auf die Plasmapolymer-Schicht oder die zumindest eine Fluoropolymer-Schicht aufgetragenen Schichten der isolierenden Beschichtung, insbesondere für die zumindest eine Isolationsschicht, am elektrischen Leiter zu erreichen, sodass die Haftung nachfolgender Schichten im Bereich von fehlerhaften Abschnitten der vorhergehenden auf dem elektrischen Leiter aufgetragenen Schichten erhöht ist, wird die gesamte isolierende Beschichtung in einer bevorzugten Ausführungsvariante der Erfindung unter Schutzgasatmosphäre aufgebracht.In order to achieve the above-described improved adhesion properties for the layers of the insulating coating applied to the plasma polymer layer or the at least one fluoropolymer layer, in particular for the at least one insulating layer, on the electrical conductor, so that the adhesion of subsequent layers in the area of defective sections of the previous ones is increased layers applied to the electrical conductor, the entire insulating coating is applied in a preferred embodiment of the invention under a protective gas atmosphere.

Um die Anzahl an unterschiedlichen Schichten in der isolierenden Beschichtung zu reduzieren und die damit verbundenen Herstellungskosten gering zu halten ist in einer weiteren Ausführungsvariante der Erfindung vorgesehen, dass die zumindest eine Isolationsschicht unmittelbar auf die Plasmapolymer-Schicht oder die zumindest eine Fluoropolymer-Schicht aufgebracht ist. In anderen Worten besteht die isolierende Beschichtung aus zumindest zwei Schichten: die erste untere, unmittelbar auf dem elektrischen Leiter aufgebrachte Schicht entsprechend der ersten oder zweiten alternativen Ausführungsvariante und die zweite obere Schicht in Form der zumindest einen Isolationsschicht aus thermoplastischem Kunststoff. Die äußerste Schicht der isolierenden Beschichtung kann dabei entweder durch die zumindest eine Isolationsschicht selbst ausgebildet sein oder aber durch eine oder mehrere weitere Schichten.In order to reduce the number of different layers in the insulating coating and to keep the associated production costs low, a further embodiment of the invention provides that the at least one insulation layer is applied directly to the plasma polymer layer or the at least one fluoropolymer layer. In other words, the insulating coating consists of at least two layers: the first lower layer applied directly to the electrical conductor in accordance with the first or second alternative embodiment variant and the second upper layer in the form of the at least one insulating layer made of thermoplastic material. The outermost layer of the insulating coating can either be formed by the at least one insulating layer itself or by one or more further layers.

Ein erfindungsgemäßer isolierter elektrischer Leiter kann durch ein Verfahren zur Herstellung eines isolierten elektrischen Leiters hergestellt werden, welches folgende Verfahrensschritte aufweist:

  • Beschießen eines unter einer Schutzgasatmosphäre angeordneten elektrischen Leiters, vorzugsweise aus Kupfer oder Aluminium, mit Ionen des Schutzgases in einem Gas-Plasma, vorzugsweise einem Niederdruckplasma, um eine auf der Oberfläche des elektrischen Leiters ausgebildete Oxidschicht zu entfernen und/oder die Oberflächenenergie des elektrischen Leiters zu erhöhen;
  • Aufbringen einer isolierenden Beschichtung auf die Oberfläche des elektrischen Leiters, wobei die isolierende Beschichtung entweder
    • zumindest eine Isolationsschicht aus thermoplastischem Kunststoff umfasst,
      oder
    • zumindest eine Isolationsschicht aus thermoplastischem Kunststoff und
    • eine Kunststoff enthaltende Zwischenschicht, vorzugsweise eine Plasmapolymer-Schicht oder zumindest eine
    • Fluoropolymer-Schicht, umfasst wobei entweder
    • die zumindest eine Isolationsschicht unter
    • Schutzgasatmosphäre unmittelbar auf die Oberfläche des
    • elektrischen Leiters aufgebracht wird oder, im dem Fall, dass die Beschichtung die Kunststoff enthaltende Zwischenschicht umfasst,
    • zumindest die Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung unter Schutzgasatmosphäre unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird.
An insulated electrical conductor according to the invention can be produced by a method for producing an insulated electrical conductor which has the following process steps having:
  • Bombarding an electrical conductor, preferably made of copper or aluminum, arranged under a protective gas atmosphere with ions of the protective gas in a gas plasma, preferably a low-pressure plasma, in order to remove an oxide layer formed on the surface of the electrical conductor and / or to add the surface energy of the electrical conductor raise;
  • Applying an insulating coating to the surface of the electrical conductor, the insulating coating being either
    • comprises at least one insulation layer made of thermoplastic material,
      or
    • at least one insulation layer made of thermoplastic material and
    • an intermediate layer containing plastic, preferably a plasma polymer layer or at least one
    • Fluoropolymer layer, comprising either
    • the at least one insulation layer underneath
    • Protective gas atmosphere directly onto the surface of the
    • electrical conductor is applied or, in the case that the coating comprises the plastic-containing intermediate layer,
    • at least the plastic-containing intermediate layer of the insulating coating is applied directly to the surface of the electrical conductor in a protective gas atmosphere.

Der elektrische Leiter, vorzugsweise aus Kuper oder Aluminium, wird in Form eines Bandes oder eines Drahts dem Verfahren unterzogen. Dabei wird der elektrische Leiter entweder "inline", also direkt anschließend an die Herstellung des elektrischen Leiters (etwa durch Kaltumformung oder Extrusion), entsprechend dem erfindungsgemäßen Verfahren behandelt oder aber der elektrische Leiter wird in aufgewickelter Form über einen Spulenablauf zur Verfügung gestellt. In der Regel wird der elektrische Leiter vor der Plasmabehandlung noch einer mechanischen und/oder chemischen Vorreinigung unterzogen. Die Plasmabehandlung wird analog zu den vorhergegangen Ausführungen durchgeführt, wobei der elektrische Leiter kontinuierlich durch die die Plasmabehandlung durchführende Plasmabehandlungs-Einheit gefördert wird. Durch die geeignete Wahl der Prozessparameter lässt sich die Dicke der durch die Plasmabehandlung vom elektrischen Leiter abgetragenen Schicht genau einstellen. Zusätzlich dazu lässt sich auch die Temperatur für das Weichglühen und die damit verbundene Rekristallisation des Gefüges des elektrischen Leiters definieren.The electrical conductor, preferably made of copper or aluminum, is subjected to the process in the form of a tape or a wire. In this case, the electrical conductor is either treated "inline", i.e. directly after the production of the electrical conductor (for example by cold forming or extrusion), in accordance with the method according to the invention, or the electrical conductor is made available in wound form via a coil payout. As a rule, the electrical conductor becomes one more before the plasma treatment mechanical and / or chemical pre-cleaning. The plasma treatment is carried out analogously to the previous explanations, the electrical conductor being continuously conveyed through the plasma treatment unit carrying out the plasma treatment. The thickness of the layer removed from the electrical conductor by the plasma treatment can be precisely adjusted by a suitable choice of the process parameters. In addition, the temperature for the soft annealing and the associated recrystallization of the structure of the electrical conductor can also be defined.

Nach der Plasmabehandlung, also dem Abtragen der Oxidschicht und jedweden Verunreinigungen von der Oberfläche des elektrischen Leiters, wobei auch dünne Schichten der Oberfläche des elektrischen Leiters selbst (kleiner als 1 µm, vorzugsweise kleiner 0,1 µm) abgetragen werden können, durch Beschuss mit Ionen im Gas-Plasma bzw. der Aktivierung der Oberfläche des elektrischen Leiters, wird die isolierende Beschichtung auf die behandelte Oberfläche des elektrischen Leiters aufgebracht. Die isolierende Beschichtung haftet aufgrund der Entfernung der Oxidschicht bzw. durch die Aktivierung der Oberfläche durch Erhöhung der Oberflächenenergie des elektrischen Leiters besonders gut auf der Oberfläche des elektrischen Leiters. Um die Ausbildung einer neuen Oxidschicht auf der Oberfläche des elektrischen Leiters zu verhindern, welche den erfindungsgemäßen Effekt unterbinden oder zumindest entscheidend abschwächen würde, wird entweder die zumindest eine Isolationsschicht oder zumindest die Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung, also insbesondere die Plasmapolymer-Schicht oder die zumindest eine Fluoropolymer-Schicht, unter Schutzgasatmosphäre unmittelbar auf die oxidschicht-frei Oberfläche des elektrischen Leiters aufgebracht. Insbesondere von Vorteil ist es dabei, wenn der elektrische Leiter bis zum Aufbringen der isolierenden Beschichtung durchgehend unter Schutzgasatmosphäre angeordnet ist. Es versteht sich dabei von selbst, dass, sofern zwei, drei oder mehr Isolationsschichten aus thermoplastischem Kunststoff vorgesehen sind, jedenfalls die erste der Isolationsschichten unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird und die nachfolgenden Isolationsschichten zumindest teilweise auf die darunterliegenden Isolationsschichten aufgebracht werden.After the plasma treatment, i.e. the removal of the oxide layer and any impurities from the surface of the electrical conductor, thin layers of the surface of the electrical conductor itself (smaller than 1 μm, preferably smaller than 0.1 μm) can also be removed by bombardment with ions in the gas plasma or the activation of the surface of the electrical conductor, the insulating coating is applied to the treated surface of the electrical conductor. The insulating coating adheres particularly well to the surface of the electrical conductor due to the removal of the oxide layer or the activation of the surface by increasing the surface energy of the electrical conductor. In order to prevent the formation of a new oxide layer on the surface of the electrical conductor, which would prevent or at least significantly weaken the effect according to the invention, either the at least one insulation layer or at least the plastic-containing intermediate layer of the insulating coating, i.e. in particular the plasma polymer layer or the at least one fluoropolymer layer, applied directly to the oxide layer-free surface of the electrical conductor in a protective gas atmosphere. It is particularly advantageous if the electrical conductor is arranged continuously under a protective gas atmosphere until the insulating coating is applied. It goes without saying that, if two, three or more insulation layers made of thermoplastic material are provided, in any case the first of the insulation layers is applied directly to the surface of the electrical conductor and the subsequent ones Insulation layers are at least partially applied to the underlying insulation layers.

Derart hergestellte isolierte elektrische Leiter weisen durch die unmittelbare Aufbringung einer Kunststoff enthaltenden Zwischenschicht der isolierenden Beschichtung oder durch die unmittelbare Aufbringung der zumindest einen Isolationsschicht aus thermoplastischem Kunststoff auf die plasmabehandelte, oxidfreie Oberfläche des elektrischen Leiters besonders gute Haftungseigenschaften auf: Wird ein Rundumschnitt am isolierten elektrischen Leiter senkrecht zu einer Leiterachse durchgeführt und der Leiter um 20% gedehnt so beträgt die Ablösung der isolierenden Beschichtung vom elektrischen Leiter in Richtung der Leiterachse gemessen lediglich maximal 3 mm, vorzugsweise maximal 2 mm, insbesondere maximal 1 mm.Insulated electrical conductors produced in this way have particularly good adhesion properties through the direct application of an intermediate layer of the insulating coating containing plastic or through the direct application of the at least one insulating layer made of thermoplastic material to the plasma-treated, oxide-free surface of the electrical conductor: If an all-round cut is made on the insulated electrical conductor carried out perpendicular to a conductor axis and the conductor stretched by 20%, the detachment of the insulating coating from the electrical conductor measured in the direction of the conductor axis is only a maximum of 3 mm, preferably a maximum of 2 mm, in particular a maximum of 1 mm.

Wenn die zumindest eine Isolationsschicht aus thermoplastischem Kunststoff unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird, wurde festgestellt, dass die Ablösung der isolierenden Beschichtung vom elektrischen Leiter üblicher Weise weit unter 1 mm bleibt, insbesondere maximal 0,2 mm, vorzugsweise maximal 0,1 mm, bevorzugt maximal 0,05 mm, besonders bevorzugt maximal 0,01 mm, beträgt. Besonders vorteilhafte Effekte werden dann erreicht, wenn der thermoplastische Kunststoff der zumindest einen Isolationsschicht ausgewählt ist aus der Gruppe bestehend aus Polyaryletherketon [PAEK], insbesondere Polyetheretherketon [PEEK], Polyimid [PI], Polyamidimid [PAI], Polyetherimid [PEI], Polyphenylensulfid [PPS] und Kombinationen davon.If the at least one insulating layer made of thermoplastic material is applied directly to the surface of the electrical conductor, it was found that the separation of the insulating coating from the electrical conductor usually remains far below 1 mm, in particular a maximum of 0.2 mm, preferably a maximum of 0.1 mm, preferably a maximum of 0.05 mm, particularly preferably a maximum of 0.01 mm. Particularly advantageous effects are achieved when the thermoplastic of the at least one insulation 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.

Eine Ausführungsvariante des Verfahrens sieht vor, dass die zumindest eine Isolationsschicht aufextrudiert wird. Die Extrusion stellt ein kostengünstiges Verfahren zum Aufbringen der Isolationsschicht dar und eignet sich insbesondere auch für PAEK, insbesondere PEEK, und PPS. Die zumindest eine Isolationsschicht lässt sich somit auch in einfacher Art und Weise als äußerste Schicht der isolierenden Beschichtung aufbringen.One embodiment variant of the method provides that the at least one insulation layer is extruded on. Extrusion is a cost-effective method for applying the insulation layer and is also particularly suitable for PAEK, in particular PEEK, and PPS. The at least one insulation layer can thus also be applied in a simple manner as the outermost layer of the insulating coating.

Durch eine Vorwärmung des elektrischen Leiters, die vor allem vorteilhaft ist, wenn die zumindest eine Isolationsschicht bzw. die isolierende Beschichtung direkt auf die Oberfläche des elektrischen Leiters aufextrudiert wird, wird eine ruckartige Abkühlung der Kunststoff enthaltenden Zwischenschicht bei Kontakt mit dem elektrischen Leiter reduziert und damit negative Einflüsse auf die Haftung minimiert. Gleichfalls kann vorgesehen sein, das der elektrische Leiter vor dem Aufbringen der isolierenden Beschichtung abgekühlt wird, um eine zu starke Erhitzung, etwa eine Schmelze, der Kunststoff enthaltenden Zwischenschicht bei Kontakt mit dem elektrischen Leiter zu verhindern. Daher ist in einer weiteren bevorzugten Ausführungsvariante des Verfahrens vorgesehen, dass der elektrische Leiter vor dem Aufbringen der isolierenden Beschichtung auf eine Temperatur von zumindest 200 °C, vorzugsweise zumindest 400 °C, gebracht wird.By preheating the electrical conductor, which is particularly advantageous if the at least one insulation layer or the insulating coating is extruded directly onto the surface of the electrical conductor, a sudden cooling of the plastic-containing intermediate layer on contact with the electrical conductor is reduced and thus negative influences on adhesion are minimized. Likewise, it can be provided that the electrical conductor is cooled before the application of the insulating coating in order to prevent excessive heating, for example a melt, of the plastic-containing intermediate layer upon contact with the electrical conductor. Therefore, in a further preferred embodiment of the method, it is provided that the electrical conductor is brought to a temperature of at least 200 ° C., preferably at least 400 ° C., before the insulating coating is applied.

In einer weiteren Ausführungsvariante des Verfahrens ist vorgesehen, dass der isolierte elektrische Leiter nach dem Aufextrudieren der zumindest einen Isolationsschicht in Abhängigkeit der zu erreichenden Festigkeit der zumindest einen Isolationsschicht abgekühlt wird. Die Einstellung der mechanischen Eigenschaften der zumindest einen Isolationsschicht, insbesondere der mechanischen Festigkeit, erfolgt unter anderem durch die definierte Abkühlung des isolierten elektrischen Leiters und die dadurch bedingte Einstellung des Kristallisationsgrades und ist besonders wichtig, wenn es sich bei der zumindest einen Isolationsschicht um die äußerste Schicht der isolierenden Beschichtung handelt. Wird der isolierte elektrische Leiter beispielsweise langsam abgekühlt, etwa durch Abkühlen an der Luft, ergibt sich eine hohe Kristallinität der zumindest einen Isolationsschicht. Denkbar ist auch ein Abschrecken in einem Wasserbad, also eine abrupte Abkühlung, oder eine Kombination aus abrupter und langsamer Abkühlung.In a further embodiment variant of the method, it is provided that the insulated electrical conductor is cooled after the at least one insulation layer has been extruded on, depending on the strength of the at least one insulation layer to be achieved. The setting of the mechanical properties of the at least one insulation layer, in particular the mechanical strength, takes place, among other things, through the defined cooling of the insulated electrical conductor and the resulting setting of the degree of crystallization and is particularly important if the at least one insulation layer is the outermost layer the insulating coating. If the insulated electrical conductor is cooled slowly, for example, by cooling in air, the result is a high degree of crystallinity of the at least one insulation layer. Quenching in a water bath, i.e. abrupt cooling, or a combination of abrupt and slow cooling is also conceivable.

Um die Haftung der isolierenden Beschichtung am elektrischen Leiter weiter zu verbessern, insbesondere wenn die zumindest eine Isolationsschicht direkt auf die Oberfläche des elektrischen Leiters aufgebracht wird, ist in einer bevorzugten Ausführungsvariante des Verfahrens vorgesehen, dass der isolierte elektrische Leiter nach dem Aufextrudieren der zumindest einen Isolationsschicht über Rollen, vorzugsweise Anpressrollen, geführt wird. Besonders vorteilhaft ist es dabei, wenn die zumindest eine Isolationsschicht die äußerste Schicht der isolierenden Beschichtung bildet. Ein enges Führen des isolierten elektrischen Leiters über die Anpressrollen unter Beaufschlagung des isolierten elektrischen Leiters mit Druck führt zu einer besonders guten Haftung der isolierenden Beschichtung bzw. insbesondere der zumindest einen Isolationsschicht auf der Oberfläche des elektrischen Leiters. Dabei werden die Grenzflächen der isolierenden Beschichtung zwischen den einzelnen Schichten, sofern mehrere vorhanden sind, und/oder die Grenzfläche der untersten Schicht der isolierenden Beschichtung und die Oberfläche des elektrischen Leiters aneinander gepresst und so die Adhäsionseffekte verstärkt.In order to further improve the adhesion of the insulating coating to the electrical conductor, in particular if the at least one insulating layer is applied directly to the surface of the electrical conductor is applied, it is provided in a preferred embodiment of the method that the insulated electrical conductor is guided over rollers, preferably pressure rollers, after the at least one insulation layer has been extruded on. It is particularly advantageous if the at least one insulation layer forms the outermost layer of the insulating coating. Closely guiding the insulated electrical conductor over the pressure rollers while applying pressure to the insulated electrical conductor leads to particularly good adhesion of the insulating coating or in particular of the at least one insulation layer on the surface of the electrical conductor. The interfaces of the insulating coating between the individual layers, if several are present, and / or the interface of the lowest layer of the insulating coating and the surface of the electrical conductor are pressed against one another, thus increasing the adhesion effects.

In einer besonders bevorzugten Ausführungsvariante der Erfindung, welche sich durch besonders gute Haftungseigenschaften auszeichnet, ist vorgesehen, dass die isolierende Beschichtung aus der zumindest einen Isolationsschicht besteht und dass die zumindest eine Isolationsschicht als Kunststoff enthaltende Zwischenschicht der isolierenden Beschichtung unter Schutzgasatmosphäre unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird. Entsprechend wird folgender Verfahrensschritt durchgeführt:

  • Aufbringen einer isolierenden Beschichtung auf die Oberfläche des elektrischen Leiters, wobei die isolierende Beschichtung aus zumindest einer Isolationsschicht aus thermoplastischem Kunststoff besteht und wobei die zumindest eine
  • Isolationsschicht unter Schutzgasatmosphäre unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht wird.
In a particularly preferred embodiment of the invention, which is characterized by particularly good adhesion properties, it is provided that the insulating coating consists of the at least one insulating layer and that the intermediate layer of the insulating coating, which contains at least one insulating layer as plastic, is directly applied to the surface of the electrical in a protective gas atmosphere Conductor is applied. The following process step is carried out accordingly:
  • Applying an insulating coating to the surface of the electrical conductor, wherein the insulating coating consists of at least one insulating layer made of thermoplastic material and wherein the at least one
  • Insulation layer is applied directly to the surface of the electrical conductor in a protective gas atmosphere.

Dadurch wird ebenfalls die zuvor erwähnte besonders geringe Ablösung von weniger als 1 mm erreicht.As a result, the above-mentioned particularly low detachment of less than 1 mm is also achieved.

Um, wie zuvor erwähnt, die Wahrscheinlichkeit eines Fehlers in der isolierenden Beschichtung drastisch zu verringern, ist in einer weiteren Ausführungsvariante vorgesehen, dass die isolierende Beschichtung aus zumindest zwei, vorzugsweise genau zwei, Isolationsschichten besteht und die isolierende Beschichtung mittels Tandemextrusion unter Schutzgasatmosphäre hergestellt wird. Durch die Tandemextrusion werden die zumindest zwei Isolationsschichten unabhängig voneinander hergestellt, sodass eine Verstopfung eines Extrusionswerkzeugs nur einen Fehler in einer der Isolationsschichten hervorruft. Dadurch wird der fehlerhafte Abschnitt durch die nachfolgenden Extrusionsschritte mit hoher Wahrscheinlichkeit abgedeckt.In order, as mentioned above, to drastically reduce the probability of a fault in the insulating coating, a further variant provides that the insulating coating consists of at least two, preferably exactly two, insulating layers and the insulating coating is produced by means of tandem extrusion under a protective gas atmosphere. As a result of the tandem extrusion, the at least two insulation layers are produced independently of one another, so that a clogging of an extrusion tool only causes a defect in one of the insulation layers. As a result, the defective section is covered with a high degree of probability by the subsequent extrusion steps.

Wenn, wie zuvor ausgeführt, aufgrund der verhältnismäßig kleinen Fläche der Fehler, auf eine verbesserte Haftung verzichtet werden kann oder eine dickere isolierende Beschichtung erforderlich ist, sieht eine weitere Ausführungsvariante der Erfindung vor, dass zumindest eine weitere Isolationsschicht aus thermoplastischem Kunststoff mittels Tandemextrusion auf die isolierende Beschichtung aufextrudiert wird, wobei die Extrusion der weiteren Isolationsschicht nicht unter Schutzgasatmosphäre stattfindet.If, as stated above, due to the relatively small area of the defect, improved adhesion can be dispensed with or a thicker insulating coating is required, a further embodiment of the invention provides that at least one further insulating layer made of thermoplastic material is applied to the insulating material by means of tandem extrusion Coating is extruded on, the extrusion of the further insulation layer not taking place under a protective gas atmosphere.

Vorzugsweise ist der thermoplastische Kunststoff der zumindest einen weiteren Isolationsschicht ausgewählt aus der Gruppe bestehend aus Polyaryletherketon [PAEK], insbesondere Polyetheretherketon [PEEK], Polyimid [PI], Polyamidimid [PAI], Polyetherimid [PEI], Polyphenylensulfid [PPS] und Kombinationen davon.The thermoplastic of the at least one further insulation layer is preferably selected from the group consisting of polyaryletherketone [PAEK], in particular polyetheretherketone [PEEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.

Wenn die isolierende Beschichtung zumindest eine Fluoropolymer-Schicht umfasst, die als Kunststoff enthaltende Zwischenschicht unmittelbar auf die Oberfläche des elektrischen Leiters aufgebracht ist, lassen sich die zur Herstellung der isolierenden Beschichtung benötigten Schritte dadurch reduzieren, dass die zumindest eine Isolationsschicht und die zumindest eine Fluoropolymer-Schicht mittels Ko- oder Tandemextrusion hergestellt werden. So können beide Schichten in nur einem einzigen Herstellungsschritt und mit einer Extrusions-Einheit hergestellt werden.If the insulating coating comprises at least one fluoropolymer layer, which is applied directly to the surface of the electrical conductor as an intermediate layer containing plastic, the steps required to produce 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 produced by means of co- or tandem extrusion. So both layers can be in can only be produced in a single production step and with an extrusion unit.

Zur Verbesserung der Haftung der isolierenden Beschichtung am elektrischen Leiter ist in einer weiteren Ausführungsvariante vorgesehen, dass unmittelbar auf der Oberfläche des elektrischen Leiters mittels Polymerisation eines gasförmigen Monomers in einem Gas-Plasma eine Plasmapolymer-Schicht als Kunststoff enthaltende Zwischenschicht aufgebracht wird.To improve the adhesion of the insulating coating to the electrical conductor, a further embodiment variant provides that a plasma polymer layer containing plastic is applied directly to the surface of the electrical conductor by polymerizing a gaseous monomer in a gas plasma.

Da eine hohe Temperaturbeständigkeit und eine hohe Haftung der isolierenden Beschichtung am elektrischen Leiter insbesondere im Elektromaschinenbau von Bedeutung ist, ist vorgesehen, dass ein erfindungsgemäßer isolierter elektrischer Leiter als Wickeldraht für Elektromaschinen, vorzugsweise Elektromotoren oder Transformatoren, verwendet wird.Since high temperature resistance and high adhesion of the insulating coating to the electrical conductor is important, especially in electrical engineering, it is provided that an insulated electrical conductor according to the invention is used as a winding wire for electrical machines, preferably electrical motors or transformers.

KURZE BESCHREIBUNG DER FIGURENBRIEF DESCRIPTION OF THE FIGURES

Die Erfindung wird nun anhand von Ausführungsbeispielen näher erläutert. Die Zeichnungen sind beispielhaft und sollen den Erfindungsgedanken zwar darlegen, ihn aber keinesfalls einengen oder gar abschließend wiedergeben.The invention will now be explained in more detail on the basis of exemplary embodiments. The drawings are exemplary and are intended to explain the concept of the invention, but in no way restrict it or reproduce it conclusively.

Dabei zeigt:

Fig. 1
eine schematische Darstellung eines erfindungsgemäßen Verfahrens;
Fig. 2a
eine erste Ausführungsvariante eines isolierten elektrischen Leiters mit rechteckigem Querschnitt;
Fig. 2b
eine zweite Ausführungsvariante eines isolierten elektrischen Leiters mit rechteckigem Querschnitt;
Fig. 2c
eine dritte Ausführungsvariante eines isolierten elektrischen Leiters mit rechteckigem Querschnitt;
Fig. 3a-3c
die erste bis dritte Ausführungsvariante mit rundem Querschnitt.
It shows:
Fig. 1
a schematic representation of a method according to the invention;
Fig. 2a
a first variant of an insulated electrical conductor with a rectangular cross-section;
Figure 2b
a second variant of an insulated electrical conductor with a rectangular cross section;
Figure 2c
a third variant of an insulated electrical conductor with a rectangular cross section;
Figures 3a-3c
the first to third variant with a round cross-section.

WEGE ZUR AUSFÜHRUNG DER ERFINDUNGWAYS OF CARRYING OUT THE INVENTION

Fig. 1 zeigt eine schematische Darstellung eines Verfahrens zur Herstellung eines isolierten elektrischen Leiters, wie er in den Figuren 2a bis 2d bzw. 3a bis 3d dargestellt ist. Der isolierte elektrische Leiter umfasst einen elektrischen Leiter 1 aus Kupfer, wobei auch andere Materialien wie etwa Aluminium denkbar sind, und eine isolierende Beschichtung 2, welche zumindest eine Isolationsschicht 3 aus thermoplastischem, vorzugsweise hochtemperaturbeständigem, Kunststoff aufweist. In den nachfolgenden Ausführungsbeispielen ist die zumindest eine Isolationsschicht 3 als eine äußere Isolationsschicht 3 ausgebildet und bildet somit die äußerste Schicht der isolierenden Beschichtung 2. Es versteht sich jedoch von selbst, dass in alternativen Ausführungsvarianten auf der Isolationsschicht 3 noch eine oder mehrere weitere Schichten, vorzugsweise Isolationsschichten, aufgebracht sein können, die dann die äußerste Schicht der isolierenden Beschichtung 2 ausbilden können. Fig. 1 FIG. 11 shows a schematic representation of a method for producing an insulated electrical conductor as shown in FIG Figures 2a to 2d or 3a to 3d is shown. The insulated electrical conductor comprises an electrical conductor 1 made of copper, other materials such as aluminum are also conceivable, and an insulating coating 2, which has at least one insulating layer 3 made of thermoplastic, preferably high-temperature-resistant plastic. In the following exemplary embodiments, the at least one insulation layer 3 is designed as an outer insulation layer 3 and thus forms the outermost layer of the insulating coating 2. However, it goes without saying that in alternative design variants, one or more additional layers, preferably Insulation layers can be applied, which can then form the outermost layer of the insulating coating 2.

Der elektrische Leiter 1 wird im dargestellten Ausführungsbeispiel als Band oder Draht über einen Spulenablauf 7 stetig dem Verfahren zugeführt und kann etwa mittels Kaltumformungsverfahren, wie Ziehen oder Walzen, oder Extrusion, beispielsweise mittels Conform® - Technologie, hergestellt sein. Es versteht sich von selbst, dass das erfindungsgemäße Verfahren auch "in-line" durchgeführt werden kann, also direkt an den Herstellungsprozess anschließt. In einem ersten Schritt wird der elektrische Leiter 1 in einer Vorreinigungs-Einheit 8 mechanisch, etwa mittels eines Schleifverfahrens, oder chemisch, etwa mittels geeigneter Lösungsmittel oder Säuren, vorgereinigt, um grobe Verschmutzungen vom elektrischen Leiter 1 zu entfernen.In the exemplary embodiment shown, the electrical conductor 1 is continuously fed to the process as a strip or wire via a coil payout 7 and can be produced using cold forming processes, such as drawing or rolling, or extrusion, for example using Conform® technology. It goes without saying that the method according to the invention can also be carried out “in-line”, that is to say directly following the manufacturing process. In a first step, the electrical conductor 1 is pre-cleaned mechanically, for example by means of a grinding process, or chemically, for example by means of suitable solvents or acids, in a pre-cleaning unit 8, in order to remove coarse dirt from the electrical conductor 1.

Im nächsten Verfahrensschritt gelangt der vorgereinigte elektrische Leiter 1 in eine Plasmabehandlungs-Einheit 9 in der eine Schutzgasatmosphäre aus Stickstoff, Argon oder Wasserstoff vorherrscht und ein Gas-Plasma in Form eines Niederdruckplasmas mit weniger als 20 mbar Druck hergestellt ist. Ein Niederdruckplasma kann jedoch auch schon bei einem Druck von weniger als 80 mbar hergestellt werden. In diesem Niederdruckplasma wird die Oberfläche des elektrischen Leiters 1 mit Ionen des Schutzgases beschossen, um eine auf einer Oberfläche des elektrischen Leiters 1 gebildete Oxidschicht abzutragen bzw. zu entfernen. Gleichzeitig wird der elektrische Leiter 1 durch die Plasmabehandlung weich geglüht und die Oberflächenenergie des elektrischen Leiters 1 erhöht also die Oberfläche aktiviert.In the next process step, the pre-cleaned electrical conductor 1 arrives in a plasma treatment unit 9 in which a protective gas atmosphere of nitrogen, argon or hydrogen prevails and a gas plasma is produced in the form of a low-pressure plasma with a pressure of less than 20 mbar. However, a low-pressure plasma can also be used at a pressure of less than 80 mbar can be produced. In this low-pressure plasma, the surface of the electrical conductor 1 is bombarded with ions of the protective gas in order to ablate or remove an oxide layer formed on a surface of the electrical conductor 1. At the same time, the electrical conductor 1 is annealed soft by the plasma treatment and the surface energy of the electrical conductor 1 increases, so the surface is activated.

Durch das Abtragen der Oxidschicht und jedweden Verunreinigungen von der Oberfläche des elektrischen Leiters 1, wobei sogar vorgesehen sein kann, dass sehr dünne Schichten des elektrischen Leiters 1 selbst von der Oberfläche abgetragen werden, und die Erhöhung der Oberflächenenergie kann die Haftung zwischen dem elektrischen Leiter 1 aus Kupfer und der auf dem elektrischen Leiter 1 aufgebrachten isolierenden Beschichtung 2 entscheidend verbessert werden.By removing the oxide layer and any impurities from the surface of the electrical conductor 1, it can even be provided that very thin layers of the electrical conductor 1 itself are removed from the surface, and the increase in surface energy can reduce the adhesion between the electrical conductor 1 made of copper and the insulating coating 2 applied to the electrical conductor 1 can be decisively improved.

In der ersten Ausführungsvariante des erfindungsgemäßen isolierten elektrischen Leiters, dargestellt in Figur 2a als Flachleiter mit rechteckigem Querschnitt und in Fig. 3a mit rundem Querschnitt, besteht die isolierende Beschichtung 2 nur aus einer Isolationsschicht 3. Die Isolationsschicht 3 weist dabei eine Temperaturbeständigkeit von über 180°C, vorzugsweise von über 220°C, auf, sodass der isolierte elektrische Leiter auch bei hohen Betriebstemperaturen eingesetzt werden kann. Die äußere Isolationsschicht 3 besteht dabei aus Polyetheretherketon [PEEK], welches sowohl die hohe Temperaturbeständigkeit als auch eine hohe Beständigkeit gegenüber einer großen Anzahl an organischen und anorganischen Substanzen aufweist. Alternativ dazu kann die äußere Isolationsschicht 3 auch aus Polyphenylensulfid [PPS] bestehen oder PEEK und/oder PPS umfassen.In the first variant of the insulated electrical conductor according to the invention, shown in FIG Figure 2a as a flat conductor with a rectangular cross-section and in Fig. 3a With a round cross-section, the insulating coating 2 consists of only one insulation layer 3. The insulation layer 3 has a temperature resistance of over 180 ° C., preferably over 220 ° C., so that the insulated electrical conductor can also be used at high operating temperatures. The outer insulation layer 3 consists of polyetheretherketone [PEEK], which has both high temperature resistance and high resistance to a large number of organic and inorganic substances. As an alternative to this, the outer insulation layer 3 can also consist of polyphenylene sulfide [PPS] or comprise PEEK and / or PPS.

Um die erhöhte Haftung zwischen dem elektrischen Leiter 1 und der äußeren Isolationsschicht 3 zu erreichen, gelangt der elektrische Leiter 1 nach dem Durchlaufen der Plasmabehandlungs-Einheit 9 in die Extrusions-Einheit 11 in der die äußere Isolationsschicht 3 auf den elektrische Leiter 1 aufextrudiert wird. Dabei wird der elektrische Leiter 1 auf eine Temperatur von zumindest 200°C, vorzugsweise zumindest 300°C, vorgeheizt. Um die erneute Ausbildung einer Oxidschicht zu verhindern, erfolgt sowohl die Extrusion als auch der Transport des Leiters 1 in die Extrusions-Einheit 11 unter Schutzgasatmosphäre. Ein derart hergestellter isolierter elektrischer Leiter kann beispielsweise als Wickeldraht, im Englischen auch als "magnet wire" geläufig, in einer Elektromaschine, wie einem Elektromotor oder einem Transformator, eingesetzt werden. Die Dicke der äußeren Isolationsschicht 3 beträgt im vorliegenden Ausführungsbeispiel etwa 30 µm.In order to achieve increased adhesion between the electrical conductor 1 and the outer insulation layer 3, the electrical conductor 1, after passing through the plasma treatment unit 9, enters the extrusion unit 11 in which the outer insulation layer 3 is extruded onto the electrical conductor 1 will. The electrical conductor 1 is preheated to a temperature of at least 200.degree. C., preferably at least 300.degree. In order to prevent the renewed formation of an oxide layer, both the extrusion and the transport of the conductor 1 into the extrusion unit 11 take place under a protective gas atmosphere. An insulated electrical conductor produced in this way can be used, for example, as a winding wire, also known as "magnet wire" in English, in an electrical machine, such as an electric motor or a transformer. The thickness of the outer insulation layer 3 is approximately 30 μm in the present exemplary embodiment.

Insbesondere wenn die Isolationsschicht 3 aus einem Polyaryletherketon [PAEK] wie Polyetheretherketon [PEEK] besteht, werden dadurch besonders gute Haftungseingenschaften erreicht. So bleibt die Ablösung der Isolationsschicht 3 vom elektrischen Leiter 1 üblicher Weise weit unter 1 mm, und beträgt insbesondere maximal 0,2 mm, vorzugsweise maximal 0,1 mm, bevorzugt maximal 0,05 mm, besonders bevorzugt maximal 0,01 mm. Auch wenn es sich bei dem thermoplastischen Kunststoff der Isolationsschicht 3 um Polyimid [PI], Polyamidimid [PAI], Polyetherimid [PEI], Polyphenylensulfid [PPS] handelt, lassen sich gesteigerte Haftungseigenschaften erreichen.Particularly when the insulation layer 3 consists of a polyaryletherketone [PAEK] such as polyetheretherketone [PEEK], particularly good adhesion properties are achieved as a result. The separation of the insulation layer 3 from the electrical conductor 1 usually remains far below 1 mm, and is in particular a maximum of 0.2 mm, preferably a maximum of 0.1 mm, preferably a maximum of 0.05 mm, particularly preferably a maximum of 0.01 mm. Even if the thermoplastic of the insulation layer 3 is polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS], increased adhesion properties can be achieved.

Im Allgemeinen kann die zumindest eine Isolationsschicht 3 auch zwei, drei vier oder mehr einzelne Isolationsschichten 3 umfassen, welche allesamt unter Schutzgasatmosphäre in der Extrusions-Einheit 11 hergestellt werden. Dadurch lässt sich die Wahrscheinlichkeit von Fehlern in der isolierenden Beschichtung 2 drastisch reduzieren, da Fehler in der untersten der Isolationsschichten 3 durch nachfolgende Isolationsschichten 3 ausgeglichen werden. Für eine solche Herstellung eignen sich insbesondere Tandemextrusionsverfahren.In general, the at least one insulation layer 3 can also comprise two, three, four or more individual insulation layers 3, all of which are produced in the extrusion unit 11 under a protective gas atmosphere. This allows the probability of defects in the insulating coating 2 to be drastically reduced, since defects in the lowest of the insulation layers 3 are compensated for by subsequent insulation layers 3. Tandem extrusion processes are particularly suitable for such a production.

Zusätzlich oder stattdessen kann auch vorgesehen sein, dass weitere Isolationsschichten, die vorzugsweise analog zu der zumindest einen Isolationsschicht 3 aufgebaut sind, also insbesondere aus einem Polyaryletherketon [PAEK] wie Polyetheretherketon [PEEK] oder einem anderen der zuvor genannten Kunststoffe bestehen, außerhalb der Schutzgasatmosphäre in einer weiteren Extrusions-Einheit 12 auf die isolierende Beschichtung 2 aufgebracht werden.In addition or instead, it can also be provided that further insulation layers, which are preferably constructed analogously to the at least one insulation layer 3, that is to say in particular made of a polyaryletherketone [PAEK] such as Polyetheretherketone [PEEK] or another of the aforementioned plastics, are applied to the insulating coating 2 in a further extrusion unit 12 outside the protective gas atmosphere.

Um die Haftung zwischen der isolierenden Beschichtung 2 und dem elektrischen Leiter 1 alternativ zur ersten Ausführungsvariante zu erhöhen, umfasst die isolierende Beschichtung 2 in der in den Figuren 2b und 3b dargestellten zweiten Ausführungsvariante neben der äußeren Isolationsschicht 3 aus PEEK oder PPS eine Kunststoff enthaltende Zwischenschicht in Form einer Plasmapolymer-Schicht 4. Diese Plasmapolymer-Schicht 4 wird im erfindungsgemäßen Verfahren in einer Plasmapolymerisations-Einheit 10 hergestellt, die nach der Plasmabehandlungs-Einheit 9 und vor der Extrusions-Einheit 11 angeordnet ist. Es ist auch denkbar, dass die Plasmabehandlung und die Plasmapolymerisation in einer kombinierten Einrichtung durchgeführt werden. Nachdem die Oxidschicht entfernt und die Oberflächenenergie erhöht wurde, siehe oben, bildet sich in der Plasmapolymerisations-Einheit 10 die Plasmapolymer-Schicht 4 auf der Oberfläche des elektrischen Leiters 1 aus, indem ein gasförmiges Monomer, wie Ethylen, Buthenol, Aceton oder Tetrafluormethan [CF4] mittels des Plasmas aktiviert wird und sich dadurch hochvernetzte Makromoleküle unterschiedlicher Kettenlänge und einem Anteil an freien Radikalen ausbilden, welche sich als Plasmapolymer-Schicht 4 auf der Oberfläche des elektrischen Leiters 1 ablagern. Die so entstandene Plasmapolymer-Schicht 4 ist im vorliegenden Ausführungsbeispiel weniger als 1 µm dick und haftet besonders gut an der aktivierten und oxidfreien Oberfläche des elektrischen Leiters 1.In order to increase the adhesion between the insulating coating 2 and the electrical conductor 1 as an alternative to the first embodiment variant, the insulating coating 2 comprises in FIG Figures 2b and 3b In addition to the outer insulation layer 3 made of PEEK or PPS, an intermediate layer containing plastic in the form of a plasma polymer layer 4 is shown in addition to the second embodiment variant the extrusion unit 11 is arranged. It is also conceivable that the plasma treatment and the plasma polymerization are carried out in a combined device. After the oxide layer has been removed and the surface energy has been increased, see above, the plasma polymer layer 4 is formed in the plasma polymerization unit 10 on the surface of the electrical conductor 1 by adding a gaseous monomer such as ethylene, buthenol, acetone or tetrafluoromethane [CF 4 ] is activated by means of the plasma and, as a result, highly crosslinked macromolecules of different chain lengths and a proportion of free radicals are formed, which are deposited as a plasma polymer layer 4 on the surface of the electrical conductor 1. In the present exemplary embodiment, the plasma polymer layer 4 produced in this way is less than 1 μm thick and adheres particularly well to the activated and oxide-free surface of the electrical conductor 1.

Die äußere Isolationsschicht 3 wird wiederum in der Extrusions-Einheit 11 wie oben beschrieben auf die Plasmapolymer-Schicht 4 aufextrudiert, wobei auch die Haftung zwischen Plasmapolymer-Schicht 4 und äußerer Isolationsschicht 3 hoch ist.The outer insulation layer 3 is in turn extruded onto the plasma polymer layer 4 in the extrusion unit 11 as described above, the adhesion between the plasma polymer layer 4 and the outer insulation layer 3 also being high.

In der dritten Ausführungsvariante, abgebildet in den Figuren 2c und 3c, umfasst die isolierende Beschichtung 2 neben der äußeren Isolationsschicht 3 aus PEEK eine als Fluoropolymer-Schicht 5 aus Polytetrafluorethylen [PTFE] oder Perfluorethylenpropylen [FEP] ausgebildete Kunststoff enthaltende Zwischenschicht, die unmittelbar auf die Oberfläche des elektrischen Leiters 1 aufgebracht ist und die Haftung zwischen dem elektrischen Leiter 1 und der äußeren Isolationsschicht 3 weiter verbessert. Hergestellt wird die Fluoropolymer-Schicht 5 gemeinsam mit der äußeren Isolationsschicht 3 in der Extrusions-Einheit 11 mittels eines Ko- oder Tandemextrusions-Verfahrens. Die Dicke der Fluoropolymer-Schicht 5 beträgt dabei im vorliegenden Ausführungsbeispiel etwa 30 µm.In the third variant, shown in the Figures 2c and 3c , the insulating coating 2 comprises, in addition to the outer insulating layer 3 made of PEEK, a fluoropolymer layer 5 made of polytetrafluoroethylene [PTFE] or perfluoroethylene propylene [FEP] plastic-containing intermediate layer which is applied directly to the surface of the electrical conductor 1 and further improves the adhesion between the electrical conductor 1 and the outer insulation layer 3. The fluoropolymer layer 5 is produced together with the outer insulation layer 3 in the extrusion unit 11 by means of a co- or tandem extrusion process. The thickness of the fluoropolymer layer 5 is approximately 30 μm in the present exemplary embodiment.

Nach dem Aufextrudieren der äußeren Isolationsschicht 3 wird der isolierte elektrische Leiter kontrolliert abgekühlt, beispielsweise durch Luftkühlung, und über eine Reihe von Anpressrollen geführt, die durch Ausüben von Druck auf den isolierte elektrische Leiter die Haftung weiter verbessern. Abschließend wird der isolierte elektrische Leiter auf einem Spulenaufwickler 13 aufgewickelt.After the outer insulation layer 3 has been extruded on, the insulated electrical conductor is cooled in a controlled manner, for example by air cooling, and passed over a series of pressure rollers which further improve the adhesion by exerting pressure on the insulated electrical conductor. Finally, the insulated electrical conductor is wound onto a reel winder 13.

Bei den dargestellten Einrichtungen in Fig. 1 handelt es sich über eine Übersicht, in der alle Einrichtungen gezeigt sind, die zur Herstellung der einzelnen Ausführungsvarianten notwendig sind. Während die Reihenfolge, von rechts nach links, der durchlaufenen Einrichtungen von der Ausführungsvariante unabhängig sind und jedenfalls die Plasmabehandlungs-Einheit 9 und die Extrusions-Einheit 11 durchlaufen werden müssen, handelt es sich bei der Plasmapolymerisations-Einheit 9 und der weiteren Extrusions-Einheit 12 um optionale Einrichtungen, die nur bei der Herstellung spezifischer Ausführungsvarianten zum Einsatz kommen. Es versteht sich von selbst, dass statt eines Ko- oder Tandemextrusions-Verfahrens auch mehrere einzelne Extrusionen sequentiell durchgeführt werden können.The facilities shown in Fig. 1 it is an overview in which all facilities are shown that are necessary for the production of the individual design variants. While the sequence, from right to left, of the devices passed through is independent of the embodiment variant and in any case the plasma treatment unit 9 and the extrusion unit 11 must be passed through, the plasma polymerization unit 9 and the further extrusion unit 12 are involved about optional equipment that is only used in the manufacture of specific design variants. It goes without saying that instead of a co- or tandem extrusion process, several individual extrusions can also be carried out sequentially.

BEZUGSZEICHENLISTEREFERENCE LIST

11
elektrischer Leiterelectrical conductor
22
isolierende Beschichtunginsulating coating
33rd
IsolationsschichtInsulation layer
44th
Plasmapolymer-SchichtPlasma polymer layer
55
Fluoropolymer-SchichtFluoropolymer layer
66th
MetallschichtMetal layer
77th
SpulenablaufBobbin run
88th
Vorreinigungs-EinheitPre-cleaning unit
99
Plasmabehandlungs-EinheitPlasma treatment unit
1010
Plasmapolymerisations-EinheitPlasma polymerisation unit
1111
Extrusions-EinheitExtrusion unit
1212th
weitere Extrusionseinheitfurther extrusion unit
1313th
SpulenaufwicklerBobbin winder

Claims (16)

  1. Insulated electric conductor, comprising an electric conductor (1), preferably made of copper or aluminum, having an insulating coating (2), wherein the insulating coating (2) either comprises
    at least one insulating layer (3) made of
    thermoplastic material,
    or
    at least one insulating layer (3) made of
    thermoplastic material and
    a plastic-containing intermediate layer (4, 5), preferably a plasma polymer layer (4) or at least one fluoropolymer layer (5),
    characterized in that that an oxide layer formed on a surface of the electric conductor (1) is removed, preferably by bombardment of the electric conductor with ions of a protective gas of a protective gas atmosphere in a gas plasma,
    and subsequently either
    the at least one insulating layer (3) is applied directly to the oxide-layer-free surface of the electric conductor (1)
    or, in the case that the coating (2) comprises the plastic-containing intermediate layer (4, 5),
    at least the plastic-containing intermediate layer (4, 5) is applied directly to the oxide-layer-free surface of the electric conductor (1).
  2. Insulated electric conductor according to claim 1, characterized in that the oxide layer formed on the surface of the electric conductor (1) is removed by bombardment of the electric conductor with ions of a protective gas of a protective gas atmosphere in a gas plasma
  3. Insulated electric conductor according to claim 1 or 2, characterized in that the insulating coating (2), in particular the at least one insulating layer (3), has a temperature resistance of at least 180°C, preferably of at least 200°C, in particular of at least 220°C.
  4. Insulated electric conductor according to one of the claims 1 to 3, characterized in that the thermoplastic material of the at least one insulating layer (3) is selected from the group consisting of polyaryletherketone [PAEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.
  5. Insulated electric conductor according to one of the claims 1 to 4, characterized in that the thermoplastic material of the at least one insulating layer (3) is a polyaryletherketone [PAEK] selected from the group consisting of polyetherketone [PEK], polyetheretherketone [PEEK], polyetherketoneketone [PEKK], polyetheretherketoneketone [PEEKK], polyetherketoneetherketoneketone [PEKEKK], and combinations thereof.
  6. Insulated electric conductor according to one of the claims 1 to 5, characterized in that the at least one insulating layer (3) has a thickness between 10 and 1000 µm, preferably between 25 µm and 750 µm, particularly preferably between 30 µm and 500 µm, in particular between 50 µm and 250 µm.
  7. Insulated electric conductor according to one of the claims 1 to 6, characterized in that the at least one insulating layer (3) can be produced by means of an extrusion process.
  8. Insulated electric conductor according to one of the claims 1 to 7, characterized in that the insulating coating (2) consists of the at least one insulating layer (3).
  9. Insulated electric conductor according to claim 8, characterized in that the insulating coating (2) consists of one insulating layer (3).
  10. Insulated electric conductor according to claim 8, characterized in that the insulating coating (2) consists of at least two, preferably exactly two, insulating layers (3).
  11. Insulated electric conductor according to one of the claims 1 to 10, characterized in that at least one further insulating layer of thermoplastic material is applied to the insulating coating (2), wherein the at least one further insulating layer is not applied under protective gas atmosphere.
  12. Insulated electric conductor according to claim 11, characterized in that the thermoplastic material of the at least one further insulating layer is selected from the group consisting of polyaryletherketone [PAEK], preferably polyetheretherketone [PEEK], polyimide [PI], polyamideimide [PAI], polyetherimide [PEI], polyphenylene sulfide [PPS] and combinations thereof.
  13. Insulated electric conductor according to one of the claims 1 to 7, characterized in that the insulating coating (2) has at least one fluoropolymer layer (5)
    and that the plastic-containing intermediate layer which is applied directly to the surface of the electric conductor (1) consists of the at least one fluoropolymer layer (5).
  14. Insulated electric conductor according to claim 13, characterized in that the fluoropolymer layer (5) comprises polytetrafluoroethylene [PTFE] or perfluoroethylenepropylene [FEP].
  15. Insulated electric conductor according to one of the claims 13 to 14, characterized in that the thickness of the at least one fluoropolymer layer (5) is between 1 µm and 120 µm, preferably between 5 µm and 100 µm, particularly preferably between 10 µm and 80 µm, in particular between 20 µm and 50 µm.
  16. Insulated electric conductor according to one of the claims 13 to 15, characterized in that the entire insulating coating (2) is applied to the electric conductor (1) under protective gas atmosphere.
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JP2019519062A (en) 2019-07-04
RS58877B1 (en) 2019-08-30
PT3226258T (en) 2019-01-09
EP3441986B8 (en) 2021-11-03
BR122020003443B1 (en) 2023-04-11
JP6877773B2 (en) 2021-05-26
RS62697B1 (en) 2022-01-31
EP3441986A1 (en) 2019-02-13
JP7055496B2 (en) 2022-04-18
ES2704893T3 (en) 2019-03-20
JP2021122007A (en) 2021-08-26
PL3441986T3 (en) 2022-03-07
EP3226258A1 (en) 2017-10-04
HUE056737T2 (en) 2022-03-28
US20230040706A1 (en) 2023-02-09
TR201910192T4 (en) 2019-08-21
RS58038B1 (en) 2019-02-28
ES2737298T3 (en) 2020-01-13
ES2903093T3 (en) 2022-03-31
EP3226258B1 (en) 2018-10-24
PL3226258T3 (en) 2019-04-30
CN109074918A (en) 2018-12-21
PT3394861T (en) 2019-07-08
KR20220137813A (en) 2022-10-12
CA3019024A1 (en) 2017-10-05
MX2018011979A (en) 2019-01-15
KR102587257B1 (en) 2023-10-10
KR102455180B1 (en) 2022-10-14
WO2017167595A1 (en) 2017-10-05
PL3394861T3 (en) 2019-10-31
PT3441986T (en) 2021-12-02
CN114520071A (en) 2022-05-20
KR20180128920A (en) 2018-12-04
EP3394861A1 (en) 2018-10-31
MD3441986T2 (en) 2022-05-31
US20190131037A1 (en) 2019-05-02
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MA44174A (en) 2018-10-31
CA3019024C (en) 2022-05-31

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