Aluminum alloy products with hot-melt lamination coatings for electrical insulation
AssigneeNovelis Inc.
InventorChristian Tussing
Life of this patent
Estimating the term…
Abstract
Described herein are electrically insulated metal products and methods for preparing electrically insulated metal products. The electrically insulated metal products can include a multilayer polymeric insulating structure, including a joining layer and a top polymer layer, disposed over a metal base layer to provide electrical insulation to the metal base layer, such as using a process of laminating the polymer film over the metal base layer. The multilayer polymeric insulation structure and metal base layer can be subjected to annealing after lamination to improve adhesion performance.
Claims22
An electrically insulated metal product comprising:
- an aluminum alloy sheet metal substrate;
- and
- a multilayer polymeric insulation structure bonded to the aluminum alloy sheet metal substrate, wherein the multilayer polymeric insulation structure comprises a joining layer adjacent to the aluminum alloy sheet metal substrate and a top polymer layer over the joining layer, wherein the multilayer polymeric insulation structure has a thickness of from 5 μm to 100 μm, and wherein the multilayer polymeric insulation structure bonded to the aluminum alloy sheet metal substrate together exhibit one or more of a surface resistance of from 1×1012Ω to 1×1015Ω, a volume resistance of from 1×1012Ω to 1×1015Ω, a breakdown voltage of from 2 kV to 50 kV, or a comparative tracking index value of from 175 V to 400 V.
A method for preparing an electrically insulated metal product, the method comprising:
- pre-heating an aluminum alloy sheet metal substrate to a first temperature of from 150° C. to 250° C.;
- and
- bonding a multilayer polymeric insulation structure to a surface of the aluminum alloy sheet metal substrate to produce a bonded product, the multilayer polymeric insulation structure comprising a joining layer and a top polymer layer over the joining layer, wherein the multilayer polymeric insulation structure has a thickness of from 5 μm to 100 μm, and wherein the multilayer polymeric insulation structure bonded to the aluminum alloy sheet metal substrate together exhibit one or more of a surface resistance of from 1×1012Ω to 1×1015Ω, a volume resistance of from 1×1012Ω to 1×1015Ω, a breakdown voltage of from 2 kV to 50 kV, or a comparative tracking index value of from 175 V to 400 V.
20-30. (canceled)
A structural enclosure for a device, the structural enclosure comprising:
- an electrically insulated metal product, the electrically insulated metal product comprising:
- an aluminum alloy sheet metal substrate;
- and
- a multilayer polymeric insulation structure bonded to the aluminum alloy sheet metal substrate, wherein the multilayer polymeric insulation structure comprises a joining layer adjacent to the aluminum alloy sheet metal substrate and a top polymer layer over the joining layer, wherein the multilayer polymeric insulation structure has a thickness of from 5 μm to 100 μm, and wherein the multilayer polymeric insulation structure bonded to the aluminum alloy sheet metal substrate together exhibit one or more of a surface resistance of from 1×1012Ω to 1×1015Ω, a volume resistance of from 1×1012Ω to 1×1015Ω, a breakdown voltage of from 2 kV to 50 kV, or a comparative tracking index value of from 175 V to 400 V.
-34. (canceled)
Dependencies are inferred from the claim text.