# US 7,408,117 B2 · Three-dimensional moulded planar cable, method for production and use thereof

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 7,408,117 B2
- Document ID: US7408117B2
- Status: Granted
- Kind: B2
- Application number: 10/537,082
- Filed: 2003-09-10
- Published: 2006-06-22
- Granted: 2008-08-05
- Earliest claimed: 2002-12-02
- Assignees: Carl Freudenberg KG
- Inventors: Denis Reibel; Thorsten Frank
- Web page: https://patentgrep.com/patent/US7408117B2

## CPC

- H01B 7/0838: {Parallel wires, sandwiched between two insulating layers}
- H01B 7/08: Flat or ribbon cables
- 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

A three-dimensional moulded planar cable, includes a laminate made from at least one conductor track, bonded between two insulation layers and at least one support layer, connected to each other by an adhesive layer. The cable is applied to a positive moulding tool, brought into shape by the application of heat and/or radiation and/or pressure and fixed in the three-dimensional shape thereof by cooling to below the glass temperature Tg of the adhesive layer or by hardening of the adhesive layer.

## Claims

### Claim 1

A three-dimensionally shaped flat cable comprising:
a laminate including at least one conductor track enclosed between two insulation layers, an adhesive layer, and at least one support layer, the support layer connected to at least one of the insulation layers via the adhesive layer, the laminate being applied to a positive die and shaped by applying one of heat, radiation and pressure and fixed in a three-dimensional shape by cooling to below the glass transition temperature of the adhesive layer or by hardening the adhesive layer.

### Claim 2 (depends on 1)

The flat cable as recited in claim 1 wherein the support layer is made of a metal foil or a plastic sheet.

### Claim 3 (depends on 1)

The flat cable as recited in claim 1 wherein the support layer is a porous layer.

### Claim 4 (depends on 3)

The flat cable as recited in claim 3 wherein an additional porous layer is provided for covering for better handling.

### Claim 5 (depends on 4)

The flat cable as recited in claim 4 wherein the porous layer is made of a nonwoven or a fabric of polymer fibers.

### Claim 6 (depends on 1)

The flat cable as recited claim 1 wherein the adhesive layer is composed of an at least one of thermoplastic adhesive, an adhesive foil and an adhesive-bonded nonwoven having a melting point Tm of <180° C. or a latent reactive adhesive having a cross-linking temperature of <140° C.

### Claim 7 (depends on 1)

The flat cable as recited claim 1 wherein the flat cable is at least partially back-coated using a thermoplastic.

### Claim 8 (depends on 1)

The flat cable as recited claim 1 wherein the conductors of the conductor track are exposed at least in partial sections of their surface prior to lamination for forming contact fields.

### Claim 9 (depends on 1)

The flat cable as recited in claim 1 wherein the flat cable is fitted with electronic components.

### Claim 10

A method for manufacturing a dimensionally stable flat cable comprising:
applying to a positive die, adjusted at room temperature, a laminate, the laminate including (a) a conductor track enclosed between two insulation layers, (b) an adhesive layer, and (c) a support layer connected to at least one of the insulation layers via the adhesive layer, each of (a), (b) and (c) defining a laminate component, or applying a positive die separately to all components for the laminate, and
shaping the laminate or the components with the aid of at least one of heat, radiation and pressure; and
fixing the laminate or the component shape by cooling to below the glass transition temperature Tg of the adhesive layer or by hardening the adhesive layer.

### Claim 11 (depends on 10)

The method as recited in claim 10 wherein for equalizing the temperature, a metal foil is used during the laminating process and/or in the die.

### Claim 12 (depends on 10)

The method as recited in claim 10 wherein the laminate components, fixed in their shape, are installed in a separate step or are back-coated in an injection molding process using a thermoplastic.

### Claim 13

A three-dimensionally shaped flat cable comprising:
a laminate including a flexible flat cable, an adhesive layer, and at least one support layer, the support layer connected to the flexible flat cable via the adhesive layer, the laminate being applied to a positive die and shaped by applying one of heat, radiation and pressure and fixed in a three-dimensional shape by cooling to below the glass transition temperature of the adhesive layer or by hardening the adhesive layer.

### Claim 14 (depends on 1)

The flat cable as recited in claim 1 wherein the laminate is fixed with respect to the die.