# US 2014/0190724 A1 · Multi-layer insulated conductor having improved scrape abrasion resistance > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0190724 A1 - Document ID: US20140190724A1 - Status: Published application - Kind: A1 - Application number: 13/737,049 - Filed: 2013-01-09 - Published: 2014-07-10 - Earliest claimed: 2013-01-09 - Assignees: Tyco Electronics Corporation - Applicants: Tyco Electronics Corporation - Inventors: Ashok K. MEHAN; Paul CABREY - Web page: https://patentgrep.com/patent/US20140190724A1 ## CPC - H01B 3/427: {Polyethers} - B32B 27/08: of synthetic resin - B32B 27/288: {comprising polyketones} - B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE} - H01B 3/36: condensation products of phenols with aldehydes or ketones - H01B 3/445: {from vinylfluorides or other fluoroethylenic compounds} - H01B 7/0275: {comprising one or more extruded layers of insulation} - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract An insulated conductor and method for making it are disclosed. The insulated conductor includes an elongate conductor and a multi-layer insulation system. The multi-layer insulation system has a first insulating layer including an aromatic thermoplastic material overlying the elongate conductor and a second insulating layer including a perfluoropolymer adjacent the first insulating layer. The first and second insulating layers are each applied to a thickness such that the multi-layer insulation system exhibits a scrape abrasion resistance that is significantly greater than sum of the scrape abrasion resistance of the first and second insulating layers individually at that thickness. ## Claims ### Claim 1 An insulated conductor comprising: an elongate conductor; and a multi-layer insulation system having an extruded first insulating layer comprising an aromatic thermoplastic material overlying the elongate conductor; and an extruded second insulating layer comprising a perfluoropolymer in contact with the first insulating layer, wherein the first and second insulating layers are each of a wall thickness such that the multi-layer insulation system exhibits a scrape abrasion resistance that is at least 50% greater than the sum of the scrape abrasion resistance of the first and second insulating layers individually at that thickness when the scrape abrasion resistance is measured in accordance with a predetermined needle abrasion test. ### Claim 2 (depends on 1) The insulated conductor of claim 1, wherein the first insulating layer has an average wall thickness in the range of about 0.003 inches to about 0.006 inches. ### Claim 3 (depends on 1) The insulated conductor of claim 1, wherein the second insulating layer has an average wall thickness in the range of about 0.002 inches to about 0.009 inches. ### Claim 4 (depends on 1) The insulated conductor of claim 1, wherein the first insulating layer comprises a polyaryleneetherketone. ### Claim 5 (depends on 4) The insulated conductor of claim 4, wherein the polyaryleneetherketone is selected from the group consisting of polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherketone (PEK), polyetherimide (PEI), and blends thereof. ### Claim 6 (depends on 1) The insulated conductor of claim 1, wherein the first insulating layer comprises PEEK. ### Claim 7 (depends on 1) The insulated conductor of claim 1, wherein the perfluoropolymer comprises a compound selected from the group consisting of perfluoroalkoxy polymers (PFA), fluorinated ethylene propylene polymers (FEP), polytetrafluoroethylene (PTFE), perfluoromethylalkoxy polymers (MFA), perfluorinated polyethers (PFPE), polychlorotrifluoroethylene (PCTFE) and blends thereof. ### Claim 8 (depends on 1) The insulated conductor of claim 1, wherein the second insulating layer comprises PTFE or FEP. ### Claim 9 (depends on 1) The insulated conductor of claim 1, wherein the first insulating layer comprises PEEK and the second insulating layer comprises PTFE or FEP. ### Claim 10 (depends on 9) The insulated conductor of claim 9, wherein the first insulating layer has an average wall thickness of about 0.003 inches and the second insulating layer has an average wall thickness of about 0.003 inches. ### Claim 11 (depends on 10) The insulated conductor of claim 10, wherein the second insulating layer overlies the first insulating layer. ### Claim 12 (depends on 1) The insulated conductor of claim 1, wherein the elongate conductor is a stranded conductor. ### Claim 13 (depends on 1) The insulated conductor claim 1, wherein the elongate conductor is a braided cable. ### Claim 14 (depends on 1) The insulated conductor of claim 1, wherein the first insulating layer is annealed. ### Claim 15 (depends on 1) The insulated conductor of claim 1, wherein the predetermined needle abrasion test employs a needle having a predetermined diameter scraped a predetermined length across the insulated conductor under a predetermined load at a rate of a predetermined number of strokes per minute. ### Claim 16 (depends on 15) The insulated conductor of claim 15, wherein the predetermined needle diameter is 0.020 inches, the predetermined stroke length is 0.394 inches, the predetermined rate is 110 strokes per minute and the predetermined load is 1.1 pounds. ### Claim 17 (depends on 16) The insulated conductor of claim 16, wherein the multi-layer insulation system exhibits a scrape abrasion resistance that is at least 100% greater than the sum of the scrape abrasion resistance of the first and second insulating layers individually at that thickness. ### Claim 18 An insulated conductor comprising: an elongate conductor; and a two-layer insulation system having an extruded first insulating layer comprising PEEK overlying the elongate conductor and having an average wall thickness of about 0.003 inches; and an extruded second insulating layer comprising PTFE overlying and in contact with the first insulating layer and having an average wall thickness of about 0.003 inches. ### Claim 19 An insulated conductor comprising: an elongate conductor comprising a braided cable; and a two-layer insulation system having an extruded first insulating layer comprising annealed PEEK overlying the elongate conductor and having an average wall thickness of about 0.0055 inches; and an extruded second insulating layer comprising FEP overlying and in contact with the first insulating layer and having an average wall thickness of about 0.0085 inches.