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EP0040034A1 - Insulated wires and electric cables - Google Patents

Insulated wires and electric cables Download PDF

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Publication number
EP0040034A1
EP0040034A1 EP81301965A EP81301965A EP0040034A1 EP 0040034 A1 EP0040034 A1 EP 0040034A1 EP 81301965 A EP81301965 A EP 81301965A EP 81301965 A EP81301965 A EP 81301965A EP 0040034 A1 EP0040034 A1 EP 0040034A1
Authority
EP
European Patent Office
Prior art keywords
cable
tape
conductor
groups
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP81301965A
Other languages
German (de)
French (fr)
Inventor
Thomas Sullivan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Balfour Beatty PLC
Original Assignee
BICC PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BICC PLC filed Critical BICC PLC
Publication of EP0040034A1 publication Critical patent/EP0040034A1/en
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/301—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen or carbon in the main chain of the macromolecule, not provided for in group H01B3/302
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/306—Polyimides or polyesterimides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/42—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
    • H01B3/427—Polyethers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material

Definitions

  • This invention relates to insulated wires and electric cables, all of which are hereinafter included in the term 'cables'.
  • the cables of the invention are primarily, but not exclusively, suitable for aircraft wiring and other electronics purposes.
  • KPA150 One of the more successful cables at present used in this market is the Applicants' "KPA150" cable.
  • this cable two tapes of aromatic polyimide foil, each thinly coated on both sides with fluorinated ethylene-propylene copolymer as a bonding agent, are lapped on the conductor each overlapping by 67% (nominally) so that each tape forms three complete overlapping layers, and a pigmented lacquer is applied to give an abrasion-resistant coating that is receptive to printing.
  • This cable is suitable for continuous service at 150 o C, and is generally satisfactory, though the slightly irregular surface has occasionally caused difficulties in sealing round the cable at terminations and may reduce the legibility of markings, and the fluorine and nitrogen contents may imply some toxic hazard under severe fire conditions.
  • the present invention provides a cable which (i) has at least as good temperature rating; (ii) has a smooth surface; (iii) contains no, or at least substantially less, fluorine and substantially less nitrogen; (iv) is easier to manufacture and requires simpler plant; and ( v ) can be at least as low in weight and bulk at the "KPA150" cable (an important consideration as the weight of cables in a modern aircraft can be a significant fraction of the payload).
  • the conventional type of tape coated with a bonding layer of fluorinated ethylene-propylene copolymer can be used, but this is not essential and the use of uncoated tape has the advantage of completely eliminating fluorine compounds from the cable.
  • the tape is helically applied to the conductor, preferably with an overlap of at least 60%.
  • the tape could be applied longitu- d inally or as a further alternative could be applied initially in a longitudinal direction and converted to a helical form by twisting the wrapped wire (before or after applying the outer layer) for example using a flyer-type winding machine (as conventionally used for twinning and bunching).
  • the conductor may be solid or stranded and is preferably of plain, tinned, nickel-plated or silver-plated copper.
  • the preferred polyimide for the tape is that sold under the trademark Kapton, which is believed to consist essentially of the polymeric pyromellitate of p,p' diamino diphenyl ether.
  • Kapton is believed to consist essentially of the polymeric pyromellitate of p,p' diamino diphenyl ether.
  • the tape is no more than 0.04mm thick and any coating thereon no more than 0.005mm thick. More especially Kapton 010 tape, an uncoated tape 0.025mm thick and Kapton 616 tape, a coated tape in which the polyimide is about 0.025mm thick and the coating about 0.0025mm thick, are preferred.
  • Suitable polymers for the outer layer are described in British Patent Specifications 971,227, 1,016, 245, 1,019,266, 1,019,458, 1,078,234, 1,086,021, 1,102,679, 1,153,035, 1,153,527, 1,164,817, 1,177,183, 1,383,393, 1,387,303, and 1,414,421, 1,414,422 and 1.414.423 and in European Patent Application 0001879.
  • Linear polymers are usually preferred, but some can be crosslinked, and this may sometimes be beneficial.
  • Polymers in which the aromatic groups are predominately phenylene and the linking groups are selected from -0-, -CO- and -S0 2 - are preferred; most preferred are polyether ketones and polyether sulphones in which (in both cases) -0- linkages are in the majority, and more especially paraphenylene polyether ketones having about twice as many -0- linkages as -C0- linkages (such as the polymer sold by ICI as "PEEK").
  • the outer layer is preferably extruded, either as a single operation or in two (or more) steps. Alternatively it might be in tape form applied helically or applied longitudinally with or without subsequent twisting; further it might be a composite layer applied partly in tape form and partly by extrusion (under, over or between tapes). When the outer layer is in two or more parts they may be of identical composition or they may differ within the range of polymers defined above.
  • the outer layer is oriented, suitable techiniques for extruded layers being described in our British Patent Application 16614/78 and our European Application No. 79301544.7.
  • Two or more wires, insulated as described, may be assembled together by twisting or otherwise to form a multiconductor cable, with or without a suitable overall sheath, braid or other coverings.
  • the combined radial thickness of the polyimide tape layer and the outer layer is not more than 0.25mm.
  • a single-conductor low-toxicity airframe cable consists of a conventionally stranded conductor made up of 19 silver plated annealed copper conductors each 0.20 mm in diameter lapped with a single tape of FEP-coated polyimide tape (Kapton 616Hf), 9.6 mm wide and applied with 67% overlap (nominal diameter over tape 1.18 mm), heat- sealed and then covered with 0.15 mm radial thickness of a polyphenylene ether-ketone (having about two ether linkages for each ketone linkage). This covering is applied by extrusion using a conventional thermoplastic extrude operating at 400°C, and raises the nominal overall diameter to 1.48 mm.
  • the polyphenylene ether-ketone can be coloured with suitably-chosen pigments, if desired; other additives are unnecessary.
  • Example 2 Two and three respectively of the conductors described in Example 1 are twisted together with a lay-length of 20 times pitch diameter, right handed.
  • a braided 2-core aircraft-wiring cable consists of the cable of Example 2 braided with 0.10 mm diameter silver-plated annealed copper wires, 16 spindles 8 ends, 19 mm lay (nominal diameter over braid 3.46 mm) and sheathed to a radial thickness of 1.0 mm with an ethylene-acrylic polymer composition formulated as follows:
  • Example 1 The single core of Example 1 is braided and sheathed substantially as described in Example 3.
  • a thirty-core cable comprises conductors according to Example 6 laid up 4, 10 and 16 with the lay-length of each layer 20 times the respective pitch diameter, with a sheath (1.2 mm radial thickness) of the same formulation set out in Example 4.
  • Example 11 This is similar to Example 11, but each core is the screened and sheathed conductor of Example 10.
  • the cables of the Examples all have excellent radiation and water resistance; those of Examples 1-5 have good resistance to notch propagation, whereas the others have the merit of a substantially zero halogen content.

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  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Insulated Conductors (AREA)
  • Organic Insulating Materials (AREA)

Abstract

A cable, suitable for aircraft wiring purposes comprises: at least one metallic conductor; a single layer of an aromatic polyimide tape, optionally coated with a bonding layer of a fluorinated ethylene-propylene copolymer, applied to the conductor with an overlap; and an extruded outer layer based on a polymer consisting of chains of aromatic rings linked by . groups selected from -0-, -S-, S02-, -CO-, and -CR2- (where R=H or alkyl or acyl), of which polyether ketone (PEEK) is preferred. The extruded layer is preferably oriented.

Description

  • This invention relates to insulated wires and electric cables, all of which are hereinafter included in the term 'cables'. The cables of the invention are primarily, but not exclusively, suitable for aircraft wiring and other electronics purposes.
  • One of the more successful cables at present used in this market is the Applicants' "KPA150" cable. In this cable two tapes of aromatic polyimide foil, each thinly coated on both sides with fluorinated ethylene-propylene copolymer as a bonding agent, are lapped on the conductor each overlapping by 67% (nominally) so that each tape forms three complete overlapping layers, and a pigmented lacquer is applied to give an abrasion-resistant coating that is receptive to printing.
  • This cable is suitable for continuous service at 150oC, and is generally satisfactory, though the slightly irregular surface has occasionally caused difficulties in sealing round the cable at terminations and may reduce the legibility of markings, and the fluorine and nitrogen contents may imply some toxic hazard under severe fire conditions.
  • The present invention provides a cable which (i) has at least as good temperature rating; (ii) has a smooth surface; (iii) contains no, or at least substantially less, fluorine and substantially less nitrogen; (iv) is easier to manufacture and requires simpler plant; and (v) can be at least as low in weight and bulk at the "KPA150" cable (an important consideration as the weight of cables in a modern aircraft can be a significant fraction of the payload).
  • The cable in accordance with the invention comprises: at least one metallic conductor; a single layer of an aromatic polyimide tape applied to the conductor with an overlap; and an extruded outer layer based on a polymer consisting of chains of aromatic rings linked by groups selected from -0-, -S-, -S02-, -CO-, and -CR2- (where R=H or alkyl or acyl).
  • If it is desired to bond the layers of tape, the conventional type of tape coated with a bonding layer of fluorinated ethylene-propylene copolymer can be used, but this is not essential and the use of uncoated tape has the advantage of completely eliminating fluorine compounds from the cable.
  • Preferably the tape is helically applied to the conductor, preferably with an overlap of at least 60%. Alternatively, however, the tape could be applied longitu- dinally or as a further alternative could be applied initially in a longitudinal direction and converted to a helical form by twisting the wrapped wire (before or after applying the outer layer) for example using a flyer-type winding machine (as conventionally used for twinning and bunching).
  • The conductor may be solid or stranded and is preferably of plain, tinned, nickel-plated or silver-plated copper.
  • The preferred polyimide for the tape is that sold under the trademark Kapton, which is believed to consist essentially of the polymeric pyromellitate of p,p' diamino diphenyl ether. Preferably the tape is no more than 0.04mm thick and any coating thereon no more than 0.005mm thick. More especially Kapton 010 tape, an uncoated tape 0.025mm thick and Kapton 616 tape, a coated tape in which the polyimide is about 0.025mm thick and the coating about 0.0025mm thick, are preferred.
  • Suitable polymers for the outer layer are described in British Patent Specifications 971,227, 1,016, 245, 1,019,266, 1,019,458, 1,078,234, 1,086,021, 1,102,679, 1,153,035, 1,153,527, 1,164,817, 1,177,183, 1,383,393, 1,387,303, and 1,414,421, 1,414,422 and 1.414.423 and in European Patent Application 0001879. Linear polymers are usually preferred, but some can be crosslinked, and this may sometimes be beneficial. Polymers in which the aromatic groups are predominately phenylene and the linking groups are selected from -0-, -CO- and -S02- are preferred; most preferred are polyether ketones and polyether sulphones in which (in both cases) -0- linkages are in the majority, and more especially paraphenylene polyether ketones having about twice as many -0- linkages as -C0- linkages (such as the polymer sold by ICI as "PEEK").
  • The outer layer is preferably extruded, either as a single operation or in two (or more) steps. Alternatively it might be in tape form applied helically or applied longitudinally with or without subsequent twisting; further it might be a composite layer applied partly in tape form and partly by extrusion (under, over or between tapes). When the outer layer is in two or more parts they may be of identical composition or they may differ within the range of polymers defined above.
  • Preferably the outer layer is oriented, suitable techiniques for extruded layers being described in our British Patent Application 16614/78 and our European Application No. 79301544.7.
  • Two or more wires, insulated as described, may be assembled together by twisting or otherwise to form a multiconductor cable, with or without a suitable overall sheath, braid or other coverings.
  • Preferably the combined radial thickness of the polyimide tape layer and the outer layer is not more than 0.25mm.
  • The following examples illustrate typical forms of the invention.
    • Example 1
  • A single-conductor low-toxicity airframe cable consists of a conventionally stranded conductor made up of 19 silver plated annealed copper conductors each 0.20 mm in diameter lapped with a single tape of FEP-coated polyimide tape (Kapton 616Hf), 9.6 mm wide and applied with 67% overlap (nominal diameter over tape 1.18 mm), heat- sealed and then covered with 0.15 mm radial thickness of a polyphenylene ether-ketone (having about two ether linkages for each ketone linkage). This covering is applied by extrusion using a conventional thermoplastic extrude operating at 400°C, and raises the nominal overall diameter to 1.48 mm. The polyphenylene ether-ketone can be coloured with suitably-chosen pigments, if desired; other additives are unnecessary.
    • Examples 2 and 3
  • Two and three respectively of the conductors described in Example 1 are twisted together with a lay-length of 20 times pitch diameter, right handed.
    • Example 4
  • A braided 2-core aircraft-wiring cable consists of the cable of Example 2 braided with 0.10 mm diameter silver-plated annealed copper wires, 16 spindles 8 ends, 19 mm lay (nominal diameter over braid 3.46 mm) and sheathed to a radial thickness of 1.0 mm with an ethylene-acrylic polymer composition formulated as follows:
    • Parts by weight Vamac N-123 masterbatch 47.50
    • (believed to consist of about
    • 80% of a terpolymer of ethylene,
    • methyl acrylate.and a carboxylic
    • monomer together'with about 20%
    • of an inert silica filler)
      Figure imgb0001
    • Process Aids:
      Figure imgb0002
    • Antioxidant:
      Figure imgb0003
    • Curing system:
      Figure imgb0004
    Example 5
  • The single core of Example 1 is braided and sheathed substantially as described in Example 3.
    • Example 6-10
  • These are identical with Examples 1-5 respectively except that the polyimide tape is uncoated (Kapton 010 tape) and not heat sealed.
    • Example 11
  • A thirty-core cable comprises conductors according to Example 6 laid up 4, 10 and 16 with the lay-length of each layer 20 times the respective pitch diameter, with a sheath (1.2 mm radial thickness) of the same formulation set out in Example 4.
    • Example 12
  • This is similar to Example 11, but each core is the screened and sheathed conductor of Example 10.
  • The cables of the Examples all have excellent radiation and water resistance; those of Examples 1-5 have good resistance to notch propagation, whereas the others have the merit of a substantially zero halogen content.

Claims (4)

1. An insulated wire or electric cable comprising: at least one metallic conductor; a single layer of an aromatic polyimide tape applied to the conductor with an overlap; and an extruded outer layer based on a polymer consisting of chains of aromatic rings linked by groups selected from -0-, -S-, -SO2-, -CO- and -CR2- (where R=H or alkyl or acyl).
2. An insulated wire or cable as claimed in Claim 1 in which the linking groups are selected from -0-, -CO- and -SO2-.
3. An insulated wire or cable as claimed in Claim 1 in which the polymer is a polyether ketone in which the linking groups are -0- and-CO-, -0- groups being in the majority.
4. An insulated wire or cable as claimed in any one of.Claims 1-3 in which the aromatic groups in the polymer are predominately phenylene groups.
EP81301965A 1980-05-08 1981-05-05 Insulated wires and electric cables Withdrawn EP0040034A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8015249 1980-05-08
GB8015249 1980-05-08

Publications (1)

Publication Number Publication Date
EP0040034A1 true EP0040034A1 (en) 1981-11-18

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP81301965A Withdrawn EP0040034A1 (en) 1980-05-08 1981-05-05 Insulated wires and electric cables

Country Status (1)

Country Link
EP (1) EP0040034A1 (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0103487A3 (en) * 1982-09-15 1984-08-01 Raychem Corporation Electrical insulation
US4678709A (en) * 1982-09-15 1987-07-07 Raychem Corporation Electrical insulation
GB2460686A (en) * 2008-06-05 2009-12-09 Tyco Electronics Polymer coated wire or cable
DE102010002721A1 (en) * 2010-03-10 2011-11-17 Siemens Aktiengesellschaft Wire i.e. winding wire, for winding of e.g. generator, has electrical conductor covered with polyimide layer and polyetheretherketone layer, where polyimide layer is arranged between conductor and polyetheretherketone layer
US8684679B2 (en) 2012-05-22 2014-04-01 Summit Esp, Llc Abrasion resistance in well fluid wetted assemblies
US9046354B2 (en) 2013-02-27 2015-06-02 Summit Esp, Llc Apparatus, system and method for measuring straightness of components of rotating assemblies
US9472987B1 (en) 2013-08-05 2016-10-18 Summit Esp, Llc Induction motor stator windings
US9800110B2 (en) 2012-04-20 2017-10-24 Summit Esp, Llc System and method for enhanced magnet wire insulation
EP3239987A1 (en) * 2016-04-28 2017-11-01 LEONI Kabel Holding GmbH Electrical conductor and use of the electrical conductor

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3822147A (en) * 1972-05-05 1974-07-02 Phelps Dodge Magnet Wire Co Insulated electrical conductor and coils formed thereof
US3842192A (en) * 1973-05-17 1974-10-15 Phelps Dodge Ind Inc Dual insulated magnet wire
GB1397261A (en) * 1971-05-26 1975-06-11 Standard Oil Co Electrical insulating material and electrical conductors insulated therewith
US3922465A (en) * 1973-01-26 1975-11-25 Sumitomo Electric Industries Solderable and thermostable insulated wires
US4161564A (en) * 1975-09-11 1979-07-17 La Barge, Inc. Coating formulation, method, and coated substrate

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1397261A (en) * 1971-05-26 1975-06-11 Standard Oil Co Electrical insulating material and electrical conductors insulated therewith
US3822147A (en) * 1972-05-05 1974-07-02 Phelps Dodge Magnet Wire Co Insulated electrical conductor and coils formed thereof
US3922465A (en) * 1973-01-26 1975-11-25 Sumitomo Electric Industries Solderable and thermostable insulated wires
US3842192A (en) * 1973-05-17 1974-10-15 Phelps Dodge Ind Inc Dual insulated magnet wire
US4161564A (en) * 1975-09-11 1979-07-17 La Barge, Inc. Coating formulation, method, and coated substrate

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0103487A3 (en) * 1982-09-15 1984-08-01 Raychem Corporation Electrical insulation
US4678709A (en) * 1982-09-15 1987-07-07 Raychem Corporation Electrical insulation
GB2460686A (en) * 2008-06-05 2009-12-09 Tyco Electronics Polymer coated wire or cable
GB2460686B (en) * 2008-06-05 2012-05-16 Tyco Electronics Ltd Uk High performance, high temperature wire or cable
US9208925B2 (en) 2008-06-05 2015-12-08 Tyco Electronics Uk Ltd. High performance, high temperature wire or cable
DE102010002721A1 (en) * 2010-03-10 2011-11-17 Siemens Aktiengesellschaft Wire i.e. winding wire, for winding of e.g. generator, has electrical conductor covered with polyimide layer and polyetheretherketone layer, where polyimide layer is arranged between conductor and polyetheretherketone layer
US9800110B2 (en) 2012-04-20 2017-10-24 Summit Esp, Llc System and method for enhanced magnet wire insulation
US8684679B2 (en) 2012-05-22 2014-04-01 Summit Esp, Llc Abrasion resistance in well fluid wetted assemblies
US9046354B2 (en) 2013-02-27 2015-06-02 Summit Esp, Llc Apparatus, system and method for measuring straightness of components of rotating assemblies
US9472987B1 (en) 2013-08-05 2016-10-18 Summit Esp, Llc Induction motor stator windings
EP3239987A1 (en) * 2016-04-28 2017-11-01 LEONI Kabel Holding GmbH Electrical conductor and use of the electrical conductor

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