Flat multi-conductor power cable with two insulating layers
First Claim
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1. A flat multi-conductor power cable comprising:
- a plurality of continuous, generally parallel, spaced apart metal conductors having flat upper and lower surfaces and generally lie in the same plane;
an internal layer of a first insulating material extruded around each of said flat conductors, said internal layer being intimately joined to and completely surrounding each of said conductors and extending continuously therealong, said first material being selected to have the property of adhesively joining to the metal of flat conductors; and
an external layer of a second insulating material extruded around said first insulating layer, said external layer being intimately joined to and completely surrounding all of the internal layers and extending continuously therealong, said second insulating material being selected to have the properties of being moisture resistant and of being intimately joined to the first material, said second insulating material being a thermoplastic vulcanizate comprising rubber particles dispersed in a continuous matrix of a thermoplastic resin;
whereby said cable is especially adapted to be used in undercarpet applications.
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Abstract
A flat multi-conductor power cable is disclosed which includes a plurality of generally parallel, spaced apart, flat conductors which are surrounded by two layers of insulation material. An internal layer is extruded around each of the flat conductors and is intimately bonded to each conductor. A single external layer is extruded around all of the internal layers and is intimately joined to all of the internal layers. Preferably, the external layer comprises a thermoplastic elastomer and the internal layer comprises a polyolefinic ionomer. A method and apparatus for making such a flat multi-conductor power cable is also disclosed.
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Citations
29 Claims
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1. A flat multi-conductor power cable comprising:
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a plurality of continuous, generally parallel, spaced apart metal conductors having flat upper and lower surfaces and generally lie in the same plane; an internal layer of a first insulating material extruded around each of said flat conductors, said internal layer being intimately joined to and completely surrounding each of said conductors and extending continuously therealong, said first material being selected to have the property of adhesively joining to the metal of flat conductors; and an external layer of a second insulating material extruded around said first insulating layer, said external layer being intimately joined to and completely surrounding all of the internal layers and extending continuously therealong, said second insulating material being selected to have the properties of being moisture resistant and of being intimately joined to the first material, said second insulating material being a thermoplastic vulcanizate comprising rubber particles dispersed in a continuous matrix of a thermoplastic resin;
whereby said cable is especially adapted to be used in undercarpet applications. - View Dependent Claims (2, 3, 4, 5, 6)
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5. The cable of claim 1 wherein the first insulating material is an ionically linked acid copolymer.
- 6. The cable of claim 1 wherein the first insulating material is a polyolefinic ionomer having the general formula
- space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
an acid content between 5 and 10 percent, which is 15 to 25 percent neutralized;
a melt index between 1 and 6; and
a weight average molecular weight over 250,000 and wherein M is a metallic ion selected from the group consisting of sodium, potassium, and zinc. - space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
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7. A method for making a flat multi-conductor power cable comprising:
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providing a plurality of continuous, generally parallel, spaced apart metal conductors having flat upper and lower surfaces and generally lie in the same plane; moving said flat conductors through extruding means; extruding an internal layer of a first insulating material directly onto each flat conductor, said internal layers being intimately joined to and made to surround each flat conductors and extending continuously therealong, said first material being selected to have the property of adhesively joining to the metal of said flat conductors; and extruding a single external layer of a second insulating material around all of the internal layers, the external layer being intimately joined to the internal layers and extending continuously therealong, said second insulating material being selected to have the properties of being moisture resistant and of being intimately joined to the first material, said second insulating material being a thermoplastic vulcanizate comprising rubber particles dispersed in a continuous matrix of a thermoplastic resin. - View Dependent Claims (8, 9, 10, 11, 12)
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11. The method of claim 7 wherein the first insulating material is an ionically linked acid copolymer.
- 12. The method of claim 7 wherein the first insulating material is a polyolefinic ionomer having the general formula
- space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
an acid content between 5 and 10 percent, which is 15 to 25 percent neutralized;
a melt index between 1 and 6; and
a weight average molecular weight over 250,000 and wherein M is a metallic ion selected from the group consisting of sodium, potassium and zinc. - space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
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13. A flat multi-conductor power cable having live, neutral and ground conductors comprising;
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a plurality of continuous, generally parallel, spaced apart metal conductors having flat upper and lower surfaces and generally lying in the same plane, said conductors defining live, neutral and ground conductors; an internal layer of a first insulating material extruded around each of said live, neutral and ground conductors, said internal layer being intimately joined to and completely surrounding each of said conductors and extending continuously therealong, said first material being selected to have the property of adhesively joining to the metal of flat conductors; and an external layer of a second insulating material extruded around said first insulating layer, said external layer being intimately joined to and completely surrounding all of the internal layers and extending continuously therealong, said second insulating material being selected to have the properties of being moisture resistant and of being intimately joined to the first material, said second insulating material being a thermoplastic vulcanizate comprising rubber particles dispersed in a continuous matrix of a thermoplastic resin;
whereby said cable is especially adapted to be used in undercarpet applications. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20)
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17. The cable of claim 13 wherein the first insulating material is an ionically linked acid copolymer.
- 18. The cable of claim 13 wherein the first insulating material is a polyolefinic ionomer having the general formula
- space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
an acid content between 5 and 10 percent, which is 15 to 25 percent neutralized;
a melt index between 1 and 6; and
a weight average molecular weight over 250,000 and wherein M is a metallic ion selected from the group consisting of sodium, potassium and zinc. - space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
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19. The cable of claim 13 wherein each of the flat conductors is a unitary ribbon of a metallic conductor.
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20. The cable of claim 13 wherein the maximum thickness of the cable is between about 0.78 and about 1.32 mm, the thickness of the internal layer is between about 0.07 and about 0.102 mm, and the thickness of the external layer is between about 0.178 and about 0.445 mm.
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21. A method for making a flat multi-conductor power cable having live, neutral and ground conductors comprising:
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providing a plurality of continuous, generally parallel, spaced apart metal conductors having flat upper and lower surfaces and generally lying in the same plane, said conductors defining live, neutral and ground conductors; moving said flat conductors through extruding means; extruding an internal layer of a first insulating material directly onto each live, neutral and ground conductor, said internal layers being intimately joined to and made to surround each flat conductors and extending continuously therealong, said first material being selected to have the property of adhesively joining to the metal of said flat conductors; and extruding a single external layer of a second insulating material around all of the internal layers, the external layer being intimately joined to the internal layers and extending continuously therealong, said second insulating material being selected to have the properties of being moisture resistant and of being intimately joined to the first material, said second insulating material being a thermoplastic vulcanizate comprising rubber particles dispersed in a continuous matrix of a thermoplastic resin. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29)
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25. The method of claim 21 wherein the first insulating material is an ionically linked acid copolymer.
- 26. The method of claim 21 wherein the first insulating material is a polyolefinic ionomer having the general formula
- space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
an acid content between 5 and 10 percent, which is 15 to 25 percent neutralized;
a melt index between 1 and 6; and
a weight average molecular weight over 250,000 and wherein M is a metallic ion selected from the group consisting of sodium, potassium and zinc. - space="preserve" listing-type="equation">[(CH2--CH2).sub.y (CH2CCH3COO--M.sup.+).sub.x ].sub.n ;
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27. The method of claim 21 wherein each of the flat conductors is a unitary ribbon of a metallic conductor.
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28. The method of claim 21 wherein the maximum thickness of the cable is between 0.78 and 1.32 mm.
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29. The method of claim 21 wherein said first and second insulating layers are extruded nearly simultaneously.
Specification
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Current AssigneeAMP Incorporated (Johnson Controls International plc)
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Original AssigneeAMP Incorporated (Johnson Controls International plc)
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InventorsBrandolf, Henry E., Walsen, Axel V., Schubert, Paul C. Jr.
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Primary Examiner(s)NIMMO, MORRIS
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Application NumberUS06/857,211Time in Patent Office924 DaysField of Search174/117 R, 174/117 F, 174/117 FF, 174/110 SR, 174/110 AR, 174/110 V, 174/120 AR, 174/120 SR, 264/174, 156/55, 156/56US Class Current174/117.0FFCPC Class CodesB29C 48/07 Flat, e.g. panelsB29C 48/12 Articles with an irregular ...B29C 48/156 Coating two or more article...B29C 48/304 specially adapted for bring...H01B 13/144 Heads for simultaneous extr...H01B 7/0823 Parallel wires, incorporate...H05K 1/0393 Flexible materials H05K1/03...H05K 3/28 Applying non-metallic prote...
