# US 6,359,230 B1 · Automotive-wire insulation

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- Number: US 6,359,230 B1
- Document ID: US6359230B1
- Status: Granted
- Kind: B1
- Application number: 09/468,432
- Filed: 1999-12-21
- Granted: 2002-03-19
- Earliest claimed: 1999-12-21
- Assignees: Champlain Cable Corporation
- Inventors: Nelson Hildreth
- Web page: https://patentgrep.com/patent/US6359230B1

## CPC

- H01B 3/441: {from alkenes}
- H01B 7/292: {using material resistant to heat}
- 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})

## Abstract

The invention pertains to multi-layer polymeric formulations for protecting or insulating metallic objects, and, more particularly, to an integrated, tri-layer, thin-wall insulation composite, for use in a high temperature, automotive-wire article. The tri-layer design comprises an inner layer of a fluoropolymer, polyether sulfone, polyether-ketone, polyetherimide, or thermoplastic polyester; a middle layer comprising a polyolefin; and an outer layer comprising a fluoropolymer. The inner and outer layers serve to protect the middle polyolefinic layer from degradation.

## Claims

### Claim 1

A composite article for use in harsh, automotive, under-the-hood environments, comprising at least one metal core having an exposed surface, a first polymeric layer comprising a fluorocarbon polymeric material disposed on said exposed surface, a second polymeric layer comprising a polyolefin disposed on said first polymeric layer, and a third polymeric layer comprising a first fluorinated polyolefin disposed on said second polymeric layer, and wherein at least one layer selected from said first polymeric, said second polymeric, and said third polymeric layers is oxidation resistant.

### Claim 2 (depends on 1)

The composite article recited in claim 1, said metal core comprising metals selected from the group of elements consisting of Group VIIIA, IB, IIB, IIIB, IVB, and combinations thereof of the periodic table of elements.

### Claim 3 (depends on 2)

The composite article recited in claim 2, wherein said elements comprise copper and its alloys selected from said Group VIIIA, IB, IIB, IIIB, and IVB of the periodic table of elements.

### Claim 4 (depends on 3)

The composite article recited in claim 3, wherein said copper is soft annealed copper.

### Claim 5 (depends on 3)

The composite article recited in claim 3, wherein said copper is hard unannealed copper.

### Claim 6 (depends on 1)

The composite article recited in claim 1, said at least one metal core having a form selected from the group consisting of an ingot, a sheet, a hollow tube, a solid wire, multiple individual wires, and multiple associated strands.

### Claim 7 (depends on 6)

The composite article recited in claim 6, said first, second and third polymer layers form concentric layers around said exposed surface of said solid wire.

### Claim 8 (depends on 6)

The composite article recited in claim 6, wherein said multiple individual wires are individually coated with said first polymer layer, a plurality of coated said individual wires being separately disposed within said second polymer layer and said third polymer layer covering said second polymer layer.

### Claim 9 (depends on 6)

The composite article recited in claim 6, wherein said individual wires are individually coated with said first polymer and said second polymer layers, wherein coated said individual wires are separately disposed within said third polymer layer.

### Claim 10 (depends on 6)

The composite article recited in claim 6, wherein said at least one metal core is in the form of said ingot and said exposed surface is essentially flat.

### Claim 11 (depends on 6)

The composite article recited in claim 6, wherein said at least one metal core is in the form of a sheet and said exposed surface is essentially flat.

### Claim 12 (depends on 6)

The composite article recited in claim 6, wherein said at least one metal core is in the form of a hollow tube and said exposed surface is an inner surface of said tube.

### Claim 13 (depends on 6)

The composite article recited in claim 6, wherein said at least one metal core is in the form of a hollow tube and said exposed surface is an outer surface of said tube.

### Claim 14 (depends on 1)

The composite article recited in claim 1, wherein said at least one metal core comprising a first metal member and a second metal member affixed to said first metal member, said second metal member separating said first metal member from said first polymeric layer.

### Claim 15 (depends on 14)

The composite article recited in claim 14, said first metal member comprising a wire structure and said second metal member concentrically disposed on said first metal member.

### Claim 16 (depends on 15)

The composite article recited in claim 15, comprising copper or its alloys from said Group VIIIA, IB, IIB, IIIB, and IVB of the periodic table of elements in at least one of said first metal member or second metal member.

### Claim 17 (depends on 1)

The composite article recited in claim 1, wherein said fluorocarbon polymeric material is selected from a group consisting of: polyether sulfone, polyether-ketone, polyetherimide thermoplastic polyester, a second fluorinated polyolefin, and mixtures thereof.

### Claim 18 (depends on 17)

The composite article recited in claim 17, said second fluorinated polyolefin comprising at least one methylene group within the backbone of said second fluorinated polyolefin.

### Claim 19 (depends on 17)

The composite article recited in claim 17, wherein said second fluorinated polyolefin is derived from ethylene and at least one of vinylidene fluoride, trifluoroethylene, tetrafluoroethylene and hexafluoropropylene monomer.

### Claim 20 (depends on 17)

The composite article recited in claim 17, wherein said second fluorinated polyolefin comprises homopolymers, copolymers and terpolymers derived from vinylidene difluoride monomer.

### Claim 21 (depends on 20)

The composite article recited in claim 20, wherein said copolymers and terpolymers are further derived from at least one of tetrafluoroethylene and hexafluoropropylene monomers.

### Claim 22 (depends on 1)

The composite article recited in claim 1, wherein said polyolefin comprises high density polyethylene, metallocene-catalyzed polyolefins, polyethylene co-polymers, and mixtures thereof.

### Claim 23 (depends on 22)

The composite article recited in claim 22, wherein said polyethylene co-polymers comprise vinyl acetate, methyl acrylate, ethyl acrylate, butyl acrylate and metal salts of methacrylic acid.

### Claim 24 (depends on 1)

The composite article recited in claim 1, wherein said first fluorinated polyolefin is selected from the group consisting of a copolymer of ethylene and chlorotrifluoroethylene; a copolymer comprising hexafluoropropylene, a homopolymer of vinylidene difluoride; a copolymer of ethylene and tetrafluoroethylene; a homopolymer of tetrafluoroethylene; and a terpolymer of tetrafluoroethylene, vinylidene fluoride and hexafluoropropylene.

### Claim 25 (depends on 24)

The composite article recited in claim 24, wherein said first fluorinated polyolefin is intermolecularly crosslinked.

### Claim 26 (depends on 1)

The composite article recited in claim 1, wherein at least one of said fluorocarbon polymeric material, said polyolefin and said first fluorinated polyolefin are intermolecularly crosslinked within said first, second, and third layer respectively.

### Claim 27 (depends on 26)

The composite article recited in claim 26, wherein said intermolecular crosslinking is achieved by electron beam irradiation.

### Claim 28 (depends on 27)

The composite article recited in claim 27, wherein said electron beam irradiation is performed at about 50 to 500 kGy.

### Claim 29 (depends on 27)

The composite article recited in claim 27, wherein said electron beam irradiation is performed at about 100 to 200 kGy.

### Claim 30 (depends on 27)

The composite article recited in claim 27, further comprises a radical generating compound selected from the group consisting of triallyl isocyanurate, triallylcyanurate, trimethylpropane trimethacrylate, decamethylene glycol dimethacrylate, divinylbenzene, diallylphthalate, diallyl maleate, pentaerythritol triacrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, or mixtures thereof.

### Claim 31 (depends on 1)

The composite article recited in claim 1, wherein at least one layer selected from said first polymeric and said third polymeric layers further comprise antimony oxide or zinc oxide.

### Claim 32 (depends on 1)

The composite article recited in claim 1, wherein at least one layer selected from said first polymeric, said second polymeric and said third polymeric layers further comprise a hindered phenolic antioxidant.

### Claim 33 (depends on 1)

The composite article recited in claim 1, wherein said second polymeric layer further comprises zinc salt of 2-methylmercaptobenzimidazole.

### Claim 34 (depends on 1)

The composite article recited in claim 1, further comprising at least one adhesion-promoting layer between adjacent layers of said first, second, and third polymeric layers.

### Claim 35 (depends on 34)

The composite article as recited in claim 34, wherein said adhesion-promoting layer is less than 0.08 mm thick.

### Claim 36

A high-temperature, automotive-wire article having an operative temperature exceeding that of at least 145° C., comprising:
an uncoated copper core; and
an integrally bonded composite insulation disposed over said uncoated copper core, comprising a fluorocarbon material forming an inner layer surrounding said copper core, a polyethylene material forming an intermediary layer disposed over said inner layer, and a second fluorocarbon material forming an outer layer disposed over said intermediary layer, said integrally bonded composite insulation having a total wall thickness of less than approximately 0.5 mm and an operative temperature exceeding 145° C.

### Claim 37 (depends on 36)

The automotive wire recited in claim 36 wherein at least one of said layers is irradiated by an electron beam.