Insulated electrical conductors

• US 6,087,591 A
• Filed: 07/31/1996
• Issued: 07/11/2000
• Est. Priority Date: 04/26/1995
• Status: Expired due to Term

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Yeung, Alan S., Sandoval, Ismael L., Nguyen, Phu D., Tondre, Stephen L.
• Primary Examiner(s): Kincaid, Kristine
• Assistant Examiner(s): Mayo, III, William H.
• Application Number:
  US08/690,092
• Time in Patent Office: 1,441 Days
• Field of Search: 174/15.1, 174/16.1, 174/110 SR, 174/120 R, 174/17.05, 428/375, 428/379, 525/444
• US Class Current: 174/110.00R
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: H01B 3/302 Polyurethanes or polythiourethanes; Polyurea or polythiourea
• CPC Class Codes: H01B 3/422 Linear saturated polyesters derived from dicarboxylic acids and dihydroxy compounds
• CPC Class Codes: H01B 3/445 from vinylfluorides or other fluoroethylenic compounds

Abstract

Polymeric compositions which contain a thermoplastic aromatic polyester, preferably polybutylene terephthalate, and a polyester block copolymer having a recrystallization temperature greater than 150° C., preferably a thermoplastic elastomer containing aromatic polyester blocks and aliphatic polyester blocks. The ratio of the block copolymer to the aromatic polyester is 0.05:1 to 0.35:1, preferably 0.15:1 to 0.30:1. These compositions are particularly useful as the insulation on hermetic lead wires for use in refrigerant systems. To prevent cracking of such insulation when it is contacted by a varnish used to provide hermetic sealing, it can be covered by a thin layer of a fluoropolymer.

Claims

1. An electrical assembly which comprises a hermetically sealed enclosure containing a refrigerant liquid and an insulated electrical wire which is within the enclosure and is contacted by the refrigerant, said insulated wire comprising a wire and, surrounding the wire, a layer of a melt-extruded electrically insulating composition which comprises a polymeric component comprising a blend of

(1) a thermoplastic aromatic polyester which consists essentially of 70 to 100% by weight of tetramethylene terephthalate units and 0 to 30% of other units which are randomly copolymerized with the tetramethylene terephthalate units, and

(2) a second polymer which has a recrystallization temperature greater than 150°

C. and is a polyester block copolymer;

said blend having a ratio by weight of the second polymer to the aromatic polyester of from 0.05;

1 to 0.35;

1.

2. An assembly according to claim 1 wherein the polymeric component consists essentially of the aromatic polyester, the second polymer, and 0-20% by weight, based on the weight of the aromatic polyester, of one or more other polymers.

3. An assembly according to claim 2 wherein at least 95% by weight of a repeating units in the aromatic polyester are tetramethylene terephthalate units, and the second polymer is a thermoplastic elastomer which comprises:

(a) aromatic polyester blocks in which a repeating units have the formula (I)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.p --O.CO.Ar.-- (I)

wherein p is at least 2 and Ar is an arylene group, and

(b) aliphatic polyester blocks in which a repeating units have the formula (II)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.q --O.CO.--(CH.sub.2).sub.r --CO-- (II)

wherein each of q and r, which may be the same or different, is at least 2.

4. An assembly according to claim 3 wherein the aromatic polyester is poly(tetramethylene terephthalate), and the thermoplastic elastomer contains 20 to 90% by weight of aromatic polyester blocks of formula I in which p is 4 and Ar is a 1,4-phenylene radical, and 10 to 80% by weight of aliphatic polyester blocks of formula II in which q is 4 and r is 4.

5. A composition according to claim 3 wherein the polymeric component has a ratio by weight of the thermoplastic elastomer to the aromatic polyester of 0.15:

1 to 0.30;

1.

6. An assembly according to claim 3 wherein the layer contacts the wire and is 0.003 to 0.030 inch thick.

7. An assembly according to claim 6 wherein the insulated wire, when subjected to a CFC extraction test, has less than 0.8% extractables.

8. An electrical assembly which comprises a hermetically sealed enclosure containing a refrigerant liquid and an insulated electrical wire which is within the enclosure and is contacted by the refrigerant, said insulated wire comprising a wire and polymeric insulation which surrounds the wire, the insulation comprising

(A) an inner layer composed of a first melt-extruded polymeric composition which comprises a polymeric component which comprises a blend of

(1) a thermoplastic aromatic polyester which consists essentially of 70 to 100% by weight of tetramethylene terephthalate units and 0 to 30% of other units which are randomly copolymerized with the tetramethylene terephthalate units, and

(2) a second polymer which has a recrystallization temperature greater than 150°

C. and is a polyester block copolymer;

said blend having a ratio by weight of the second polymer to the aromatic polyester of from 0.05;

1 to 0.35;

1; and

(B) an outer layer composed of a second melt-extruded polymeric composition which comprises a polymeric component which consists essentially of one or more fluoropolymers.

9. An assembly according to claim 8 wherein

(a) the polymeric component in the inner layer consists of aromatic polyester, the second polymer, and 0-20% by weight, based on the weight of the aromatic polyester of one or more other polymers, and

(b) the polymeric component in outer second layer consists essentially of an ethylene/chlorotrifluoroethylene polymer.

10. An assembly according to claim 9 wherein, the ethylene/chlorotrifluoroethylene polymer has a ratio by weight of ethylene units to chlorotrifluoroethylene units of from 0.4:

1 to 0.6;

1.

11. An assembly according to claim 10 wherein the outer layer is 0.0005 to 0.005 inch thick.

12. An assembly according to claim 11 wherein the inner layer is 0.003 to 0.030 inch thick.

13. An assembly according to claim 8 wherein the outer layer contains more than 25% by weight of fluorine.

14. An assembly according to claim 8 wherein the outer layer consists essentially of a single crystalline fluoropolymer.

15. An assembly according to claim 8 wherein the outer layer contains 0-10% by weight, based on the weight of the composition, of non-polymeric ingredients.

16. An electrical assembly which comprises a hermetically sealed enclosure containing a refrigerant liquid and an insulated electrical wire which is within the enclosure and is contacted by the refrigerant, said insulated wire comprising a wire having an outside diameter of 0.116 to 0.029 inch (2.95 to 0.737 mm, 10 to 22 AWG) and polymeric insulation which surrounds the wire, the insulation consisting of

(A) an inner layer which contacts the wire, which is 0.006 to 0.02 inch thick and which is composed of a first melt-extruded polymeric composition which comprises

(i) a polymeric component which consists essentially of a blend of

(1) polybutylene terephthalate, and

(2) a second polymer which has a recrystallization temperature greater than 150°

C. and which is a thermoplastic elastomer which comprises;

(a) 70 to 90% by weight of aromatic polyester blocks in which repeating units have a formula (I)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.p --O.CO.Ar.-- (I)

wherein p is 4 and Ar is a 1,4-phenylene radical, and

(b) 10 to 30% by weight of aliphatic polyester blocks in which the repeating units have the formula (II)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.q --O.CO.--(CH.sub.2).sub.r --CO-- (II)

wherein each of q and r is 4;

the ratio by weight of the thermoplastic elastomer (2) to the polybutylene terephthalate being from 0.15;

1 to 0.30;

1; and

(3) 0-20% by weight, based on the weight of the polybutylene terephthalate, of one or more other polymers; and

(ii) 0 to 10% by weight, based on the weight of the composition, of non-polymeric ingredients; and

(B) an outer layer which is 0.001 to 0.004 inch thick and which is composed of a second melt-extruded polymeric composition which consists essentially of

(i) at least one fluorinated polymer selected from ethylene/chlorotrifluoroethylene polymers and ethylene/tetrafluoroethylene polymers, and

(ii) 0 to 10% by weight, based on the weight of the composition, of non-polymeric ingredients.

17. An electrical assembly which comprises an electrical motor, an insulated lead wire for delivering electrical power to the motor, a housing which surrounds the motor, and a layer of a cured epoxy polymer varnish which hermetically seals the housing and which extends over at least part of the insulated lead wire, the lead wire (i), when subjected to a CFC extraction test, having less than 0.8% by weight extractables, and (ii) comprising a wire and polymeric insulation surrounding the wire, the insulation comprising

(A) an inner layer composed of a first melt-extruded polymeric composition which comprises a blend of

(1) a thermoplastic aromatic polyester, and

(2) a second polymer which has a recrystallization temperature greater than 150°

C. and is a polyester block copolymer; and

(B) an outer layer which is composed of a second melt-extruded polymeric composition comprising a fluoropolymer and which, when the varnish on the surface of the insulated wire cracks, prevents cracking of the varnish from causing cracking of the inner layer of insulation.

18. An assembly according to claim 17 wherein

(1) the thermoplastic aromatic polyester consists essentially of 70 to 100% by weight of tetramethylene terephthalate units and 0 to 30% of other units which are randomly copolymerized with the tetramethylene terephthalate units, and

(2) the second polymer has a recrystallization temperature greater than 150°

C. and is a polyester block copolymer;

the first polymeric composition having a ratio by weight of the second polymer to the aromatic polyester of from 0.05;

1 to 0.35;

1.

19. An assembly according to claim 18 wherein the polymeric component consists essentially of the aromatic polyester, the second polymer, and 0-20% by weight, based on the weight of the aromatic polyester, of one or more other polymers.

20. An assembly according to claim 19 wherein at least 95% by weight of the repeating units in aromatic polyester are tetramethylene terephthalate units, and the second polymer is a thermoplastic elastomer which comprises:

(a) aromatic polyester blocks in which the repeating units have the formula (I)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.p --O.CO.Ar.-- (I)

wherein p is at least 2 and Ar is an arylene group, and

(b) aliphatic polyester blocks in which the repeating units have the formula (II)

space="preserve" listing-type="equation">--O--(CH.sub.2).sub.q --O.CO.--(CH.sub.2).sub.r --CO-- (II)

wherein each of q and r, which may be an equal or different number which is at least 2.

21. An assembly according to claim 20 wherein the aromatic polyester is poly(tetramethylene terephthalate), and the thermoplastic elastomer contains 20 to 90% by weight of aromatic polyester blocks of formula I in which p is 4 and Ar is a 1,4-phenylene radical, and 10 to 80% by weight of aliphatic polyester blocks of formula II in which q is 4 and r is 4.

22. An assembly according to claim 20 wherein a polymeric component has a ratio by weight of the thermoplastic elastomer to the aromatic polyester of 0.15:

1 to 0.30;

1.

23. An assembly according to claim 22 wherein the polymeric component in the second polymeric composition consists essentially of an ethylene/chlorotrifluoro-ethylene polymer.

24. An assembly according to claim 18 wherein the second polymeric composition comprises a polymeric component consists essentially of one or more fluoropolymers.

25. An assembly according to claim 24 wherein, the ethylene/chlorotrifluoro-ethylene polymer has a ratio by weight of ethylene units to chlorotrifluoroethylene units of from 0.4:

1 to 0.6;

1.

26. An assembly according to claim 24 wherein the outer layer is 0.0005 to 0.005 inch thick and the inner layer is 0.003 to 0.030 inch thick.

27. An assembly according to claim 17 wherein the outer layer contains more than 25% by weight of fluorine.

28. An assembly according to claim 17 wherein the outer layer consists essentially of a single crystalline fluoropolymer.

29. An assembly according to claim 17 wherein the outer layer contains 0-10% by weight, based on the weight of the composition, of non-polymeric ingredients.