A method and apparatus for preparing flat conductor cable having a plurality of ribbon-like conductors disposed upon and adhesively bonded to the surface of a substrate is described. The conductors are brought into contact with the substrate surface, and while maintained in axial tension on said substrate, the combination is seated on a yieldably compressible layer to permit the conductor to become embedded into the surface of the substrate film

Marcell, G. V.

English

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Enclosure
r{NASA-Case-HFS-10946-1) HETHOD AND
APPARATUS FOB PBEPABIBG HULTICCNDOCTOB CABLE
WITH FLAT COHDUCTOBS Patent (NASA) U F
CSCL 13H
00/_31
N79-21226
Onclas
20371
https://ntrs.nasa.gov/search.jsp?R=19790013055 2020-03-20T18:34:28+00:00Z
Dec. 2. 1969 G. v. MARCELL < 3,481,802
, METHOD AND APPARATUS FOR PREPARING MULTI-CONDUCTOR
CABLE WITH FLAT CONDUCTORS
Filad Sept. 26. 1965,
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. 3,481,802
Patented Dec. 2, 1969
3,481,802
METHOD AND APPARATUS FOR PREPARING
MULTICONDUCTOR CABLE WITH FLAT
CONDUCTORS
Gerald V. Marcell, Northfield, Minn., assignor to G. T.
Schjeidahl Company, Northfield, Minn., a corpora-
lion of Minnesota '"'
Filed Sept. 26,1966, Ser. No. 581,843
Int Cl. HOlb 13/06,13/22
U.S. CL 156—52 6 Claims
10
ABSTRACT OF THE DISCLOSURE
A method and apparatus for preparing flat conductor
cable having a plurality of ribbon-like conductors disposed )g
upon and adhesively bonded to the surface of a substrate
wherein the conductors are brought into contact with the
substrate surface, and while maintained in axial tension
on said substrate, the combination is seated on a yielda-
bly compressible layer to permit the conductor to become 20
embedded into the surface of the substrate film.
30
40
The invention described herein was made in' the per-
-formance of work under a NASA contract and is subject 25
to the provisions of section 305 jf the National Aero-
nautics and Space Act of 1958, Public Law 85-568 (72
Stat. 435: 42 U.S.C. 2457).
The present invention relates generally to the prepara-
tion of an electrical cable of the flat cable type wherein the
individual-iconductoTs are arranged in a planar configura-
tion in a relatively high density pattern. Generally, these
conductors are substantially rectangularly shaped ribbon-
like members having a pair of relatively broad surfaces,
and having a relatively small cross-sectional dimension. 35
The electrical cable product which is formed in< accord-
ance with the present invention is preferably substantially
flexible and have the individual conductors arranged in
generally parallelly disposed relationship between a sub-
strate member and a coverlay member.
In accordance with the present invention, the substrate
member is provided, along one surface, with a heat soften-
able adhesive bonding film which is compatible with the
substrate, and also with the conductors,, these conductors
preferably and generally being ccpper. The substrate is 45
passed along the surface of a heated member until the ad-
hesive bonding film is rendered somewhat soft and pliable.
The individual ribbon-like conductors are then brought
into contact with the bonding film and by means of ten-
sion or other forces, the ribbon-like conductors are forced 50
or urged against the adhesive bonding film and generally
embedded therein. While this embedding is accomplished
generally by the softened condition of the adhesive bond-
ing film, it is a feature of the invention that the substrate
be backed by a yieldable, compressible member such as, 55
for example, blotter paper of the like. Because of heat
transfer conditions, a layer of blotter paper of about 20
mils in thickness has been found to be extremely satis-
factory. After the individual conductors have been properly
embedded within the surface of the heat softenable ad- 60
hesive bonding film, the substrate, conductors, and a cover-
lay film are then passed through a nip zone between a
pair of pressure members, and (he individual components
form a laminate structure therefrom. As indicated in the
drawings, the system preferably utilizes a pair of heated 65
rollers which rollers form both the heated surface covered
by a yieldable and compressible member, and also con-
veniently form a pressure nip zone. Also, it will be appre-
ciated that in this aspect, the rollers will be heated, and
the dwell time of the substrate material on the surface is 70
sufficient to permit the adhesive bonding film to become
moderately softened.
2
The availability of the yieWable, compressible surface
together with the softened adhesive bonding film permit
the individual conductors to become embedded into the
softened adhesive film and thereby arrange, some signifi-
cant flow of the adhesive bonding film around the edge
surfaces of the individual conductors. It is the availability
of this adhesive along the edge surfaces of the conductors
which has been found to provide for a firm establishment
of the conductor in a pre-determined point along the sur-
face of the substrate, this arrangement eliminating the
danger of relative movement or slippage of the conductors
during subsequent processing operations, including, for ex-
ample', the application 'of a second or coverlay film over
the surfaces of the individual conductors and the substrate
member. After the subsequent operations, the adhesive
material is cured to its final cured stage.
Therefore, it is an object of the. present invention to
provide, an improved apparatus an.', technique for prepar-
ing electrical cable of the flat cab j type wherein the indi-
vidual conductors are arranged n a generally parallelly
disposed relationship, one to another.
Yet it is a further object of th'e present invention to pro-
vide an imp/oved apparatus and technique for the prepara-
tion of electrical cable of the- flat cable type wherein the
individual conductors are arranged in a high density pat-
tern.
It is yet a further object of the- present invention to
provide an improved apparatus and technique for pre-
paring electrical cable utilizing generally flat, ribbon-like
conductors, these conductors being arranged in a generally
parallel, non-distorted pattern, and in high density.
Other and further objects cf the present invention win
become apparent to those skilted in the art upon a study
of the following specification, appended claims and accom-
panying drawings, wherein:
FIGURE 1 is a perspective view showing a typical ar-
rangement of apparatus which may be utilized to prepare
flexible electrical cable with a plurality of ribbon-like con-
ductors arranged in generally parallel relationship;
FIGURE 2 is a detailed view of the nip portion of the
laminating rolls of the apparatus shown m FIGURE 1,
and illustrating, in section, the cable as it is entering the
nip portion of the rolls,' the rolk being shown on a some-
what enlarged scale, with the component portions of the
cable being shown on a substantially enlarged scale and
with the compressible backing being shown on the bottom
roll only; and
FIGURE 3 is a detail elevatieiial view of a guideTolIer
taken normal to the roller axis and along the line and in
the direction of the arrows 3—3 of FIGURE 1.
In accordance with the preferred modification of the
present invention, and with particular attention directed
to the apparatus shown in FIGURE 1, the cable-laminat-
ing machine generally designated 10 comprises a suitable
framing assembly 11 including means for retaining a plu-
rality of supply spool members 12—12 which carry the
individual conductors such as the flat ribbon conductors
13—13. The supply spools 12—12 are, of course, jour-
naled for appropriate rotation along the frame member
11. If desired, appropriate drag devices or tension con-
trol devices may be employed in combination wilh the
supply spools 12—12 in order to assist in appropriately
guiding the individual flat ribbon-like conductors during
the encapsulation or mounting process. The assembly 10
further includes a pair of supply rolls 15 and 16 for carry-
ing and supplying substrate and coverlay films respective-
ly, these supply rolls also being journaled for rotation
within the frame means 11. Again, if desired, appropriate
drag or tension-control means may be utilized in connec-
tion with the supply rolls 15 and 16 in order to appro-
priately de'iver the material to the various processing sta-
tions of the apparatus.
3,481,802
As indicated, a pair of tension regulating systems may
be employed in'connection with the film supply rolls 15
and 16, such as is shown at 18 and 19. The individual
rollers 18 and 19 are arranged to provide the desired
tension on the film supply portions of the system.
As shown in FIGURE 1, a pair of laminating rollers
21 and 22 are arranged in axially parallel relationship,
these rollers 21 and 22 being journaled for rotation with-
in the frame 11. Suitable drive means, not shown, are
bedding of the individual conductors within the adhesive
film surface. The availability of the compressible layer
26 between the hea'ed roll 21 and the substrate ISa en-
hances the ability, of the individual conductors to be-
come embedded in the adhesive film 30 and also enhances
the flow of the softened adhesive about the surface of the
individual conductors 13—13. At the point of lime when
these embedded conductors laying upon the surface of
.the substrate 15a enter the nip between the rollers 21 and
provided for the individual laminating rollers; this drive
 ](j 22, any tendency for migration of the adhesive film 30
means preferably comprising a chain drive assembly which
will assist in driving the1 individual roliers 21 and 22 at'
appropriately controlled speeds so that the individual pe-
ripheral velocities are substantially equal. The individual
rolls 21 and 22 are preferably provided with means for
heating the peripheral surfaces-thereof,'the heating means
preferably including a temperature control system for pro-.
vid'ng reasonably close control of the surface, tempera-
tues.
With attention now being re-directed to the conductor
supply arrangement, a guide roller 23" is shown between
the laminating rollers 21 and 22 and the individual sup-
ply spools 12—12, this guide roll 23 being disposed close
to the nip and being provided with appropriately spaced
grooves 2-1—24, these grooves being adapted to receive
the individual flat ribbon conductors therein, and being
spaced apart in accordance with the desired conductor
spacing on the cable product. An auxiliary guide may be
employed as shown at 24a in order to control the.feed
of the conductors to the laminating rollers.
It will be observed in connection with FIGURE 1 that
the substrate and coverlay films pass across the heated
laminating rollers 21 and 22 for a distance of about 180
degrees of arc prior to reaching Ihe nip portion of the
will normally be retarded because of the embedded-dispo-
sition of the conductors 13—13 therein. Thus, the coverlay
film 16a may be effectively bonded to the surface of the
adhesive film 30 without causing movement or motion to
15 occur between the conductors 13—13. Thus, a carefully
controlled ..cable may be produced having lines arranged
in parallelly disposed relationship, and in carefully con-
trolled spaced relationship. It will be appreciated that flat
* conductor cable having carefully controlled inter-conduc-
20 tor spacings is highly desirable from the standpoint of uni-
form electrical properties.
After the product leaves the laminating rollers 21 and
22, it passes through a cooling chamber 29, and there--
after may be cut, slit, or otherwise treated by the slitters
25 (not showrl). Draw rolls 31—31 carry the material to a
take-up roll 32. The take-up roll 32, which is also jour-
naled for rotation within the frame assembly 11, may also
provide drive means, not shown, in order to take up the
product thereon.
30 Thus, in accordance with the apparatus and technique
of the present invention, -\ highly desirable eiettrically
conductive flat conductor cable having a plurality of rib-
bon-like conductors disposed upon and adhesively bonded
to tns surface of an insulating substrate member may be
rollers 21 and 22. In addition, it will be observed that
 35 prepared. In addition, this electrically conductive flat con-
the individual conductors 13—13 move across a distance diictor cable may be provided with a coverlay member to
of about 90 degrees of arc while in contact with the sur- " ' "
face of the substrate 15a. With further attention being
directed to the nip portion of the laminating rollers, ii
will be observed that a compressible member 26 is inter- 40
posed between the surface of the laminating roller 21 anci
the substrate ISa. This compressible material is necessarily
one which is reasonably thermally conductive, and it has
been found that blotter paper having a thickness of about
.020 inch is preferred. In this cont/ection, the blotter paper
is compressible and sufficiently thermally conductive so as 45 the spirit and scope of the present invention^,
to permit compression of the paper with an accompanying What is claimed is:
transfer of heat therethrough. A compressible material is
desired in this application since a material which is merely
resilient or d*-formable may cause anomalous characteris-
tics to occur in the laminated product due to the possible. 50 face of an insualting substrate member, s?id apparatus
creation of different relative speeds at the surfaces of the comprising:
individual rollers 21 and 22. It is sometimes desirable for
uniformity to utilize a similar or matching material along
the top roll, such as, for example, a similar blotter paper
roll system as shown at 26o. In order to retain the indi- 55
vidual conductors in place on its surface, the substrate
15a is provided with a film of a heat softenable adhesive
bonding material along one surface thereof, this film of
heat softenable adhesive bonding material being shown
GO
appropriately encapsulate the conductors between a pair
of insulating films, as is normally desired in practice. The
flat ribbon-like conductors are generally formed of cop-
per having a thickness of from about 1 to 5 mils and hav-
ing a width of from about J/is to about V4 inch.
It will be appreciated that the specific examples pro-
vided herein are for purposes of illustration only, and
that those individuals skilled in the art may depart from
these specific illustrations without actually departing from
1. An apparatus for producing- electrically conductive
flat conductor cable having a plurality of ribbon-like con-
ductors disposed upon and adhesively bonded to the sur-
at 30. Thus, as the substrate material ISa moves across
the approximate 180 degrees of arc on the heated roller
21, this film of heat softenable adhesive bonding material
is softened and permits the individual conductors 13—13
to become embedded therein, such as is illustrated in some
detail in FIGURE 2. Heat softenable adhesives, such as,
for example, polyester base adhesives an generally use-
ful and are widely commercially available. It will be re-
called that the individual conductors 13—13 leave the
supply spools 12—12 under tension, and thus this tension
in the individual conductors 13—13 is reflected in an em-
bedding of the conductors into the adhesive film with a
consequent flow of the softened adhesive therearound.
Thus, it will be observed that the sequence of events in-
cludes an original softening of the adhesive Him 30 on the
70
surface of the substrate 15n, this accommodating an em- 70 is abput 9Q degrees.
(a) means for retaining a supply of ribbon-like con-
ductors;
(b) first and second rollers having their axes arranged
in generally parallelly disposed relationship and form-
ing a nip area at a certain first arcuate position be-
tween the surfaces thereof, at least the first of said
rollers having means for heating the surface thereof;
(c) means for retaining a supply of generally flexible
substrate film and for directing said film to the nip
area;
(d) a yieldably compressible layer disposed a:ung the
surface of at least one of said rollers and arranged
for arcuate movement therewith;
(e) means for directing said conductors on to the sur-
face of said rollers under tension to deform said yield-
ably compressible layer, said conductor directing
means being arranged to bring said conductors into
contact with the peripheral surface of said first roller
at a second arcuate position spaced a substantial
arcuate distance from said nip area.
2. The apparatus as defined in claim 1 being particu-
larly characterized in that said substantial arcuate distance
3,481,802
G
•3; A method of preparing electrically conductive flat
conductor cable having a plurality of ribbon-like conduc-
tors disposed upon and adhesively bonded 10 the surface
of an insulating substrate member, within a laminating
apparatus having a zone with a pair of pressure members
arranged on opposite sides of the nip' zone, said method
comprising:
(a) moving a first substrate film having a heat soften-
able adhesive bonding film along one surface there-
of along a certain path through a heating zone until
said bonding film is softened;
(b) bringing a plurality of tension stressed ribbon-like
conductors into contact with said bonding film on'
said substrate film, and then maintaining the tension
stressed contact therebetween while said bonding film
is being maintained in softened condition, while said
conductors are being urged against said substrate sur--
face* by said applied tension stress, and while said
• substrate is being backed by a yieldable compressible
member; " • '
(c) thereafter bringing a coverlay film into superim-.
posed relationship with said substrate and with said
conductors; and thereafter
(d) passing "said substrate, conductors and coverlay
materials, through a nip zone to form a laminate
structure.
4. , The method as set^ forth in claim 3 being particu-
larly characterised in that said substrate film, said con-
20
tfnctors, and said coverlay film are supplied to said lami-
nating apparatus in roll form, the completed laminate
structure being removed from said laminating apparatus
and accumulated on a take-up roll.
5. The method as set forth in claim 3 being particu-
larly characterized in that said yieldable compressible
member is carried along the surface of one of said pres-
sure members.
6. The method as set forth in claim 3 being particu-
j larly characterized in that said substrate is brought into
contact with said heated pressure member at a first point
.of time, and said conductors are brought into contact with
the surface of said substrate following a finite lapse of
, time..
; References Cited
UNITED STATES PATENTS
. 3,068,135 12/1962 Bower ". 156—179,
3,-239,396 3/1966 Bohannon L 156—52
3,265,548 8/1966 Harkins et al 156—298 X
3,270,122 8/1966 Binek 156—52 X
3,380,867 4/1968 Morey 15C—179
HAROLD ANSHER, Primary Examiner
25 T. R. SAVO1E, Assistant Examiner. -•
U.S. Cl. X.R.
' 156—179, 436, 161; 174—117


Method and apparatus for preparing multiconductor cable with flat conductors

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