Method for extrusion of multi-layer coated elongate member

• US 20100219555A1
• Filed: 02/27/2009
• Published: 09/02/2010
• Est. Priority Date: 02/27/2009
• Status: Abandoned Application

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Mehan, Ashok K.
• Application Number:
  US12/380,516
• Publication Number:
  US 20100219555A1
• Time in Patent Office: Days
• US Class Current: 264/173.120
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/17 the components having different colours
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/32 with annular openings, e.g. for forming tubular articles
• CPC Class Codes: B29K 2027/16 PVDF, i.e. polyvinylidene fluoride
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/08 PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29K 2079/085 Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/06 PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2105/0026 Flame proofing or flame retarding agents
• CPC Class Codes: B29K 2105/0032 Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/0044 Stabilisers, e.g. against oxydation, light or heat
• CPC Class Codes: B29K 2105/005 : Heat sensitisers or absorbers
• CPC Class Codes: D07B 1/162 : characterised by a plastic or rubber enveloping sheathing
• CPC Class Codes: D07B 2201/2087 : being of the coated type
• CPC Class Codes: D07B 2201/2088 : having multiple layers
• CPC Class Codes: D07B 7/145 : Coating or filling-up interstices
• CPC Class Codes: H01B 13/141 : of two or more insulating layers

Abstract

A method of making a multi-layer insulated elongate member is disclosed. The method includes providing an elongate member and tube extruding a first thermoplastic material onto an outer surface of the elongate member to create a first layer having a thickness less than or equal to 0.064 mm (0.0025 inch) using a first extruder apparatus. The method further includes using a second extruder apparatus for pressure extruding a compound comprising a second thermoplastic material different from the first thermoplastic material onto an outer surface of the first layer to create a second layer. The second layer fully wets the first layer and the flow point of the first thermoplastic material is at least 30° C. greater than the extrusion melt temperature of the second thermoplastic material.

Claims

1. A method of making a multi-layer coated elongate member comprising:

providing an elongate member;

thereafter

tube extruding a compound comprising a first thermoplastic material onto an outer surface of the elongate member to create a first layer having a thickness less than about 0.064 mm (0.0025 inch) using a first extruder apparatus; and

thereafter

pressure extruding a compound comprising a second thermoplastic material different from the first thermoplastic material onto an outer surface of the first layer to create a second layer adjacent the first layer using a second extruder apparatus,

the second layer fully wetting the first layer, and the flow point of the first thermoplastic material being at least 30°

C. greater than the extrusion melt temperature of the second thermoplastic material.

2. The method of claim 1, further comprising extruding a compound comprising a third thermoplastic material different from the second thermoplastic material onto an outer surface of the second layer to create a third layer adjacent the second layer.

3. The method of claim 2, wherein the first thermoplastic material is different from the third thermoplastic material.

4. The method of claim 2, comprising tube extruding the third thermoplastic material onto the outer surface of the second layer.

5. The method of claim 2, comprising pressure extruding the third thermoplastic material onto the outer surface of the second layer.

6. The method of claim 5, comprising simultaneously co-extruding the second and third layers.

7. The method of claim 1, wherein the step of pressure extruding is in-line with the step of tube extruding.

8. The method of claim 1, wherein the first thermoplastic material has a tensile modulus of greater than 1241 MPa (180,000 psi) at 25°

C.

9. The method of claim 1, comprising tube extruding the first thermoplastic material to form a first layer having a thicknesses of equal to or less than about 0.025 mm (0.001 inch).

10. The method of claim 9, wherein the first thermoplastic material has a tensile modulus of greater than 1724 MPa (250,000 psi) at 25°

C.

11. The method of claim 9, comprising pressure extruding the second thermoplastic material to form a second layer having a thickness of equal to or less than about 0.038 mm (0.0015 inch).

12. The method of claim 1, wherein the steps of tube extruding and pressure extruding form an insulated elongate member having a total thickness of the first and second layers of less than 0.076 mm (0.003 inch).

13. The method of claim 1, wherein the elongate member is a stranded conductor having a diameter in the range of about 0.46 mm (0.0180 inch) to about 1.04 mm (0.041 inch).

14. The method of claim 1, wherein the first layer is bonded to the second layer.

15. A method of making a multi-layer coated elongate member comprising:

providing a tube extruder apparatus having a tube extruder die and a tube extruder guider tip positioned within the tube extruder die;

providing a pressure extruder apparatus having a pressure extruder die and a pressure extruder guider tip positioned within the pressure extruder die, the pressure extruder guider tip defining a pressure extruder guider tip opening;

drawing an elongate member through the tube extruder guider tip to tube extrude a first insulating layer of a first thermoplastic material onto an outer surface of the elongate member to a first insulating layer thickness of less than or equal to 0.051 mm (0.002 inch);

drawing the elongate member through the pressure extruder guider tip of the pressure extruder die to pressure extrude a second insulating layer of a second thermoplastic material different from the first thermoplastic material onto an outer surface of the first insulating layer to a second insulating layer thickness of less than or equal to 0.038 mm (0.0015 inch); and

extruding a third insulating layer of a third thermoplastic material onto an outer surface of the second insulating layer;

wherein the second insulating layer fully wets the first insulating layer,

wherein the flow point of the first thermoplastic material is at least 30°

C. greater than the extrusion melt temperature of the second thermoplastic material, and

wherein the tensile modulus of the first thermoplastic material is greater than 1241 MPa (180,000 psi) at 25°

C. and the tensile modulus of the second thermoplastic material is greater than 1379 MPa (200,000 psi) at 25°

C.

16. The method of claim 15, wherein the step of pressure extruding the second insulating layer is in-line with the step of tube extruding the first insulating layer.

17. The method of claim 16, wherein the method further comprises

providing a second tube extruder apparatus in line with the pressure extruder apparatus, the second tube extruder having a second tube extruder die and a second tube extruder guider tip positioned within the die;

and

immediately after the step of drawing the elongate member through the pressure extruder die, drawing the elongate member through the second tube extruder guider tip of the second tube extruder die to tube extrude the third insulating layer onto the outer surface of the second insulating layer.

18. The method of claim 15, wherein the elongate member is a stranded conductor having a diameter in the range of about 0.46 mm (0.0180 inch) to about 1.04 mm (0.041 inch).

19. The method of claim 15, further comprising crosslinking the third insulating layer.

20. The method of claim 15, wherein the second insulating layer is bonded to the first insulating layer.