# US 6,017,626 A · Automotive-wire insulation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 6,017,626 A - Document ID: US6017626A - Status: Granted - Kind: A - Application number: 09/078,754 - Filed: 1998-05-14 - Granted: 2000-01-25 - Earliest claimed: 1998-05-14 - Assignees: Champlain Cable Corporation - Inventors: Nelson Hildreth - Web page: https://patentgrep.com/patent/US6017626A ## CPC - H01B 7/292: {using material resistant to heat} - Y10T 428/2929: Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type] - Y10T 428/2931: Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.] - 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}) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention features a high-temperature, automotive-wire article having a thin wall construction and an operative temperature of at least 135 degrees Centigrade. The wire article is made of an inner core of copper that is surrounded by a single layer of insulation, the latter of which includes an integral composite of two insulations. The inner layer of the composite consists of a fluorocarbon material; the outer layer of the composite is made of an irradiated, cross-linked polyolefin material. The outer layer may be irradiation cross-linked with between approximately 60 to 400 kGy, and preferably between 100 and 200 kGy. The inner and outer layers can optionally be adhesively bonded together or thermal fused together using a meltable resin, in order to form a single layer. The total wall thickness of the composite is less than approximately 0.5 mm. ## Claims ### Claim 1 A high-temperature, automotive-wire article that has an operative temperature exceeding that of at least 135.degree. C., comprising: an uncoated copper core; an integrally bonded composite insulation disposed over said uncoated copper core comprising a fluorocarbon material forming an inner layer surrounding said copper core and a cross-linked polyethylene material forming an outer layer disposed over said inner layer, said integrally bonded composite insulation having a total wall thickness of less than approximately 0.5 mm and an operative temperature exceeding 135.degree. C. ### Claim 2 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said composite insulation further comprises an intermediate layer disposed between the inner and outer layers, said intermediate layer providing adhesion between said inner layer and said outer layer so as to form a single, integral composite of insulation. ### Claim 3 (depends on 2) The high-temperature, automotive-wire article in accordance with claim 2, wherein said intermediate layer is less than 0.08 mm thick. ### Claim 4 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said polyolefin material is selected from a group consisting of high density polyethylene, metallocene-catalyzed polyolefins, other polyethylene co-polymers, and mixtures thereof. ### Claim 5 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said fluorocarbon polymer material inner layer consists of a fluorocarbon polymer that contains CH.sub.2 groups as part of a polymer chain. ### Claim 6 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said fluorocarbon polymer material of said inner layer consists of a fluorocarbon polymer that contains a CH.sub.2 group as part of a polymer chain and a triallyl isocycanurate monomer, and further wherein the fluorocarbon polymer and polyethylene compound is irradiation cross-linked. ### Claim 7 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said inner layer is selected from a group consisting of: polyether sulfone, polyether-ketone, polyetherimide thermoplastic polyesters, and mixtures thereof. ### Claim 8 (depends on 1) The high-temperature, automotive-wire article in accordance with claim 1, wherein said composite insulation has a total wall thickness in a range of between approximately 0.15 mm and 0.41 mm. ### Claim 9 A high-temperature, automotive-wire article that has an operative temperature exceeding 135.degree. C., comprising: a uncoated copper core; an integrally bonded composite insulation disposed upon said uncoated copper core and comprising a fluorocarbon material forming an inner layer surrounding said copper core and a cross-linked polyethylene material forming an outer layer disposed over said inner layer and integrally bonded thereto by means of an intermediate layer, said integrally bonded composite insulation having a total wall thickness of less than approximately 0.5 mm and meeting the 3,000 hour aging test at 150.degree. C., as specified in ISO-6722. ### Claim 10 (depends on 9) The high-temperature, automotive-wire article in accordance with claim 9, wherein said intermediate layer bonds said inner and outer layers into a single, integral composite of insulation. ### Claim 11 (depends on 10) The high-temperature, automotive-wire article in accordance with claim 10, wherein the intermediate layer bonding said inner and outer layers into a single, integral composite of insulation, comprises an adhesive. ### Claim 12 (depends on 9) The high-temperature, automotive-wire article in accordance with claim 9, wherein said intermediate layer comprises a thickness of approximately less than 0.08 mm. ### Claim 13 (depends on 9) The high-temperature, automotive-wire article in accordance with claim 9, wherein said polyethylene material is selected from a group consisting of: high density polyethylene, metallocenecatalyzed polyolefins, polyethylene co-polymers, and mixtures thereof. ### Claim 14 (depends on 9) The high-temperature, automotive-wire article in accordance with claim 9, wherein said inner layer material is selected from a group consisting of: polyether sulfone, polyetherketone, polyetherimide thermoplastic polyesters, and mixtures thereof. ### Claim 15 (depends on 9) The high-temperature, automotive-wire article in accordance with claim 9, wherein said composite insulation has a total wall thickness of less than approximately 0.5 mm. ### Claim 16 A high-temperature, automotive-wire article that has an operative temperature exceeding 135.degree. C., comprising: a stranded, bare copper wire core; an integrally bonded composite insulation comprising a fluorocarbon material forming an inner layer surrounding said copper core and a cross-linked polyethylene material forming an outer layer disposed over said inner layer with a composite insulation having a total wall thickness of less than approximately 0.5 mm and an operative temperature exceeding 135.degree. C., said cross-linked polyolefin material having been irradiated with between approximately 60 to 400 kGy. ### Claim 17 (depends on 16) The high-temperature, automotive-wire article in accordance with claim 16, wherein said cross-linked polyolefin material is irradiated with between approximately 100 and 200 kGy. ### Claim 18 (depends on 16) The high-temperature, automotive-wire article in accordance with claim 16, wherein said polyethylene material is selected from a group consisting of high density polyethylene, metallocenecatalyzed polyolefins, polyethylene co-polymers, and mixtures thereof. ### Claim 19 (depends on 16) The high-temperature, automotive-wire article in accordance with claim 16, wherein said inner layer material is selected from a group consisting of: polyether sulfone, polyether-ketone, polyetherimide thermoplastic polyesters, and mixtures thereof. ### Claim 20 (depends on 16) The high-temperature, automotive-wire article in accordance with claim 16, wherein said composite insulation has a total wall thickness in a range of between approximately 0.15 mm and 0.41 mm. ### Claim 21 (depends on 16) The high-temperature, automotive-wire article in accordance with claim 16, wherein said cross-linked polyethylene material is preferably irradiated with between approximately 100 and 200 kGy.