ADHESIVE TAPE FOR JACKETING ELONGATED ITEMS SUCH AS MORE PARTICULARLY CABLE HARNESSES AND METHOD FOR JACKETING

Abstract

The invention relates to adhesive tape, especially for lengthwise jacketing of elongate items such as cable harnesses in a motor vehicle, comprising a carrier having a top side and a bottom side, where the carrier, based on the cross direction, has a width BT, and at least one layer of adhesive applied on the bottom side of the carrier, the adhesive layer bearing a second carrier, the first carrier with the adhesive layer protrudes at least on one long edge relative to a side edge of the second carrier, where the first protrusion has a width of B.sub.start, characterized in that the first carrier is a woven fabric or a nonwoven fabric and the second carrier is a metallic layer, and the first carrier has a basis weight of 50 g/m2 to 600 g/m2.

Claims

1. An adhesive tape comprising (A) a carrier having a top side and a bottom side, the carrier, based on a cross direction, having a width B.sub.T, and (B) at least one layer of adhesive applied on the bottom side of the carrier, the adhesive layer bearing a second carrier, the first carrier with the adhesive layer protruding at least on one long edge relative to a side edge of the second carrier, where a first protrusion of the first carrier has a width of B.sub.start, wherein the first carrier is a woven fabric or a nonwoven fabric and the second carrier is a metallic layer, and the first carrier has a basis weight of 50 g/m.sup.2 to 600 g/m.sup.2.

2. Adhesive tape according to claim 1, wherein a width B.sub.Protect of the second carrier on the adhesive layer is selected such that the width B.sub.protect is lower than the width B.sub.T of the first carrier such that the first carrier with the adhesive layer protrudes two-sidedly relative to side edges of the second carrier, so as to form a second protrusion having a width B.sub.Wrap.

3. Adhesive tape according to claim 1, wherein the width B.sub.Protect of the second carrier on the adhesive layer is selected such that the second carrier protrudes relative to a second side edge of the first carrier with the adhesive layer, so as to form a second protrusion having a width B.sub.Flag.

4. Adhesive tape according to claim 1, wherein B.sub.start has a width of 3 to 20 mm, B.sub.Protect has a width of 50 to 200 mm, B.sub.Wrap has a width of 50 to 200 mm, and/or B.sub.Flag has a width of 50 to 200 mm.

5. Adhesive tape according to claim 1, wherein the construction of the woven fabric is as follows: the warp thread count is 10 to 60/cm the weft thread count is 10 to 40/cm the warp threads possess a yarn weight between 40 and 400 dtex, the weft threads possess a yarn weight between 40 and 660 dtex.

6. Adhesive tape according to claim 1, wherein the nonwoven fabric is a spunbonded web.

7. Adhesive tape according to claim 1, wherein the adhesive has a coatweight, based on an area of the carrier between 40 and 160 g/m.sup.2.

8. Adhesive tape according to claim 1, wherein the metallic layer used comprises aluminium foil having a thickness of 15 to 100 μm, copper foil having a thickness of 10 to 80 μm, stainless steel foil having a thickness of 10 to 60 μm, layer laminates of a polymeric film and metallic surface, metallized woven or nonwoven fabrics.

9. Adhesive tape according to claim 1, wherein an acrylate-based adhesive is used as adhesive.

10. Adhesive tape according to claim 1, wherein at least one marker line extending in a longitudinal direction is present on the top side of the first carrier.

11. A method of jacketing elongate items with an adhesive tape, said method comprising enveloping the elongate item with an adhesive tape according to claim 1 in an axial direction.

12. An elongate item jacketed with an adhesive tape according to claim 1.

13. A vehicle comprising a jacketed elongate item according to claim 12.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0194] The intention of the text below is to illustrate the invention in more detail with reference to a number of figures, without thereby wishing to restrict the invention unnecessarily.

[0195] FIG. 1 shows the method of abrasion measurement (detailed explanations are given below),

[0196] FIGS. 2a, 2b and 2c show variants of cars with hybrid or electric drive, featuring a cable harness jacketed with the adhesive tape of the invention,

[0197] FIGS. 3a, 3b and 3c show the adhesive tape in different forms in lateral section,

[0198] FIGS. 4a and 4b show longitudinal bandaging of the cable loom with an adhesive tape as in FIG. 3a, where the metallic layer (a) does not or (b) does form a ring closure,

[0199] FIGS. 5a and 5b show longitudinal bandaging of the cable loom with an adhesive tape as per FIG. 3b, where (a) the metallic layer forms a ring closure or (b) there is a drain line in the metallic layer,

[0200] FIG. 6 shows the results of attenuation measurements.

[0201] FIGS. 2a, 2b and 2c show vehicles with different drive concepts. The individual components within the vehicle are connected by cables.

[0202] FIG. 2a shows a hybrid vehicle 201, HEV, FIG. 2b a plug-in hybrid 201, PHEV.

[0203] Both concepts have a high-voltage battery 204, from which the current is passed via a high-voltage lead harness to an inverter 203 and then further via a motor lead harness 205 to the electric motor 202. The high-voltage lead harness 206 is jacketed with the adhesive tape of the invention.

[0204] In contrast to the HEV, the PHEV additionally has a charging current connection 207, allowing the high-voltage battery 204 to be charged by way of a further inverter 203. In the case of the conventional electric vehicle 201, BEV, as in FIG. 2c, there is a high-voltage battery 204, which can be charged via a high-voltage lead harness 206, jacketed with the adhesive tape of the invention, from the charging current connection 207.

[0205] FIG. 3a shows the variant of the adhesive tape in which the width B.sub.Protect of the second carrier in the form of the metallic layer 303 on the adhesive layer 302 is selected such that the width B.sub.Protect is less than the width B.sub.T of the first carrier 301, specifically such that the first carrier 301 protrudes, with the adhesive layer 302 applied preferably over the full area, on both sides relative to the side edges of the second carrier 303, to form a second protrusion having a width B.sub.Wrap.

[0206] The adhesive tape according to FIG. 3a has a first carrier 301 of woven fabric with a width B.sub.T. On the top side of the first carrier 301 there are two marker lines (marker line start 304, marker line end 305) disposed above the long edges of the second carrier 303.

[0207] Applied on the bottom side of the first carrier 301, over the full area, is an adhesive 302. Applied beneath the adhesive 302 is the second carrier 303, which has a lower width B.sub.Protect than the first carrier 301. The second carrier 303 leaves two stripes of adhesive free on either side, with the respective widths B.sub.start and B.sub.Wrap.

[0208] The first stripe of adhesive is used for preliminary securement, while the second secures the adhesive tape after wrapping.

[0209] FIG. 3b shows the (second) variant of the adhesive tape, wherein the width B.sub.Protect of the second carrier in the form of the metallic layer 303 on the adhesive layer 302, applied preferably over the full area, is selected such that the second carrier 303 protrudes with the adhesive layer 302 relative to the second side edge of the first carrier 301, to form a second protrusion having a width B.sub.Flag.

[0210] The width B.sub.protect selected for the second carrier 303 is (slightly) greater than the width B.sub.T of the first carrier 301, and so the width B.sub.start of the first protrusion is less than the width B.sub.Flag of the second protrusion.

[0211] FIG. 3c shows the adhesive tape according to FIG. 3a, but the layer 302 of adhesive is not applied over the full area of the first carrier 301; instead, there are two adhesive-free stripes in the layer 302, these stripes being located above the second carrier 303. This makes the adhesive tape more flexible.

[0212] In FIG. 4a the adhesive tape as per FIG. 3a is wrapped axially—that is, in the form of an Archimedean spiral, around a cable harness 306, so that the latter is completely surrounded (360°).

[0213] The second carrier 303 leaves two stripes of adhesive free on either side, with the respective widths B.sub.start and B.sub.Wrap. The first stripe of adhesive with width B.sub.start serves for preliminary securement of the adhesive tape on the cable harness 306. The cable harness 306 is then wrapped such that there is an overlap 307 for sealing the adhesive tape, said overlap 307 having the width B.sub.Wrap.

[0214] The jacketing is carried out such that the metallic layer 303 does not form a ring closure.

[0215] In FIG. 4b the adhesive tape as per FIG. 3a is wrapped likewise axially—that is, in the form of an Archimedean spiral, around a cable harness 306, so that the latter is completely surrounded (360°).

[0216] The second carrier 303 leaves two stripes of adhesive free on either side, with the respective widths B.sub.start and B.sub.Wrap. The first stripe of adhesive with width B.sub.start serves for preliminary securement of the adhesive tape on the cable harness 306. The cable harness 306 is then wrapped such that there is an overlap 307 for sealing the adhesive tape, said overlap 307 having the width B.sub.Wrap.

[0217] The jacketing this time is performed such that the metallic layer 303 does form a ring closure and there is therefore a contact area 308.

[0218] In FIG. 5a the adhesive tape as per FIG. 3b is wrapped axially—that is, in the form of an Archimedean spiral, around a cable harness 306, so that the latter is completely surrounded (360°).

[0219] The second carrier 303 protrudes relative to the second side edge of the first carrier 301 with the adhesive layer 302, to form a second protrusion 303a having a width B.sub.Flag. Before the cable loom 306 is wrapped, the second protrusion 303a is folded over the second edge of the first carrier 301, so that the second side edge is surrounded by the metallic layer 303.

[0220] The jacketing is then performed such that the metallic layer 303 forms a ring closure via the contact area 308.

[0221] In FIG. 5b the adhesive tape as per FIG. 3b is wrapped likewise axially—that is, in the form of an Archimedean spiral, around a cable harness 306, so that the latter is completely surrounded (360°).

[0222] The second carrier 303 protrudes relative to the second side edge of the first carrier 301 with the adhesive layer 302, to form a second protrusion 303a having a width B.sub.Flag. Before the cable loom 306 is wrapped, the second protrusion 303a is folded around an uninsulated drain line 309, so that the drain line 309 is surrounded by the metallic layer 303.

[0223] The jacketing is then preferably performed such that the metallic layer 303 additionally forms a ring closure via the contact area 308.

Implementation of the Tests

[0224] Unless expressly stated otherwise, the measurements are carried out under test conditions of 23±1° C. and 50±5% relative humidity.

Abrasion Resistance of an Adhesive Tape

[0225] Within the motor vehicle industry, adhesive tapes for cable jacketing are tested and classified in accordance with extensive bodies of standards such as, for example, the VW 60360-3 “Protective systems for wiring harnesses in motor vehicles, Test requirements for hoses” (2019-05), the BMW GS 95008-3-1 “Protective systems for wiring harnesses in motor vehicles, Adhesive tapes, Requirements, Tests” or the ES-KU5T-1A303-AA rev. E (2017/06) “Harness Tape Performance Specification”. These standards are referred to below in abbreviated form as the VW, BMW and Ford specifications, respectively.

[0226] The abrasion resistance of an adhesive tape and protective hose is determined by BMW and VW likewise on the basis of a defined test method. The classification of the adhesive tapes and hoses in terms of their abrasion resistance is shown in Table 1 (classification of adhesive tape abrasion resistance to BMW GS 95008-3-1) for a mandrel diameter of 5 mm; adhesive tapes and hoses are arranged according to identical abrasion classes, and hoses may additionally be tested at an elevated ambient temperature (see Table 2: Classification of hose abrasion resistance to VW 60360-3).

TABLE-US-00001 TABLE 1 Classification of adhesive tape abrasion resistance to BMW GS 95008-3-1 Abrasion class (at RT) Requirement A no abrasion protection <100 double strokes B little abrasion protection 100 to 499 double strokes C moderate abrasion protection 500 to 999 double strokes D high abrasion protection 1000 to 4999 double strokes E very high abrasion protection 5000 to 14999 double strokes F extremely high abrasion protection 15000 to 29999 double strokes G Abrasion protection for special ≥30000 double strokes applications

TABLE-US-00002 TABLE 2 Classification of hose abrasion resistance to VW 60360-3 Abrasion class At At At RT 40° C. 90° C. Requirement A AT40 AT90 no abrasion <100 double strokes protection B BT40 BT90 little abrasion 100 to 499 double protection strokes C CT40 CT90 moderate abrasion 500 to 999 double protection strokes D DT40 DT90 high abrasion 1000 to 4999 double protection strokes E ET40 ET90 very high abrasion 5000 to 14999 double protection strokes F FT40 FT90 extremely high abrasion 15000 to 29999 double protection strokes G GT40 GT90 abrasion protection for ≥30000 double special applications strokes

[0227] The test element 103, with a length of 10 cm, is wound as a single ply around a 5 mm thick steel mandrel 102, in the lengthwise direction of the product under test, and placed in a sample holder 101. The test element 103 is held down by a hold-down element 104. In the case of an adhesive tape system which is not the same over the full area, the part tested for abrasion is that which constitutes the protective function in use. The abrading tool is a steel wire 105 0.45 mm in diameter, which is caused to rub centrally over the test element 103 under a weight loading of 7 N (generated by an applied weight 106), with a drive 108 causing the steel wire to move back and forth in a cyclical movement 107 parallel to the axis of the steel mandrel 102. The numerical parameter for the abrasion properties is the number of double strokes performed until the test element 103 is destroyed.

[0228] Measurement of the abrasion resistance permits simulation of the resistance to relatively sharp objects such as a metal edge in the application, for example.

[0229] The method of abrasion measurement is shown in FIG. 1.

Bending Force

[0230] Measurement of the suppleness is a key quality feature of textiles, leather, paper and plastics having flexurally slack properties. The testing of the bending force, by the softometer method, serves to determine the suppleness or stiffness of the sheetlike materials in a comparable way, under specified conditions.

[0231] For determining the bending force on an expanse of textile, a sample specimen measuring 75×60 mm is punched out. A rotatably mounted sample holder comprising two parallel plates secures the punched-out sample over an area of 60×60 mm. The sample holder with the sample is pivoted against a force sensor, so that the portion of the sample that is not clamped in, with a length of 15 mm, is bent by 30°. The bending force required in this position is measured after a measuring time of 10 s as the bending force in the unit mN. To describe the textile properties, a sample can be punched out in machine and cross directions and also, if the application requires it, in a diagonal direction, for the measurement. The extension in the direction of the sample side 75 mm long in this case also describes the bending direction which is to be assessed.

[0232] Flexural stiffness, MD: the longer side of the test specimen extends parallel to the machine direction of the material or warp direction of the woven fabric

[0233] Flexural stiffness, CD: the longer side of the test specimen extends at right angles to the machine direction of the material or warp direction of the woven fabric

[0234] In all cases, the direction of bending of the test specimen corresponds to the subsequent use of the adhesive tape—that is, the material with EMC protective function faces the leads of the cable harness.

[0235] With regard to the basis weight, the twin-ply region is contemplated; single-ply edge regions have the holding and securing function.

Electromagnetic Shielding/Attenuation

[0236] The high-voltage jacketed leads with braided shielding are used for supplying electrical drives in motor vehicles. The properties of such leads are determined by testing according to BMW standard GS 95007-6-2. The high-frequency properties and the attenuation provided by the surrounding shield are performed in the frequency range from 100 Hz to 200 MHz. The use of other materials as a substitute or as a supplement to the known braided shields is measured and evaluated for high-frequency capacity by comparison with these. The test is carried out using a high-voltage lead with a lead cross section of 35 mm.sup.2. The test lead is provided with a shield, applied to the lead over a length of 100 cm, and secured in an electrically conducting manner at both ends. Measurement generators (transmitters) installed in the network analyzer feed the object of measurement and at the same time capture the changes in signal occurring via the measurement receiver in the network analyzer, in the frequency range from 100 Hz to 30 MHz the attenuation (measured in dB) provided by the shield used around the high-voltage lead is measured.

EXAMPLES

Outline of the Examples

[0237] The adhesive tape of the invention is described below in a preferred embodiment by means of a number of examples, without any intention thereby to subject the invention to any restriction whatsoever.

[0238] In addition, a comparative example is given, which shows an unsuitable adhesive tape.

TABLE-US-00003 A B C D E Material type Woven PET — — Woven PET Woven PET adhesive tape adhesive tape adhesive tape adhesive tape Material type — Aluminium Aluminium Aluminium Aluminium EMC adhesive tape adhesive tape adhesive tape adhesive tape protection (B) (C) Basis weight 230 115 250 345 480 [g/m.sup.2] Thickness 260 65 125 325 385 [μm] Flexural 16.1 48 290 134 395 stiffness MD [mN] Flexural 5.4 49 301 118 388 stiffness CD [mN] Abrasion 1268 30 394 1423 1857 5 mm mandrel [double strokes] Attenuation in 2 0 0 2 2 [db(A)] F G H I Material type — — Woven PET Woven PET adhesive tape fabric fabric Material type Spunbonded PET, Woven PET Nonwoven Woven fabric EMC metal-coated Ripstop fabric, (F) (G) protection metal-coated Basis weight 85 80 315 310 [g/m.sup.2] Thickness 130 92 380 350 [μm] Flexural 74 22 211 130 stiffness MD [mN] Flexural 67 21 185 108 stiffness CD [mN] Abrasion 122 427 1678 2236 5 mm mandrel [double strokes] Attenuation in 1 1 2.5 2 [db(A)] J K L Material type Nonwoven PET Nonwoven PET Nonwoven PET adhesive tape adhesive tape adhesive tape adhesive tape Material type — Aluminium Nonwoven EMC adhesive tape (F) protection (B) Basis weight 140 255 325 [g/m.sup.2] Thickness 250 195 260 [μm] Flexural 2.5 51 76 stiffness MD [mN] Flexural 4.0 54 70 stiffness CD [mN] Abrasion 110 223 205 5 mm mandrel [double strokes] Attenuation in 6.0 6.0 6.5 [db(A)] Flexural stiffness, MD: the longer side of the test specimen extends parallel to the machine direction of the material or warp direction of the woven fabric Flexural stiffness, CD: the longer side of the test specimen extends at right angles to the machine direction of the material or warp direction of the woven fabric

[0239] The direction of bending of the test specimen corresponds in all cases to the subsequent use of the adhesive tape; that is, the material with EMC protective function faces the leads of the cable harness.

[0240] With regard to basis weight, the double-ply region is contemplated; single-ply edge regions have the holding function and securing function.

[0241] The results of the attenuation measurement are reported in FIG. 6.

[0242] It is apparent that the attenuation achieves the values for a braided shield in the case of longitudinal bandaging. The attenuation values in the case of spiral bandaging are lower.

LIST OF REFERENCE SYMBOLS

[0243] 101 Sample holder [0244] 102 Steel mandrel [0245] 103 Test element [0246] 104 Hold-down element [0247] 105 Replaceable steel wire [0248] 106 Applied weight [0249] 107 Cyclical movement [0250] 108 Drive [0251] 201 Hybrid vehicle, HEV/Plug-in hybrid vehicle, PHEV/electric vehicle, BEV [0252] 202 Electric motor [0253] 203 Inverter [0254] 204 High-voltage battery [0255] 205 Motor lead harness [0256] 206 High-voltage lead harness [0257] 207 Charging current connection [0258] 301 First carrier [0259] 302 Applied adhesive [0260] 303 Second carrier [0261] 303a Second protrusion [0262] 304 Marker line start [0263] 305 Marker line end [0264] 306 Cable harness in the form of various leads [0265] 307 Overlap for sealing the adhesive tape [0266] 308 Contact area [0267] 309 Drain line [0268] 601 High-voltage lead 35 mm.sup.2 with braided shield [0269] 602 High-voltage lead 35 mm.sup.2 with longitudinal aluminium/woven fabric bandaging [0270] 603 High-voltage lead 35 mm.sup.2 with spiral aluminium/woven fabric bandaging