Multiconductor cable assemblies and methods of making multiconductor cable assemblies

• US 20060131059A1
• Filed: 10/24/2005
• Published: 06/22/2006
• Est. Priority Date: 12/17/2004
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Peters, Richard, Rajamani, Vijay, Xu, James J., Mhetar, Vijay R.
• Granted Patent: US 7,332,677 B2
• Time in Patent Office: Days
• US Class Current: 174/117.F
• CPC Class Codes: H01B 3/427 Polyethers
• CPC Class Codes: H01B 3/441 from alkenes

Abstract

A multiconductor cable assembly and a method of making a multiconductor cable assembly are disclosed. The multiconductor cable assembly comprises a conductor and a covering comprising a thermoplastic composition. The thermoplastic composition comprises a poly(arylene ether), a polyolefin and a polymeric compatibilizer. The thermoplastic composition may further comprise a flame retardant.

Claims

20. A method of making a multiconductor cable assembly comprising:

arranging two or more coated wires in a side-by-side contiguous relationship to provide one or more substantially interfacing contact areas between adjacent coated wires; and

at least partially bonding the two or more coated wires using at least one of heat-pressing, ultrasonic welding, solvent welding, laser welding, adhesive bonding, and vibration welding

wherein one or more of the coated wires comprises;

a conductor, and

a covering comprising a, thermoplastic composition and the thermoplastic composition comprises;

(i) a poly(arylene ether)

(ii) a polyolefin; and

(iii) a polymeric compatibilizer

wherein the covering is disposed over the conductor.

21. The method of claim 20, wherein each coated wire is at least partially bonded to an adjacent coated wire using solvent bonding with a solvent selected from the group consisting of toluene, xylene, and combinations thereof.

22. The method of claim 21, wherein the method further comprises evaporating the solvent at a temperature of 100-175°

C.

23. A multiconductor cable assembly is produced by a method comprising:

interposing a plurality of conductors between a first insulator sheet and a second insulator sheet; and

at least partially bonding the first insulator sheet to the second insulator sheet,

wherein the first and second insulator sheets, each have a length and a width and the length is greater than the width, and

wherein the plurality of conductors are arranged in parallel relation to one another along a length of the first and second insulator sheets; and

wherein one or more of the first and second insulator sheets comprise a thermoplastic composition comprising;

(i) a poly(arylene ether)

(ii) a polyolefin; and

(iii) a polymeric compatibilizer.

1. A multiconductor cable assembly comprising two or more coated wires arranged in a side-by-side contiguous relation providing one or more substantially interfacing contact areas between adjacent coated wires;

wherein one or more of the coated wires comprises;

a conductor, and

a covering comprising a thermoplastic composition and the thermoplastic composition comprises;

(i) a poly(arylene ether)

(ii) a polyolefin; and

(iii) a polymeric compatibilizer

wherein the covering is disposed over the conductor, and

wherein each coated wire is at least partially bonded to an adjacent coated wire.

2. The multiconductor cable assembly of claim 1, wherein the multiconductor cable assembly is a ribbon cable comprising three or more coated wires.

3. The multiconductor cable assembly of claim 1, wherein the multiconductor cable assembly is a ribbon cable comprising nine or more coated wires.

4. The multiconductor cable assembly of claim 1, wherein the multiconductor cable assembly is a ribbon cable comprising twenty or more coated wires.

5. The multiconductor cable assembly of claim 1, wherein the thermoplastic composition comprises a polyolefin continuous or co-continuous phase and a poly(arylene ether) dispersed or co-continuous phase.

6. The multiconductor cable assembly of claim 1, wherein the polyolefin is selected from the group consisting of polypropylene, high density polyethylene and combinations of polypropylene and high density polyethylene.

7. The multiconductor cable assembly of claim 1, wherein the polymeric compatibilizer comprises a block copolymer having a block that is a controlled distribution copolymer.

8. The multiconductor cable assembly of claim 1, wherein the polymeric compatibilizer comprises a first block copolymer having an aryl alkylene content greater than or equal to 50 weight percent based on the total weight of the first block copolymer and a second block copolymer having an aryl alkylene content less than or equal to 50 weight percent based on the total weight of the second block copolymer.

9. The multiconductor cable assembly of claim 1, wherein the polymeric compatibilizer comprises a diblock copolymer and a triblock copolymer.

10. The multiconductor cable assembly of claim 1, wherein the polymeric compatibilizer comprises a polypropylene-polystyrene graft copolymer.

11. The multiconductor cable assembly of claim 1, wherein the thermoplastic composition further comprises a flame retardant.

12. The multiconductor cable assembly of claim 1, wherein the thermoplastic composition comprises polyolefin in an amount by weight that is less than the amount of poly(arylene ether) by weight, based on the combined weight of polyolefin and poly(arylene ether).

13. The multiconductor cable assembly of claim 1, wherein at least one coated wire is a coaxial cable.

14. The multiconductor cable assembly of claim 1, wherein at least two coated wires have different colors.

15. The multiconductor cable assembly of claim 1, wherein at least one conductor comprises one or more electrical conductive wires, one or more electrically conductive foils, one or more electrically conductive inks, or a combination thereof.

16. The multiconductor cable assembly of claim 1, wherein the conductor has a size of 20 to 46 AWG and the covering has a thickness of 0.15 to 1.25 millimeters.

17. The multiconductor cable assembly of claim 1, wherein the conductor has a cross sectional area of 0.30 square millimeter to 1.30 square millimeters and the covering has a thickness of 0.15 to 0.35 millimeter.

18. The multiconductor cable assembly of claim 1, wherein the conductor has a cross sectional area of 1.20 square millimeters to 2.10 square millimeter and the covering has a thickness of 0.29 to 0.36 millimeter.

19. The multiconductor cable assembly of claim 1, wherein the conductor has a cross sectional area of 2.90 square millimeters to 4.50 square millimeters and the covering has a thickness of 0.3 to 0.8 millimeter.

24. The multiconductor cable assembly of claim 23, where said first and second insulator sheets are at least partially bonded by at least one of heat bonding, ultrasonic welding, solvent welding, laser welding, adhesive bonding, and vibration welding.

25. The multiconductor cable assembly of claim 23, wherein the polyolefin is a continuous or co-continuous phase and wherein the poly(arylene ether) is a dispersed or co-continuous phase.

26. The multiconductor cable assembly of claim 23, wherein the multiconductor cable assembly is a ribbon cable comprising twenty or more conductors.

27. The multiconductor cable assembly of claim 23, wherein the polyolefin is selected from the group consisting of polypropylene, high density polyethylene and combinations of polypropylene and high density polyethylene.

28. The multiconductor cable assembly of claim 23, wherein the polymeric compatibilizer comprises a block copolymer having a block that is a controlled distribution copolymer.

29. The multiconductor cable assembly of claim 23, wherein the polymeric compatibilizer comprises a first block copolymer having an aryl alkylene content greater than or equal to 50 weight percent based on the total weight of the first block copolymer and a second block copolymer having an aryl alkylene content less than or equal to 50 weight percent based on the total weight of the second block copolymer.

30. The multiconductor cable assembly of claim 23, wherein the polymeric compatibilizer comprises a diblock copolymer and a triblock copolymer.

31. The multiconductor cable assembly of claim 23, wherein the polymeric compatibilizer comprises a polypropylene-polystyrene graft copolymer.

32. The multiconductor cable assembly of claim 23, wherein the thermoplastic composition further comprises a flame retardant.

33. The multiconductor cable assembly of claim 23, wherein the thermoplastic composition comprises polyolefin in an amount by weight that is less than the amount of poly(arylene ether) by weight, based on the combined weight of polyolefin and poly(arylene ether).

34. The multiconductor cable assembly of claim 23, wherein at least one of the conductors comprises a conductive wire, a metal foil, a conductive ink, or a combination thereof.

24-1. The multiconductor cable assembly of claim 23, wherein the multiconductor cable assembly is a ribbon cable comprising three or more conductors.

25-2. The multiconductor cable assembly of claim 23, wherein the multiconductor cable assembly is a ribbon cable comprising nine or more conductors.