EP-4738389-A1 - LOW PFAS INSULATED DATA COMMUNICATIONS CABLE

Abstract

A cable capable of communicating large amounts of data while withstanding high heat conditions without the need for PFAS substances. The cable includes conductors encompassed by insulation. The insulation may include a non-PFAS fluoropolymer or materials such as polymethyl pentene or crosslinked polyalkene. The insulation may be encapsulated by a bedding layer, a shielding layer, a braid layer and a jacket. The insulation is designed to withstand temperatures of at least 125 degrees Celsius to ensure a high throughput of data even in demanding conditions.

Inventors

• KONNIK, ROBERT
• TRAHAN, Richard
• SCHERZINGER, Ken

Assignees

• Champlain Cable Corporation

Dates

Publication Date

20260506

Application Date

20251031

Claims (15)

1. A data communication cable, comprising: at least one conductor; and an insulating layer disposed over the at least one conductor, wherein the insulating layer comprises less than 95% w/w of a fluoropolymer, and is void of PFAS (Per- and polyfluoroalkyl substances).
2. The cable of claim 1, wherein the insulating layer comprises a solid insulation.
3. The cable of claim 1 or 2, wherein the insulating layer comprises a chemical foam insulation.
4. The cable of claim 3, wherein the insulating layer further comprises a solid skin layer of insulation disposed on the chemical foam such that the chemical foam is disposed between the at least one conductor and the solid skin layer.
5. The cable of any of the preceding claims, further comprising an inner layer of conductive shielding surrounding the conductors.
6. The cable of any of the preceding claims, further comprising a filler material disposed within the cable.
7. The cable of any of the preceding claims, further comprising an outer cable jacket surrounding the insulating layer.
8. The cable of any of the preceding claims, wherein the cable is configured to be disposed within an electric system of a vehicle.
9. The cable of any of the preceding claims, wherein the cable is configured to operate at substantially maximum efficiency when the conductor is heated to 125C.
10. The cable of any of the preceding claims, further comprising a second insulating layer, in particular wherein the second insulating layer comprises polymethyl pentene and/or crosslinked polyalkene.
11. A data communication cable, comprising: one or more conductors, an insulating layer disposed over the conductors, wherein the insulating layer comprises polymethyl pentene, and is void of PFAS.
12. The cable of claim 11, wherein the insulating layer comprises polymethyl pentene foam, in particular wherein the insulating layer further comprises a solid skin layer of insulation disposed on the polymethyl pentene foam such that the polymethyl pentene foam is disposed between the one or more conductors and solid skin layer.
13. A data communication cable, comprising: one or more conductors; and an insulating layer disposed over the conductors, wherein the insulating layer comprises crosslinked polyalkene, and is void of PFAS, in particular wherein the crosslinked polyalkene is crosslinked by at least one of: moisture curing; and electron beam curing.
14. The cable of claim 13, wherein the crosslinked polyalkene is crosslinked by both moisture curing and electron beam curing.
15. The cable of claim 13 or 14, further comprising a second insulating layer, in particular wherein the second insulating layer comprises at least one of: polymethyl pentene and a fluoropolymer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY This patent application claims priorities from U.S. Provisional Patent Application No. 63/715,351 filed November 1, 2024, and U.S. Non-Provisional Patent Application No. 19/366,730 filed October 23, 2025. These patent applications are herein incorporated by reference in their entirety. FIELD OF THE DISCLOSURE The present disclosure relates to communication cables and, more particularly, to cables used for data communication in high heat environments. BACKGROUND Modern computer systems have continuously increasing demands for data. These increasing data demands are becoming ever more present in computer systems used in motor vehicles. The motor vehicle industry has typically relied on CAN bus cables for data transfer within a motor vehicle computer system, but those cables are not capable of handling the data demands of high-bandwidth low-latency applications which are becoming common in modern and upcoming motor vehicle computer systems (e.g., autonomous driving, infotainment, telematics). The Institute of Electrical and Electronics engineers (IEEE) and the Society of Automotive Engineers (SAE) have indicated that Ethernet, the universal networking standard used in buildings, will become the new networking protocol for the motor vehicle industry. Unfortunately, the materials used in previously known Ethernet cables are not capable of withstanding the environmental conditions of the interior of a motor vehicle while the vehicle is in use or are spurring regulatory concerns over adverse health impacts. Thus, what is needed are new types of communication cables (including, but not limited to Ethernet cables) capable of meeting the data demands of modem vehicle computer systems as well as withstanding the environmental conditions of a motor vehicle while reducing or eliminating harmful substances contained within the communication cable. SUMMARY The use of fluoropolymers for high-speed data communications is well known. With new regulatory concerns and challenges arising in response to the use of per- and poly fluoroalkyl substances ("PFAS"), fluoropolymers which are suitable for high-speed data communications but do not contain PFAS substances or limit PFAS substances are made more desirable. The present disclosure provides compositions of high-speed data cables which are insulated without using PFAS materials or limited PFAS materials and which may be durable enough for use in motor vehicles. According to one embodiment of the present disclosure, a data communication cable is provided for addressing the above issues. The cable includes one or more conductors, as well as an insulating layer disposed over the conductors. The insulating layer is less than 95% weight-over-weight ("w/w") of a fluoropolymer and contains limited or no per- and polyfluoroalkyl substances. The insulating layer may comprise a number of different materials and forms. Some embodiments of the insulating layer may comprise less than 95% fluoropolymer insulation. In some embodiments where the insulating layer comprises less than 95% fluoropolymer insulation, the fluoropolymer may be embodied as solid insulation. In some other embodiments where the insulating layer comprises less than 95% fluoropolymer insulation, the fluoropolymer may be embodied as a foam. In some embodiments where the insulating layer is embodied as a fluoropolymer foam, the insulating layer may further include a thin skin layer of solid insulation. When present, such a skin layer may be disposed on the exterior of the insulating layer, such that the foam is disposed between the conductors and the skin layer. The data communication cable may also comprise one or more other components. In some embodiments, the data communication cable may include a layer of conductive shielding. Such a shielding may consist of metal cladding or metal tubing. Adding shielding to a data communication cable may improve the durability of the cable in challenging environments where the cable may be exposed to physical or thermal abuse. In some other embodiments, the data communication cable may include a filler material. Such a filler material may provide resistance to physical abuse or harmful temperatures. In some other embodiments, the data communication cable may include an outer cable jacket. Such a jacket may be comprised of a low smoke zero halogen material, as an example. Adding a jacket to a data communication cable may improve the cable by shielding the cable from physical abuse. The data communication cable may be configured to be disposed within a vehicle. A vehicle may mean an automobile, boat, airplane, train, or any other vehicle which may be used to transport people or cargo. A cable may be configured for use in a vehicle both by its data-carrying capacity and by its adaptation to the environmental conditions of a motor vehicle. As motor vehicles become ever more reliant on software, cameras, sensors, and processors, the abili