WO1992004719A1 - Cable multiconducteur isole en polytetrafluoroethylene et sa fabrication - Google Patents

Cable multiconducteur isole en polytetrafluoroethylene et sa fabrication Download PDF

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Publication number
WO1992004719A1
WO1992004719A1 PCT/US1991/006057 US9106057W WO9204719A1 WO 1992004719 A1 WO1992004719 A1 WO 1992004719A1 US 9106057 W US9106057 W US 9106057W WO 9204719 A1 WO9204719 A1 WO 9204719A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductors
cable
porous
layer
poiytetrafluoroethylene
Prior art date
Application number
PCT/US1991/006057
Other languages
English (en)
Inventor
James George Vana
Paul Revere Warren
Michael Lewis Eckert
Original Assignee
W.L. Gore & Associates, Inc.
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 W.L. Gore & Associates, Inc. filed Critical W.L. Gore & Associates, Inc.
Publication of WO1992004719A1 publication Critical patent/WO1992004719A1/fr

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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
    • H01B7/08—Flat or ribbon cables
    • H01B7/0853—Juxtaposed parallel wires, fixed to each other without a support layer
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401—Optical cables
    • G02B6/4403—Optical cables with ribbon structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/002—Pair constructions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/18—Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/20—Cables having a multiplicity of coaxial lines
    • H01B11/203—Cables having a multiplicity of coaxial lines forming a flat arrangement
    • 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
    • H01B7/08—Flat or ribbon cables
    • H01B7/0876—Flat or ribbon cables comprising twisted pairs

Definitions

  • This invention relates to an improved poiytetrafluoroethylene multiconductor cable and the manufacture thereof.
  • PTFE poiytetrafluoroethylene
  • thermoplastic adhesives such as FEP (a copolymer of tetrafluoroethylene and hexafluoropropylene) to hold the ulticonductors together and maintain their position in a flat plane.
  • Multiconductor flat or ribbon cable having at least one laminating film of PTFE insulation is known in the art.
  • U.S.P. No. 4,000,348 discloses a process to make flat multiconductor cable involving the lamination of fluorocarbon and similar high temperature resins.
  • the patent describes a process for bonding and sintering unsintered extruded polytetrafluoroethylene (PTFE) containing a multiconductor cable with thermoplastic fluorocarbon resins and in turn to other materials including PTFE.
  • PTFE polytetrafluoroethylene
  • U.S.P. No. 4,443,657 discloses a cable construction having a plurality of conductors spaced apart in a planar relationship; a plurality of inner layers each surrounding one of the conductors, the inner layers formed of porous substantially unsintered poiytetrafluoroethylene; a plurality of outer layers each substantially surrounding one of the inner layers, the outer layer being formed of impermeable sintered PTFE; and a plurality of webs, each connecting an outer layer to an adjacent outer layer, each of the webs being formed of impermeable sintered PTFE.
  • a multiconductor cable having a plurality of conductors spaced apart in planar relationship and at least one layer of porous PTFE surrounding each of said conductors as an exterior layer wherein a contact area exists between adjacent exterior layers in which the porous PTFE unites with the porous PTFE of the adjacent exterior layer.
  • the individual conductors may also have several layers of insulation surrounding the conductor and a final exterior layer of porous PTFE then surrounds the insulation.
  • the conductors may be any electrically conductive material, and/or electromagnetic signal transmission fibers.
  • the individual conductors may be color coded.
  • additional embodiments include a multiconductor cable having a plurality of conductors insulated in discrete clusters so that each cluster has two or more conductors surrounded by either an exterior layer of expanded porous PTFE or a first layer of insulation and then an exterior layer of expanded porous PTFE. At least one of the individual conductors comprising each cluster should be insulated prior to the exterior layer of expanded porous PTFE being applied. Additionally, the conductors of a cluster may be twisted together before the exterior layer is applied. Multiple clusters are then united by bonding the exterior layers of expanded porous PTFE together.
  • Another embodiment includes a multiconductor cable comprising a plurality of coaxial cables in which each coaxial cable comprises a conductor surrounded by a dielectric insulating material, a second conductor surrounding the dielectric material and surrounding the second conductor, either an exterior layer of expanded porous PTFE or one or more insulating layers then surrounded by expanded porous PTFE.
  • each coaxial cable comprises a conductor surrounded by a dielectric insulating material, a second conductor surrounding the dielectric material and surrounding the second conductor, either an exterior layer of expanded porous PTFE or one or more insulating layers then surrounded by expanded porous PTFE.
  • a process to make multiconductor cable having the steps of individually surrounding a plurality of conductors with an exterior layer of porous PTFE; aligning said conductors in parallel; pulling said parallel conductors over a curved shoe having a concave groove so that the conductors migrate towards the center of the groove wherein exterior layers of adjacent conductors are forced in contact with each other and are simultaneously heat treated to at least the crystalline melt point of the exterior layer so that a bond forms.
  • Figure 1 is a perspective view of the inventive article.
  • Figure 2 is a magnified schematic cross-sectional view of another embodiment of the invention.
  • Figure 3 is a schematic representation of the process of this invention.
  • Figure 4 is an enlarged perspective view of the shoe shown in Figure 3.
  • Figure 5 is an enlarged end view of the shoe shown in Figure 3.
  • Figure 6 is a photomicrograph (left side) of a cross-section of the multiconductor cable described in Example 1 taken at 50 X magnification and a photomicrograph (right side) of the contact area of the cross-section taken at 1000 X magnification of the cable.
  • Figure 7 is a photomicrograph (left side) of a cross-section of the cable described in Example 2 taken at 100 X magnification and a photomicrograph (right side) of the contact area of the cross-section taken at 1000 X magnification.
  • Figure 8 is a photomicrograph (left side) of a cross-section of the cable described in Example 3 at 50 X magnification and a photomicrograph (right side) of the contact area of the cross-section taken at 500 X magnification.
  • Figure 9 is a schematic representation of an embodiment in which the bonded conductors are twisted together to form a twisted assembly.
  • Figure 10 is a cross-sectional view of the clustered multiconductor cable in which each cluster has two individually insulated conductors.
  • Figure 11 1 s a cross-sectional view of the multiconductor coaxial cable assembly.
  • the cable of the present invention provides for a plurality of conductors, each conductor insulated or surrounded by at least one outer layer of porous poiytetrafluoroethylene (PTFE) preferably porous expanded PTFE and aligned in a planar relationship to form a flat multiconductor cable.
  • PTFE porous poiytetrafluoroethylene
  • the individual conductors with layers of porous PTFE surrounding them are attached to one another by bonds formed between adjacent layers of porous PTFE.
  • the bonds formed between the porous PTFE layers thus eliminates the need for use of adhesives or tapes to bond individual conductors and insulation together.
  • clusters of two or more conductors or coaxial cables may be used instead of single conductors.
  • the resulting cables are lighter than conventional cables.
  • the individual conductors of the cable are also easily separated for stripping, termination and routing. Because no adhesives are used, the inventive cable is not limited to temperature ranges often required for cables where adhesives are used.
  • the multiconductor cable may also be color-coded so that individual conductors may be surrounded by porous PTFE containing a pigment.
  • the cable also maintains desirable signal transmitting properties.
  • the bond strength between the individual conductors depends on the contact area between the conductors.
  • the contact area is the space where the porous PTFE surrounding adjacent conductors are in intimate contact and adhere together along the full length of the conductors. As can be seen from Figure 1, the contact area is shown by the contact plane "y" and the length of the insulated conductor "I.”
  • the contact area is proportional to the size of the wire and is preferably constructed to have dimensions which fall within the following range:
  • the bond strength between adjoining insulated conductors varies proportionally with the contact area.
  • the bonding between adjacent conductors may be intermittent or continuous. In general, the greater the contact area, the greater the bond strength.
  • the bond strength must be strong enough to hold the insulated conductors in their planar position during bonding, flexing and other types of handling. The bond strength need not be excessively high as easy separation of individual insulated conductors from the cable is desirable.
  • the electrical characteristics of the inventive multiconductor cable remain consistent and perform similarly to that of flat ribbon cable.
  • geometric positioning of conductors enables a wide range of transmission line properties such as impedance and capacitance to be achieved with the inventive cable. For example, conventional cables with webs result in a characteristic impedance of about 125 ohms.
  • the inventive cable allows the impedance to be reduced to 100 ohms because of the closer spacing between insulated conductors.
  • the density of the porous PTFE in the contact area may increase to greater than the initial density.
  • the resulting cable may also be twisted using two or more parallel bonded conductors to form a twisted assembly with matched physical and electrical properties.
  • Figure 9 shows an illustration of a twisted assembly in which two insulated conductors 10_, covered by a first layer of insulation H and then by an exterior layer of porous expanded PTFE 12 are bonded together and then twisted to form the assembly.
  • the multiconductor cable includes a plurality of conductors spaced apart in planar relationship.
  • Figure 2 shows a cross-section view of the multiconductor cable 1 that has a plurality of conductors 10 . (four being shown in Figure 2) positioned 1n parallel side-by-side relationship.
  • the conductors 1_Q depicted in Figure 2 are single strand electrical signal carrying bare copper wire.
  • the improved multiconductor cable includes at least one layer of porous poiytetrafluoroethylene (PTFE) 12 surrounding or insulating individual conductors 10. as its outermost layer.
  • PTFE porous poiytetrafluoroethylene
  • the porous PTFE 12 especially suitable for use in Cable 1 is porous expanded PTFE that has been produced by the process described in U.S.P. No. 3,953,566 and has properties described in U.S.P. No. 4,187,390.
  • the layer of porous PTFE used in the construction has not been heat treated to above its crystalline melt point (i.e. unsintered).
  • the multiconductor cable may be comprised of individual conductors 10 that are first surrounded by conventional types of high temperature insulation U such as PTFE, porous PTFE, polyi ide ( apton®), polyetheretherketone, or polyimidesiloxane and then covered by an exterior layer of porous PTFE 12 similar to that described above.
  • U high temperature insulation
  • the outermost (or exterior) layer of the individually insulated conductors be comprised of porous PTFE that has preferably not been heat treated.
  • the method of fabricating the improved multiconductor cable includes first insulating the bare wires with desired layers of insulation of choice.
  • the final, exterior layer of porous PTFE is then applied to the conductor using conventional technology and is preferably wrapped around the conductor.
  • the insulated conductors are then aligned in parallel relationship to one another in area 12 ( Figure 3).
  • the aligned conductors are simultaneously pulled with uniform tension over a shoe having a concave groove.
  • the process can be seen schematically in Figure 3 where the parallel wrapped conductors H - IS are pulled over a shoe 2Q.
  • the shoe 2Q of which a perspective is shown in Figure 4 has a concave region or groove 21 on the exterior side of the shoe over which the conductors pass.
  • the groove causes the insulated conductors to migrate towards each other.
  • Figure 5 shows an end view of the shoe.
  • the conductors merge within the concave region towards each other so that the exterior surfaces of adjacent insulated conductors contact and compress against each other.
  • FIG. 3 shows a cross-sectional view of the multiconductor cable 30 having a plurality of clustered conductors (four being shown in Figure 10) positioned in parallel side by side relationship.
  • the individual clusters 21 shown in Figure 10 each comprises a pair of twisted conductors 3_4» further in which each conductor 5 is insulated with at least one layer of insulation 3J5-
  • a cluster may contain more than two conductors and in fact a preferable embodiment includes the clusters each having three twisted conductors.
  • the individual conductors comprising each cluster may be each covered with a layer of insulation 3 . 6 prior to the application of the exterior layer of expanded porous PTFE.
  • Other embodiments but not shown may include clusters where only one of two conductors are covered with a layer of insulation.
  • Figure 10 also shows that the individual clusters are each surrounded by an exterior layer of expanded porous poiytetrafluoroethylene 3_8_.
  • additional layers of insulation may first surround each cluster before the outermost layer of expanded porous PTFE is applied.
  • small air gaps 3_9_ may be formed when the exterior layers of expanded porous PTFE or plurality of layers of insulation including the exterior layer of expanded porous PTFE is applied around the twisted pair cluster as the layer(s) maintain a circumference around the cluster and do not sag or conform to the exact shape of the twists.
  • Figure 11 shows a cross-sectional view of a multiconductor cable 4Q having a plurality of coaxial cables (four being shown in Figure 11) positioned in parallel side by side relationship.
  • Each of the individual coaxial cables 41 shown in Figure 11 1s comprised of a center conductor 42, a layer of high temperature dielectric material 44. a conductive shield 4£ and an exterior layer of expanded porous poiytetrafluoroethylene 48.
  • the high temperature dielectric material 44 includes materials selected from the group consisting of poiytetrafluoroethylene, polyimide ( apton ⁇ ), polyetheretherketone, polyimidesiloxane and preferably expanded porous poiytetrafluoroethylene sold under the trademark GORE-TEX®, commercially available from W. L.
  • the conductive shield 4£ may be selected from the group consisting of braided wires (woven), served wires (non-woven) that are helically-wrapped about the dielectric material, and a foil with or without a drain wire.
  • the exterior layer of expanded porous poiytetrafluoroethylene serves as a "bonding agent" which forms a bond with the adjacent cables thereby forming a multiconductor coaxial cable.
  • Impedance - 276 / dielectric constant x log [2 x center spacing / (.97 x conductor diameter)]
  • AWG 24(19/36) silver plated copper conductors were used for this example. Each conductor was preinsulated with .006 inches of PTFE and then each helically wrapped with a layer of unsintered expanded PTFE. The wires were pulled side by side over a concave shoe in a salt bath at a temperature of above 370 ⁇ C. Adjacent wires were forced together due to the combined effects of their tensions and the profile of the shoe. Transverse forces caused the layers of expanded PTFE of adjacent wires to compress, changing the geometry of the contact area from a line to a plane.
  • FIG. 6 is a photo micrograph of a cross-section of two adjacent wires in the cable assembly taken at 50 X magnification.
  • the photo on the right ( Figure 6) shows a close-up (at 500 X magnification) of the contact area designated by the rectangle shown on the left photo.
  • AWG 30(19/42) silver plated copper conductors were used for this example. Each conductor was preinsulated with .006 inches of PTFE and then each helically wrapped with a layer of unsintered expanded PTFE. The wires were pulled side by side over a concave shoe in a salt bath at a temperature of above 370 ⁇ C. Adjacent wires were forced together due to the combined effects of their tensions and the profile of the shoe. Transverse forces caused the layers of expanded PTFE of adjacent wires to compress, changing the geometry of the contact area from a line to a plane.
  • the heat of the salt bath caused the expanded PTFE of adjacent wires to coalesce and form a bond strength necessary to keep the wires held together in a single plane.
  • a continuous transverse force was provided to the assembly during heat treatment to ensure a large contact area between wires and to compensate for any shrinkage of the expanded PTFE.
  • Figure 7 The left side of Figure 7 is a photomicrograph of a cross-section of two adjacent wires in the cable assembly taken at 100 X magnification.
  • the photo on the right ( Figure 7) shows a close-up (at 1000 X magnification) of the contact area designated by the rectangle shown on the left photo.
  • Bond Thickness measurements were made with an optical microscope at 50 X magnification equipped with an x-y table and a digital readout. Twenty-one measurements were taken and averaged to determine bond thickness.
  • Each conductor was preinsulated with .015 inches of expanded PTFE and then each helically wrapped with a layer of unsintered expanded PTFE.
  • the wires were pulled side by side over a concave shoe in a salt bath at a temperature of above 370 ⁇ C. Adjacent wires were forced together due to the combined effects of their tension and the profile of the shoe. The transverse force caused the layer of expanded PTFE of adjacent wires to compress, changing the geometry of the contact area from a line to a plane.
  • the heat of the salt bath caused the expanded PTFE of adjacent wires to coalesce and form a bond strength necessary to keep wires held together in a single plane.
  • a continuous transverse force was provided to the assembly during heat treatment to ensure a large contact area between wires and to compensate for the shrinkage of the expanded PTFE.
  • Figure 8 is a photomicrograph showing a cross-section of two adjacent wires in the cable assembly (left side) taken at 50 X and a close-up of the contact area (right side) at 500 X magnification designated by the rectangle shown on the left photo.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Insulated Conductors (AREA)

Abstract

Câble multiconducteur comportant des conducteurs isolés séparables. Ledit câble comprend une pluralité de conducteurs isolés espacés dans un plan. Au moins la couche extérieure est en PTFE poreux. Une zone de contact existe entre les couches extérieures adjacentes, de sorte que les conducteurs isolés adjacents se lient les uns aux autres. On décrit également un câble multiconducteur comprenant une pluralité de conducteurs isolés en grappes discrètes, chacune des grappes étant entourée d'une couche extérieure en PTFE poreux expansé qui forme une liaison avec la couche extérieure adjacente. On décrit en outre un câble multiconducteur comprenant des câbles coaxiaux qui sont liés ensemble par la couche extérieure de PTFE poreux expansé. De plus, la présente invention a trait au procédé de fabrication dudit câble multiconducteur.
PCT/US1991/006057 1990-08-29 1991-08-23 Cable multiconducteur isole en polytetrafluoroethylene et sa fabrication WO1992004719A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
USNOTFURNISHED 1987-05-22
US57470490A 1990-08-29 1990-08-29
US574,704 1990-08-29

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WO1992004719A1 true WO1992004719A1 (fr) 1992-03-19

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5286924A (en) * 1991-09-27 1994-02-15 Minnesota Mining And Manufacturing Company Mass terminable cable
US5306869A (en) * 1991-09-27 1994-04-26 Minnesota Mining And Manufacturing Company Ribbon cable construction
WO2014042714A3 (fr) * 2012-05-31 2014-05-08 Corning Cable Systems Llc Alignement angulaire de fibres optiques pour câbles rubans à fibres optiques, et procédés associés
US10001597B2 (en) 2015-09-22 2018-06-19 Corning Incorporated Multicore optical fibers and interconnection methods for the same

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1937372A1 (de) * 1968-07-24 1970-06-11 Cotton Silk & Man Made Fibres Verfahren zur Nassbehandlung von Warenbahnen
FR2036798A1 (en) * 1969-04-02 1970-12-31 Fileca Flat multi-conductor insulated cable
DE2203531A1 (de) * 1972-01-21 1973-07-26 Siemens Ag Verfahren zur herstellung von flachleitungen mit einer isolierung oder umhuellung aus polytetrafluoraethylen
US4359597A (en) * 1976-09-22 1982-11-16 Eltra Corporation Twisted pair multi-conductor ribbon cable with intermittent straight sections
US4412092A (en) * 1981-08-24 1983-10-25 W. L. Gore & Associates, Inc. Multiconductor coaxial cable assembly and method of fabrication
DE8405418U1 (de) * 1984-02-22 1984-06-14 W.L.Gore & Co GmbH, 8011 Putzbrunn Rundleiterbandkabel
US4645868A (en) * 1984-04-18 1987-02-24 Junkosha Company, Ltd. Electrical transmission line
JPH0298013A (ja) * 1988-10-03 1990-04-10 Fujikura Ltd ４ふっ化エチレン樹脂フラットケーブル及びその製造方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1937372A1 (de) * 1968-07-24 1970-06-11 Cotton Silk & Man Made Fibres Verfahren zur Nassbehandlung von Warenbahnen
FR2036798A1 (en) * 1969-04-02 1970-12-31 Fileca Flat multi-conductor insulated cable
DE2203531A1 (de) * 1972-01-21 1973-07-26 Siemens Ag Verfahren zur herstellung von flachleitungen mit einer isolierung oder umhuellung aus polytetrafluoraethylen
US4359597A (en) * 1976-09-22 1982-11-16 Eltra Corporation Twisted pair multi-conductor ribbon cable with intermittent straight sections
US4412092A (en) * 1981-08-24 1983-10-25 W. L. Gore & Associates, Inc. Multiconductor coaxial cable assembly and method of fabrication
DE8405418U1 (de) * 1984-02-22 1984-06-14 W.L.Gore & Co GmbH, 8011 Putzbrunn Rundleiterbandkabel
US4645868A (en) * 1984-04-18 1987-02-24 Junkosha Company, Ltd. Electrical transmission line
JPH0298013A (ja) * 1988-10-03 1990-04-10 Fujikura Ltd ４ふっ化エチレン樹脂フラットケーブル及びその製造方法

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5286924A (en) * 1991-09-27 1994-02-15 Minnesota Mining And Manufacturing Company Mass terminable cable
US5306869A (en) * 1991-09-27 1994-04-26 Minnesota Mining And Manufacturing Company Ribbon cable construction
WO2014042714A3 (fr) * 2012-05-31 2014-05-08 Corning Cable Systems Llc Alignement angulaire de fibres optiques pour câbles rubans à fibres optiques, et procédés associés
CN104620146A (zh) * 2012-05-31 2015-05-13 康宁光电通信有限责任公司 用于光纤带状电缆的光纤的角对准、和相关方法
US9057815B2 (en) 2012-05-31 2015-06-16 Corning Cable Systems Llc Angular alignment of optical fibers for fiber optic ribbon cables, and related methods
US10001597B2 (en) 2015-09-22 2018-06-19 Corning Incorporated Multicore optical fibers and interconnection methods for the same

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