Securing electrical conductors

• US 20040016565A1
• Filed: 04/25/2003
• Published: 01/29/2004
• Est. Priority Date: 10/25/2000
• Status: Active Grant

• Current Assignee: Velcro BVBA
• Original Assignee: Velcro Industries BV (Chartwell Industries Ltd)
• Inventors: Demain, John, Labrecque, Michel, Gallant, Christopher M., Clarner, Mark A.
• Granted Patent: US 6,977,055 B2
• Time in Patent Office: Days
• US Class Current: 174/117F
• CPC Class Codes: B29C 2043/465 having one or more cavities, e.g. for forming distinct products
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/28 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
• CPC Class Codes: B29L 2031/729 Hook and loop-type fasteners
• CPC Class Codes: B60R 16/0207 Wire harnesses
• CPC Class Codes: B60R 16/0215 Protecting, fastening and routing means therefor
• CPC Class Codes: H01B 7/08 Flat or ribbon cables
• CPC Class Codes: H01B 7/40 with arrangements for facilitating mounting or securing
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/209 Auto-mechanical connection between a component and a PCB or between two PCBs
• CPC Class Codes: H05K 2203/0113 Female die used for patterning or transferring, e.g. temporary substrate having recessed pattern
• CPC Class Codes: H05K 2203/0143 Using a roller; Specific shape thereof; Providing locally adhesive portions thereon
• CPC Class Codes: H05K 2203/1545 Continuous processing, i.e. involving rolls moving a band-like or solid carrier along a continuous production path
• CPC Class Codes: H05K 3/0014 Shaping of the substrate, e.g. by moulding
• CPC Class Codes: H05K 3/0058 Laminating printed circuit boards onto other substrates, e.g. metallic substrates H05K1/0281 takes precedence
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/326 the printed circuit having integral resilient or deformable parts, e.g. tabs or parts of flexible circuits H05K3/365 takes precedence
• CPC Class Codes: H05K 3/365 by abutting, i.e. without alloying process
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core

Abstract

An elongated electrical cable or flexible circuit board includes an electrically conductive path and an insulating body encompassing and electrically isolating the conductive path, the insulating body including an exposed surface having an array of fastener elements extending therefrom, the fastener elements arranged and constructed to engage mating fastener elements associated with a supporting surface to selectively secure the cable or flexible circuit board to the supporting surface. The fastener elements can be loop-engageable fasteners and/or loops. Such a cable or flexible circuit board is continuously formed by introducing an electrical insulating material including a thermoplastic resin into a gap formed adjacent a peripheral surface of a rotating mold roll, the mold roll defining an array of cavities therein, the insulating material being introduced under pressure and temperature conditions selected to cause the insulating material to at least partially fill the cavities to form fastener element stems integrally with and extending from one broad side of a strip of said insulation material; while introducing conductive wires and/or a conductive path formed on or within a substrate to the gap so as to cause the insulating material to envelop and electrically isolate the conductive path and/or to cause the conductive path to become an integral part of the strip of insulation material from which the fastener element stems extend.

Claims

1. An elongated electrical cable comprising:

at least two electrical conductors extending longitudinally along the cable; and

an insulating body encompassing and electrically isolating the conductors from one another, the insulating body including an exposed surface having an array of fastener elements extending therefrom, the fastener elements arranged and constructed to engage mating fastener elements associated with a supporting surface to selectively secure the cable to the supporting surface.

2. The elongated electrical cable of claim 1 wherein the fastener elements are shaped to engage exposed loop fibers associated with the supporting surface.

3. The elongated electrical cable of claim 2 wherein said exposed surface of the insulating body comprises a first broad surface of thermoplastic resin, the array of fastener elements comprising raised projections of the thermoplastic resin.

4. The elongated electrical cable of claim 3 wherein said exposed surface further comprises a second broad surface of thermoplastic resin, a second array of fastener elements comprising raised projections of the thermoplastic resin extending from said second broad surface.

5. The elongated electrical cable of claim 3 wherein the array of fastener elements is substantially coextensive with said first broad surface of the insulating body.

6. The elongated electrical cable of claim 1 wherein the array of fastener elements forms a longitudinal band of fastener elements extending between lateral edge regions of the cable, the lateral edge regions being void of said fastener elements.

7. The elongated electrical cable of claim 3 having an entire thickness, measured from distal ends of the fastener elements to an exposed broad surface of the insulating body opposite the fastener elements, of less than about 0.050 inch.

8. The elongated electrical cable of claim 7, wherein the entire thickness is less than about 0.030 inch.

9. The elongated electrical cable of claim 2 wherein the insulating body comprises a laminate, the laminate including a first and a second layer of thermoplastic resin and an adhesive layer disposed therebetween, the first layer defining a first broad surface of the exposed surface, the second layer defining a second broad surface of the exposed surface, said array of fastener elements comprising raised projections of the thermoplastic resin of at least one of said first and said second broad surfaces.

10. The elongated electrical cable of claim 2 wherein the insulating body comprises a unitary structure of thermoplastic resin, the unitary structure defining a first and a second broad surface of the exposed surface, said array of fastener elements comprising raised projections of the thermoplastic resin of at least one of said first and said second broad surfaces.

11. The elongated electrical cable of claim 10, wherein further comprising a conductor supporting substrate.

12. The elongated electrical cable of claim 2 wherein the insulating body comprises a first and a second layer of thermoplastic resin with the conductors disposed therebetween, the first and second layers being permanently welded to one another in a manner to encompass and electrically isolate the conductors from one another, the array of fastener elements comprising raised projections of the thermoplastic resin of an exposed surface of one of the first and second layers.

13. The elongated electrical cable of claim 1 wherein the fastener elements are exposed loop fibers.

14. The elongated electrical cable of claim 13 wherein the insulating body comprises a thermoplastic resin and the exposed loop fibers are part of a web of fibers, the web being attached to the insulating body by encapsulation of fibers of the web by the thermoplastic resin.

15. The elongated electrical cable of claim 14 wherein the web of fibers is a nonwoven material.

16. The elongated electrical cable of claim 1 defining a fixed cable length between opposite longitudinal ends, the cable further comprising an electrical connector electrically attached to at least one of the conductors and mechanically attached to the cable at one of said longitudinal ends.

17. A releasably securable ribbon cable extending to define a longitudinal direction, the cable comprising:

a plurality of longitudinally extending electrical conductors;

an insulating body encompassing and electrically isolating the plurality of conductors from one another; and

a strip of loop-engageable fastener elements formed of thermoplastic resin, the strip extending longitudinally along the ribbon cable and being permanently attached to a surface of the insulating body such that said fastener elements are exposed for engagement with a loop material.

18. A method of continuously forming an electrical cable, the method comprising:

introducing an electrical insulating material comprising a thermoplastic resin into a gap formed adjacent a peripheral surface of a rotating mold roll, the mold roll defining an array of cavities therein, the insulating material being introduced under pressure and temperature conditions selected to cause the insulating material to at least partially fill the cavities to form fastener element stems integrally with and extending from one broad surface of a strip of said insulation material;

while

introducing at least two longitudinally continuous and spaced apart electrical conductors to the gap so as to cause the insulating material to envelop and electrically isolate the conductors and cause the conductors to become an integral part of the strip of insulation material from which the fastener element stems extend.

19. The method of claim 18 wherein the cavities of the mold roll are shaped to mold distal heads on said fastener element stems, said distal heads being shaped to overhang the broad surface of the strip of insulating material so as to be engageable with exposed loop fibers.

20. The method of claim 18 wherein each of said stems defines a tip portion, the method further comprising deforming said tip portion of a plurality of said stems to form engaging heads overhanging the broad side of the strip of insulating material, the engaging heads being shaped to be engageable with exposed loop fibers.

21. The method of claim 18 wherein the gap comprises a nip defined between the rotating mold roll and a counter-rotating pressure roll.

22. The method of claim 18 wherein the gap comprises a nip defined between the rotating mold roll and a counter-rotating mold roll, each of said rotating mold roll and said counter-rotating mold roll defining an array of cavities therein, the insulating material being introduced under pressure and temperature conditions selected to cause the insulating material to at least partially fill the array of cavities of each of said rotating and said counter-rotating mold roll to form fastener element stems integrally with and extending from each of opposite broad sides of the strip of said insulation material.

23. The method of claim 18 wherein the insulating material comprises a layer of thermoplastic resin and a film backing, the film backing carrying the electrical conductors on a surface thereof, the layer of thermoplastic resin being introduced to the gap directly adjacent the rotating mold roll, the film backing carrying the electrical conductors being introduced to the gap under pressure and temperature conditions which cause the film backing to become permanently bonded to the thermoplastic resin to envelop and electrically isolate the conductors.

24. The method of claim 18 wherein the insulating material comprises a first and a second film of thermoplastic resin, wherein the electrical conductors and the first and second films are introduced to the gap with the electrical conductors disposed between the first and the second film, said first film being introduced directly adjacent the rotating mold roll under temperature and pressure conditions that cause the first and second films to become permanently bonded to each other in a manner enveloping and electrically isolating the conductors.

25. The method of claim 18 further comprising downstream of the gap, longitudinally severing the electrical insulation material after solidification to form two electrical cables, each cable containing at least one said conductor.

26. A method of continuously forming an electrical cable, the method comprising:

introducing molten resin into a gap formed adjacent a rotating mold roll, the mold roll having a peripheral surface defining an array of molding cavities therein, under pressure and temperature conditions selected to cause the resin to fill the mold cavities and form an array of fastener element stems integrally molded with and extending from a broad strip of resin;

while

simultaneously introducing a preformed electrical ribbon-type cable to the nip adjacent the pressure roll, such that the broad strip of resin becomes permanently bonded to a broad side of the ribbon-type cable such that the fastener element stems are exposed.

27. A method of continuously forming an electrical cable, the method comprising:

providing a fastener tape of continuous length, the fastener tape comprising a base and an array of loop-engageable fastener elements, the base being of thermoplastic resin and defining a first and a second, opposite, broad surface, the array of loop engageable fastener elements comprising protrusions of the thermoplastic resin of the first surface;

arranging a backing film of continuous length adjacent the fastener tape, the backing film defining a broad surface, the broad surface of the backing film being arranged to face the second broad surface of the fastener tape;

disposing a plurality of spaced apart electrical conductors of continuous length between the second broad surface of the fastener tape and the broad surface of the backing film; and

permanently attaching the fastener tape to the backing film with the plurality of conductors enveloped therebetween, the conductors being electrically isolated from one another.

28. The method of claim 27, wherein said step of permanently attaching the fastener tape to the backing film comprises disposing a layer of electrically insulating adhesive between the second broad surface of the fastener tape and the broad surface of the backing film to cause the layer of adhesive to electrically isolate the plurality of conductors from one another while permanently bonding the fastener tape to the backing film to envelop the plurality of conductors therebetween.

29. The method of claim 27, wherein said step of permanently attaching the fastener tape to the backing film comprises heat welding along locations between said conductors.

30. A method of forming an electrical cable, the method comprising:

introducing a strip of molten electrical insulation material into a gap formed adjacent a peripheral surface of a rotating roll;

while

introducing a continuous strip of loop material having hook-engageable fiber portion to the gap along the surface of the roll, under conditions selected to cause the loop material to become at least partially embedded in the electrical insulation material to permanently bond the loop material to the resin while leaving the hook-engageable fiber portions exposed for engagement; and

introducing at least two longitudinally continuous and spaced apart electrical conductors to the gap so as to cause the insulating material to envelop and electrically isolate the conductors in the gap to form a multi-conductor electrical cable having engageable loops extending from an outer surface thereof.

31. A flexible circuit board comprising:

a substrate having first and second, opposite broad surfaces, and a through-hole surface extending from the first to the second broad surface defining a passage between the first and second broad surfaces, the substrate further having an array of hook fastener elements extending from the first broad surface, the first broad surface and the array of hook fastener elements being formed integrally of a thermoplastic resin; and

a pattern of electrically conductive material attached to the thermoplastic substrate, the pattern encompassing at least a portion of the through-hole surface.

32. The flexible circuit board of claim 31 wherein the pattern of electrically conductive material is disposed only on the second broad surface and the at least a portion of the through-hole surface.

33. The flexible circuit board of claim 31 wherein the pattern of electrically conductive material is disposed only on the first broad surface and the at least a portion of the through-hole surface.

34. The flexible circuit board of claim 33 wherein the pattern of electrically conductive material encompasses at least a portion of the array of hook fastener elements.

35. The flexible circuit board of claim 33 wherein the pattern of electrically conductive material encompasses an entirety of the first or second broad surface.

36. An electrical cable comprising:

a strip-form substrate having first and second, opposite broad surfaces and an array of hook fastener elements extending from the first broad surface, the first broad surface and the array of hook fastener elements being formed integrally of a thermoplastic resin; and

a continuous conductive path attached to one of the first and second broad surfaces, the continuous strip being longitudinally coextensive with the strip-form substrate.

37. The electrical cable of claim 36, wherein the continuous conductive path comprises a continuous strip of conductive material.

38. The electrical cable of claim 36, wherein the continuous conductive path comprises discontinuous strips of conductive material electrically connected by an electrical component.

39. The electrical cable of claim 36 comprising a plurality of continuous strips of conductive material, each of said continuous strips being spaced from one another.

40. The electrical cable of claim 36 wherein the continuous strip of conductive material is disposed on the first broad surface of the strip-form substrate.

41. The electrical cable of claim 36 wherein the continuous strip of conductive material is disposed on at least a portion of the hook fastener elements.

42. The electrical cable of claim 36 further comprising electrical connectors disposed at opposite longitudinal ends of the strip-form substrate, the electrical connectors being conductively connected by the continuous strip of conductive material.

43. A method of forming an electrically conductive hook tape, the method comprising:

providing a substrate having first and second, opposite broad surfaces and an array of hook fastener elements extending from the first broad surface, the first broad surface and the array of hook fastener elements being formed integrally of a thermoplastic resin;

applying a sensitizer to an exterior surface of the substrate; and

applying a solution comprising a conductive material to the exterior surface at least to a portion of an area where the sensitizer was applied, to produce a chemical reduction reaction between the conductive material and the sensitizer wherein the conductive material attaches to the exterior surface of the substrate.

44. The method of claim 43, wherein a wetting agent is applied to areas of the substrate to be coated with the conductive material prior to application of the sensitizer.

45. The method of claim 43, wherein the sensitizer includes an anodic material that is disposed on the external surface of the substrate and the conductive material includes a cathodic material relative to the anodic material.

46. The method of claim 45, wherein the sensitizer comprises tin and the conductive material comprises silver.

47. The method of claim 43 wherein the solution further comprises an activator.

48. The method of claim 47 wherein the activator solution further comprises a reducer.

49. The method of claim 43, wherein the conductive material is applied to the first broad surface of the thermoplastic substrate.

50. The method of claim 48, wherein the conductive material coats at least a portion of the array of hook fastener elements.

51. The method of claim 43 further comprising a step of masking selected regions of the surface of the substrate prior to the step of applying sensitizer, thereby preventing attachment of the conductive material in the selected regions.

52. The method of claim 51 wherein the substrate further comprises a throughhole surface extending between the first and second broad surfaces to define a passage.

53. The method of claim 52 wherein the conductive material is attached to at least a portion of the through-hole surface.

54. A method of forming a flexible circuit board with integral hook fastener elements, the method comprising:

introducing an elongated flexible circuit including a substrate and at least one electrically conductive path to a gap adjacent a peripheral surface of a mold roll, the mold roll having hook fastener element stem forming cavities extending inwardly from said peripheral surface, while simultaneously,

introducing a thermoplastic resin into said gap directly adjacent said peripheral surface under temperature and pressure conditions causing said thermoplastic resin to at least partially fill said stem forming cavities and to permanently bond to said substrate; and

stripping the permanently joined thermoplastic resin and substrate from said mold roll to expose said fastener element stems.

55. The method of claim 54, wherein said conductive path is electrically insulated within said substrate prior to being introduced to the gap.

56. The method of claim 54, wherein a portion of said conductive path is exposed within the substrate for making an electrical connection with said conductive path.

57. The method of claim 56, wherein said portion of said conductive path is exposed prior to entering the gap.

58. The method of claim 56, wherein said portion of said conductive path is exposed by partial removal of the substrate after stripping the thermoplastic resin from the mold roll.

59. The method of claim 54, wherein said conductive path is disposed on an exterior surface of said substrate prior to being introduced to the gap, said thermoplastic resin being of an electrically insulating material, said conductive path being enveloped by said thermoplastic resin and said substrate.

60. The method of claim 54, wherein said conductive path is comprised of continuous strips of conductive material.

61. The method of claim 54, wherein said conductive path is comprised of discontinuous strips of conductive material that are electrically joined by electrical components.

62. A securable flexible circuit comprising:

a carrier substrate of thermoplastic resin having a first broad surface and a second broad surface, the first broad surface being exposed and having an array of hook fastener elements protruding therefrom, the hook fastener elements comprising raised projections of the thermoplastic resin of the first broad surface; and

an electrically conductive path disposed on said second broad surface.

63. The securable flexible circuit of claim 62 further comprising:

a backing substrate having a first broad surface and a second broad surface, the backing substrate laminated to said carrier substrate with said electrically conductive path disposed between the second broad surface of the backing substrate and the second broad surface of the carrier substrate.

64. The securable flexible circuit of claim 63 wherein said backing substrate includes an array of hook fastener elements protruding from the first broad surface thereof.

65. The securable flexible circuit of claim 64 wherein said backing substrate defines through-holes extending from said backing strip first broad surface to said backing strip second broad surface, the through-holes exposing portions of the conductive path.

66. The securable flexible circuit of claim 65 further comprising a layer of adhesive disposed between the backing substrate and the carrier substrate for lamination.

67. The securable flexible circuit of claim 66 wherein said through-holes extend through the layer of adhesive.