WO2002076726A1

WO2002076726A1 - Wiring harness wrap

Info

Publication number: WO2002076726A1
Application number: PCT/US2001/009206
Authority: WO
Inventors: Daniel Poisson; Scott Barnes; Elwyn Huddleston
Original assignee: Scapa Tapes North America Inc.
Priority date: 2001-03-23
Filing date: 2001-03-23
Publication date: 2002-10-03

Abstract

The wiring harness wrap has a backing (18) containing from about 30 % to about 95 % low density polyethylene, from about 5 % to about 60 % of a second polymer such as ethylene-acrylic copolymers, ethylene-acetate copolymers, ethylene-acrylic acid copolymers, and elastomers; and a rubber-based adhesive on one side of the backing.

Description

WIRING HARNESS WRAP

FIELD OF THE INVENTION

The present invention relates to adhesive tape for harness wraps for a wiring system of a motor vehicle. More specifically, the present invention relates to a recyclable, halogen-free polymer film tape harness wrap, and to a method for making the harness wrap.

BACKGROUND OF THE INVENTION Wiring systems within an automobile play a vital role in the proper operation of a motor vehicle over its service life. These wiring systems are designed, manufactured, specific to each model type, and supplied in a modular form (harnesses) to an automobile plant. Each harness segment is wrapped with a continuous layer of tape which may or may not have an adhesive coating on one side, to help contain and protect the individual coated wires in the harness assembly. Performance criteria will vary depending on the location of the harness within the automobile. Engine compartments offer the most severe conditions including extreme temperature ranges and exposure to fluids, e.g., gasoline, oil, transmission fluid, brake fluid and radiator coolant. Passenger compartments are relatively friendly to materials but a need exists for low fogging (the out-gassing of a vapor that can deposit a film on window surfaces), along with a good level of noise suppression. In all areas of use, the tape must provide resistance to damage (primarily physical), resist flagging and be economically attractive.

Additionally, environmental initiatives are pushing the automotive industry to use more recyclable materials in their vehicle designs. Federal and state environmental regulations require the automotive industry to use less environmentally hazardous materials in the manufacture of their vehicles. By way of example, halogens, in some forms, are strongly suspected to deplete the ozone layer. These concerns put added pressure on the material suppliers as they must find a way to meet these demands while still satisfying the performance requirements of the application. In the case of halogen containing prior art wiring harness wraps, said products are not recyclable in that combustion and /or heat degradation of the wrap material to recycle the copper leads to the emission of toxic gases.

A variety of prior art wiring harness tape products are typically used within an automobile depending on the harness location. Problematically, however, the materials used in these prior art tapes do not meet many of the environmental initiatives or regulations being imposed on the automotive industry, e.g., recyclable and halogen-free products.

PVC tapes are by far the most common material for wrapping and securing wires in automotive harness assemblies. PNC tapes are produced through the solution coating of adhesive on to a calendered PNC sheet. It is a multiple stage process first requiring the production of a PVC sheet in roll form. The film is then coated with adhesive, dried and wound into logs. Logs are then cured at elevated temperatures, e.g., 90°C, to cross-link the adhesive. Cross-linking is essential when monomeric plasticizers are used in the sheet in order to prevent the damaging effects of plasticizer migration.

Characteristic benefits of PVC tapes can be summarized as follows: conformable, inherently flame retardant, good resistance to fluid damage, and economical. However, PVC tapes have disadvantages in that they have generally poor fogging properties due to plasticizer out-gassing, are not recyclable, and contain halogens which give off highly toxic gases when burned.

Some non-PVC tapes may also contain undesirable halogens and are, therefore, also not recyclable. U.S. Patent No. 5,407,726 assigned to The Kendall Company describes conformable high temperature resistant tapes comprising a chlorinated polymeric backing having a pressure sensitive adhesive layer disposed on one side of the backing. The chlorinated polymeric backing renders the tape non-recyclable and adds hazards to the environment upon degradation. Cloth tape is also widely used, particularly in the passenger compartment and instrument panel areas where noise due to harness rattle is a concern. Woven print cloth is typically coated directly with adhesive. Beneficial characteristics of cloth tapes are: conformability, good resistance to abrasion and good noise suppression. However, cloth tapes have disadvantages in that they have poor fluid resistance and are relatively expensive. For example, U.S. Patent No. 5,804,510 assigned to Beiersdorf Aktiengesellschaft discloses a halogen- and antimony-free fabric adhesive tape for wrapping cable harnesses which has a permeable fabric base, a polar self- adhesive composition and a flameproofing agent in both the base and adhesive.

Polymer coated scrim tapes are somewhat of a hybrid offering a combination of features found in both PVC and cloth tapes. The backing is comprised of a scrim (gauze) cloth or other woven /nonwoven cloth, coated with an extruded layer of polymer. A tie coat between the film backing and the cloth is required and critical. Beneficial characteristics of scrim tapes are conformable, good resistance to fluid damage, good abrasion resistance, puncture resistance, and low cost. However, to their disadvantage, scrim tapes, if they are flame resistant types, typically contain halogens and are not recyclable.

Another example of a polymer coated cloth tape is disclosed in U.S. Patent No. 5,246,773 (773), assigned to the Kendall Company, which describes industrial tapes comprising a lightweight nonwoven synthetic cloth, a polymeric backing layer(s) (3 to 5 mils thick) bound to one surface of the cloth, and a layer of pressure sensitive adhesive material (at least 1.0 mils thick) disposed on the opposite surface of the cloth. A tie coat may also be used in the tapes of the 773 patent, and halogens may also be present. Another example is described in U.S. Patent No. 4,992,331 ('331), also assigned to The Kendall Company, which teaches a flame-retardant conformable adhesive tape useful as a wire harness having a water-impermeable chlorinated polyethylene backing layer (about 1 to 3 mils thick), a fiber cloth/scrim, a flame retardant adhesive layer (preferably rubber-based), and a thin tie coat layer between the backing and the scrim. The tapes of the '331 patent have the disadvantage of containing the halogen chlorine which, as mentioned previously, is environmentally harmful and not recyclable.

None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed.

SUMMARY OF THE INVENTION

The present invention offers advantages and alternatives over the prior art by providing a recyclable, halogen-free wiring harness wrap for a wiring system of a motor vehicle. The harness wrap of the present invention offers many of the benefits of plasticized PVC but addresses the need for a low cost, low fog, halogen-free and recyclable alternative. The wrap comprises a halogen-free copolymer backing layer with a rubber-based adhesive layer disposed on a surface of the backing layer.

Advantageously, the process of manufacturing the wiring harness wrap of the present invention includes a single production step for forming the backing film and applying the adhesive to the film.

The preferred method to make the present invention involves a tape calendering procedure. Tape calendering procedures provide in-situ film formation and solvent free adhesive application. The regular and widespread process of PVC tape production is to use a pre-formed film and spread an adhesive solution on it. The tape is then dried in an oven before converting. The present method consumes less energy and is environmentally friendly.

The formation of the tape backing directly on the calender roll is more economical then outsourcing the film. The compounding of the backing film right on line allows the manufacturer to be flexible and in control. Flexibility is in the dimensional characteristics of the film (thickness) and properties (softness). Tensile and elongation of the film can be adjusted to suit the application. Furthermore, the use of a hot-melt type of adhesive eliminates the use of expensive and volatile solvents. Risks of explosions or atmosphere contamination are avoided. Thick coating, if needed, can be more easily achieved.

In an exemplary embodiment of the invention, the harness wrap comprises low density polyethylene (LDPE) and ethylene-methyl acrylate (EMA) copolymer containing about 21.5% methyl acrylate. The copolymer films of the present invention offer many benefits in a harness wrap application because they are halogen-free, recyclable, inherently low-fogging, conformable, light weight, of relatively low cost and have good physical properties, e.g. degradation resistant, abrasion and puncture resistant, and good electrical insulation properties.

The harness wrap of the present invention further comprises an adhesive layer formed on the copolymer film backing. The adhesion of the tape to itself (as a self-wound product) must also be balanced. If the roll is too easy to unwind, the application will suffer from lack of proper tensioning during wrapping. If the roll is too difficult to unwind, the end-user will experience finger and wrist strain over the repetitive application of the tape. In addition, the tape roll must unwind smoothly and without excessive noise or chattering. PVC tapes have highly plasticized backing and lead readily to a smooth unwind. To obtain the same effect is a challenge with polyethylene based tapes. The advantage of the present adhesive formulation is to offer a well balanced set of properties such as tack, adhesion and unwind characteristics. Such an adhesive layer may be based on synthetic rubbers such as styrenic block copolymers (SBC) or natural rubbers. Unlike the typical prior art, a tie coat is not required to achieve proper anchorage of the adhesive to the film, and the resulting tape product features a soft, flexible film with good adhesion and a smooth unwind. An object of the present invention is to provide a harness wrap which is environmental friendly. By eliminating halogens, the harness wrap eliminates a major source of pollution when incinerated during recycling. During combustion and /or heat degradation, PVC can emit noxious and toxic gases such as hydrogen chloride HCl and phosgene COCl₂. This is caused by the presence of chlorine on the polymer backbone. In contrast, the combustion of ethylene based polymers will evolve only harmless carbon dioxide and water vapor.

The instant invention can be made fire retardant by addition of known non-halogen organic chemicals such as phosphorus based or boron based systems. Inorganic chemicals such as magnesium hydroxide or alumina trihydrate are also used and known to those skilled to the art.

Another object of the invention is the elimination of a tie coat. The present invention does not utilize a tie coat which results in fewer steps to make the product.

Yet another object of the invention is to provide a low fog alternative to plasticized PVC. By eliminating plasticized PVC, the harness wrap eliminates the disadvantage of fogging found in PVC -based alternatives.

The above discussed and other features, objects and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the described embodiments are specifically set forth in the appended claims; however, embodiments relating to the structure and process of making the present invention, may best be understood with reference to the following description and accompanying drawing. Figure 1 is a schematic representation of a three-roll vertical calender apparatus used to make the wiring harness wrap of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is a wiring harness wrap for use in an automobile. The harness wrap has a halogen-free backing with a rubber-based adhesive disposed on one side thereof. The backing is composed of a low- density polyethylene (LDPE) with a soft copolymer or equivalent, such as ethylene-methyl acrylate (EM A). The adhesive may be a synthetic or a natural rubber-based adhesive.

The components of the backing are expressed in percentages while the components of the rubber-based adhesive portion are expressed in parts per hundred rubber (phr).

A typical backing film formulation of the present invention comprises about 65% low-density polyethylene polymer (LDPE), and about 30% of a second polymer such as an ethylene-acrylic copolymer, an ethylene-acetate copolymer, an ethylene-acrylic-acid copolymer, or an elastomer. Additives such as carbon black, antioxidant, and stabilizers (if desired) may also be present. In the production of such backing films, a thickness of from about 3 to about 6 mils is desirable.

A preferred LDPE is an extrusion grade resin such as LE0220 available from Nova Chemicals Corp. (Calgary AL, Canada). It is clear, however, that a wide range of LDPE resins may be used. It is recognized that regardless of the LDPE used, the melt flow index should be between 2 and 15. For example, a series of high melt index (12-13) coating resins from CHEVRON™ such as CHEVRON™ PE1013 or CHEVRON™ PE1018 process well and are also of interest. The LDPE content ranges from about 30% to about 95%, preferably from about 45% to about 85%, and most preferably from about 60% to about 70%. Copolymers which may be used with the LDPE are selected from the group consisting of ethylene-acrylic copolymers, ethylene-acetate copolymers, and ethylene acrylic-acid copolymers. The acetate-based copolymers include ethylene- vinyl acetate (EVA). Ethylene-acrylic copolymers include ethylene- methyl acrylate (EM A), ethylene-ethyl acrylate (EEA), ethylene-acrylic elastomer, and ethylene-acrylic acid (EAA). EMA is the most preferred copolymer and is quite compatible with the adhesive. Preferred grades include CHEVRON™ SP-2205 available from Eastman Chemicals Company (Kingsport TN) and OPTEMA™ TC- 110 available from Exxon Chemical Company (Houston TX). It is also possible to replace the copolymer with an elastomer. Suitable elastomers include natural rubber, ethylene propylene rubbers (EPR), diene terpolymers, butyl rubber, and styrene-butadiene-styrene (SBS). Polymers and copolymers miscible with LDPE or which can form interpenetrating networks with LDPE may be used.

The preferred EMA copolymer has a methyl acrylate content of about 20% to about 22%. OPTEMA™ TC-110 has about 21.5% methyl acrylate content. EMA copolymers with a higher content of methyl acrylate can be used if the overall content of methyl acrylate of the backing is maintained. It has been found that a range of from about 5% to about 60%, preferably from about 5% to about 45%, with about 30% being the most preferred (about 6% total methyl acrylate). The level of methyl acrylate in the total formula is the controlling factor and as a result, other grades of EMA could potentially be used.

With respect to the additives, carbon black masterbatches containing about 50% carbon black may be used. About 4% of the masterbatch is preferably used in the backing of the present invention. Black pigment masterbatches in polyethylene can be obtained from many suitable sources. The amount of the carbon black masterbatch used ranges from about 1% to about 5%, most preferably from about 1.5% to about 5%, and optimally from about 2% to about 4%. Antioxidant systems typically employed for polyethylene are used in normal amounts. In the present invention, a masterbatch containing 1% of SANTONOX™ (Monsanto, Saint-Louis MO) in polyethylene is used. About 1% of this masterbatch is preferably used. Other antioxidants may be used such as IRGANOX™ B215 (Ciba Specialty Chemicals, Mississauga, Ontario, Canada). The preferred content of antioxidant concentrate ranges from about 0.5% to about 3%, preferably from about 0.5% to about 2%, and optimally from about 0.5% to about 1.5%.

The adhesive which is applied to the backing film may be prepared in a number of known ways. Once the adhesive is formulated, it is applied to the backing film using a calendering method discussed hereinafter. The preferred adhesive thickness is about 1.5 to about 4 mils.

A wide range of rubber-based adhesives maybe employed and formulated in such a way so as to be to be compatible with the calendering process. Suitable adhesives include natural rubber, thermoplastic rubber and elastomeric polymer rubber. These rubbers include, but are not be limited to, natural rubber, block copolymers (SIS, SBS and SEBS), butyl rubbers, and ethylene-propylene rubbers (EPR). Naturally, blends of two or more of these polymers can be beneficial and highly desirable in achieving the necessary performance. In addition, cross-linking may be employed to further enhance the performance of these systems. Regardless of the polymer system used, all adhesives contain additional materials including tackifiers, fillers, plasticizers and stabilizers. The term "rubber-based adhesives", as used herein, refers to adhesives which contain natural and /or synthetic rubber.

A preferred composition of the adhesive is a mixture of about 85 % of the styrene-isoprene block copolymer VECTOR™ 4113 available from Dexco Polymers (Houston TX), about 15 % of the styrene-isoprene block copolymer VECTOR™ 4114 also available from Dexco Polymers, about 9 phr of the liquid petroleum hydrocarbon resin ADTAC™ LV available from Hercules Canada (Mississauga, Ontario, Canada), about 45 phr of the tackifying resin ESCOREZ™ 1310 available from Exxon Chemical Company (Houston, TX), about 25 phr of the mineral oil PARAFLEX™ HT 68 available from Petro-Canada (Calgary, Alberta, Canada), and about 1 phr of the IRGANOX™ B-215 available from Ciba Specialty Chemicals (Mississauga, Ontario, Canada).

The base elastomer for the adhesive is a polystyrene-polyisoprene- polystyrene polymer, SIS. The preferred SIS is VECTOR™ from Dexco Polymers. VECTOR™ 4113 and 4114 are styrene-isoprene-styrene block copolymers, and both have a styrene content of about 15% and a specific gravity of about 0.92. VECTOR™ 4113 has a diblock content of about 18% while VECTOR™ has a diblock content of about 42%. The high diblock content is considered beneficial to tack and unwind characteristics of the tape. Other SIS such as KRATON™ D1107P polymer from Shell Chemical (Houston, TX) can be used.

There may be from about 50% to about 100% of a SIS block copolymer having a diblock content of about 18% and from about 1% to about 50% of SIS having a diblock content of about 42%. It is preferred that the styrene- isoprene-styrene block copolymer has from about 70% to about 95% of SIS block copolymer having a diblock content of about 18% and from about 5% to about 30% of SIS having a diblock content of about 42%. It is most preferred that the block copolymer content is from about 80 to about 90% of SIS block copolymer having a diblock content of about 18% and from about 5% to about 20% SIS having a diblock content of about 42%.

The amount of tackifying additive employed depends essentially upon the level of tack desired. It will be understood that the specific tackifying additives which can be combined and the amount of each tackifying additive which can be employed to achieve the desired level of tack can be readily determined by those skilled in the art using reasonable and routine experimentation. Particularly useful tackifying resin additives used to practice this invention include low molecular weight petroleum-derived hydrocarbon resins commercially available from Exxon Chemical Company under the registered trademark ESCOREZ™. Suitable tackifying resin additives include ESCOREZ™ 1304, ESCOREZ™ 1310, and ESCOREZ™ 1315. These resins are characterized as being thermoplastic, aliphatic hydrocarbons having softening points of about 85°C to about 125°C, and weight average molecular weights ranging from about 360 to about 2570. The content of the petroleum hydrocarbon tackifying resin additive ranges from about 1 phr to about 85 phr, preferably from about 10 phr to about 60 phr, and most preferably from about 35 phr to about 55 phr.

ADTAC™ LV is the preferred liquid petroleum hydrocarbon resin. Other particularly useful aliphatic hydrocarbon resins are the highly viscous liquid petroleum-derived resins available under the trademark WINGTACK™ 10 from Goodyear Chemical (Beaumont, TX). Such a resin has a softening point of about 10°C, a molecular weight of about 660 and a specific gravity of about 0.90 at 25°C. This resin serves as a processing aid as well as to impart additional tack to the surface of the calendered adhesive. It is considered to have a favorable effect on the smoothness of the unwind of the finished tape. The content of the viscous liquid petroleum-derived resin ranges from about 1 phr to about 25 phr, preferably from about 5 phr to about 20 phr, and most preferably from about 5 phr to about 15 phr.

The quantity of the mineral oil ranges from about 1 phr to about 50 phr, preferably from about 5 phr to about 45 phr, and most preferably from about 15 to about 35 phr. PARAFLEX™ HT 68 may be substituted for KAYDOL™ USP, which is a white mineral oil available from Daminco Inc. (Oakville ON, Canada). Both of these products are 100% pure mineral oil.

IRGANOX™ B215 is a preferred antioxidant which is a 2:1 blend of IRGAFOS™ 168 and IRGANOX™ 1010. The amount of antioxidant used ranges from about 0.5 phr to about 5 phr, preferably from about 0.5 phr to about 3 phr, and most preferably from about 0.5 phr to about 1.5 phr.

Other ingredients may also be included in the adhesive composition. For example, additional conventional rubber compounding additives such as fillers, pigments, antiozonants, flame retardants and the like may be included in conventional amounts.

The adhesive composition can be initially admixed by conventional means using conventional rubber compounding equipment such as a Banbury mixer, a Sigma-blade mixer, a two-roll mill, an extruder and /or any other mixers and the like which are suitable for compounding the ingredients of the composition. The ingredients are admixed at temperatures ranging from about 50°C to about 150°C. In the preferred embodiment, a Sigma-blade mixer is used at a temperature of about 150°C.

The tape calendering process used to produce the harness wrap of the present invention employs a three-roll vertical calender 10, as shown in Figure 1. The initial step for making the present invention involves blending from about 30% to about 95% of a low density polyethylene, and from about 5% to about 60% of a second polymer selected from the group consisting of ethylene- acrylic copolymers, ethylene-acetate copolymers, ethylene-acrylic acid copolymers and elastomers to form a molten LDPE composition. The molten LDPE composition is extruded at about 345°F (174°C) to a first nip 11 between the top roll 12 and the center roll 14 by a single-screw extruder. The top roll 12 maintains a temperature of about 380°F (193°C), and the center roll 14 maintains a temperature of about 180°F (82°C).

A backing sheet 18 is then formed from the LDPE composition on the center roll 14. The thickness of the backing 18 is controlled by the gap between the top and center roll 12 and 14. The backing 18 is then coated with an adhesive layer. The molten adhesive is extruded at about 290°F (143°C) and fed to the nip 13 between the center roll 14 and the bottom roll 16 by single- screw extrusion. The bottom roll 16 maintains a temperature of about 310°F (154°C). The thickness of the tape adhesive is therefore controlled by the gap between the center and the bottom roll 14 and 16. The calendered adhesive tape 20 is then cooled by means of cooling cans. The tape is then wound up and ready for converting. While the overall web speed is about 80 feet per minute (fpm), the top roll moves at about 0.5 fpm, the center roll moves at about 80 fpm, and the bottom roll moves at about 4.0 fpm.

Several test procedures were run on an example of the present invention produced by the above method and containing a backing with 65% LDPE (LE0220), 30% EMA with 21.5% methyl acrylate (OPTEMA™ TC-110), 4% of a black masterbatch containing 50% carbon black dispersed in a polyethylene matrix and 1% antioxidant masterbatch (1% Santonox™) dispersed in a polyethylene matrix. A thermoplastic rubber adhesive having 85 % of a polyisoprene midblock with polystyrene endb locks SIS block copolymer having a diblock content of about 18% (VECTOR™ 4113), 15 % of a polyisoprene midblock with polystyrene endblocks SIS having a diblock content of about 42% (VECTOR™ 4114), 45 phr of a tackifying resin (ESCOREZ™ 1310), 9 phr of a liquid resin (ADTAC™ LV), 25 phr of mineral oil (PARAFLEX™ HT 68), and 1 phr of an antioxidant (IRGANOX™ B215) was coated onto the backing sheet. The overall thickness of the test sample was 6.0 mils with a backing thickness of 4.1 mils. The tensile strength was 15 lbs /in with an 85% elongation. Adhesion properties are 16 oz/inch adhesion to steel and 9 oz/inch adhesion to the backing. Subjectively, the test sample was found to have very good tack.

The present invention is designed to produce an adhesive tape for harness wraps which meets or exceeds Automotive Engineering Specification Ford Part. No. ES-XU5T-1A303-AA, Type A (temperature rating of 85°C). There is reference to low fogging characteristics, adhesion levels, physical performance, long-term heat aging, cold resistance and so on. While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration, and is not limited to the embodiments described above but encompasses any and all embodiments within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1. A non-halogen wiring harness wrap for a wiring system of a motor vehicle, the wrap comprising a backing having opposing sides comprising from about 30% to about 95% low-density polyethylene, and from about 5% to about 60% of a second polymer selected from the group consisting of ethylene-acrylic copolymers, ethylene-acetate copolymers, ethylene-acrylic acid copolymers, and elastomers; and a rubber-based adhesive disposed on one side of the backing forming an adhesive layer.

2. The wiring harness wrap of Claim 1, wherein the backing comprises from about 45% to about 85% low density polyethylene, and from about 5% to about 45% of an ethylene-acrylic copolymer.

3. The wiring harness wrap of Claim 1, wherein the backing comprises from about 45% to about 85% low density polyethylene, and from about 5% to about 45% of an ethylene-acetate copolymer.

4. The wiring harness wrap of Claim 1, wherein the backing comprises from about 45% to about 85% low density polyethylene, and from about 5% to about 45% of an ethylene-acrylic acid copolymer.

5. The wiring harness wrap of Claim 1, wherein the backing comprises from about 45% to about 85% low density polyethylene, and from about 5% to about 45% of an elastomer.

6. The wiring harness wrap of Claim 1, wherein the rubber-based adhesive is selected from the group consisting of natural rubbers, thermoplastic rubbers, and elastomeric polymer rubbers.

7. The wiring harness wrap of Clam 1, wherein the backing further comprises from about 0.5% to about 5% carbon black masterbatch, and from about 0.5% to about 5% antioxidant masterbatch.

8. The wiring harness wrap of Claim 7, wherein the backing further comprises from about 1% to about 5% carbon black masterbatch, and from about 0.5% to about 3% antioxidant masterbatch.

9. The wiring harness wrap of Claim 8, wherein the backing comprises from about 45% to about 85% low density polyethylene, from about 5% to about 45% of the second polymer, from about 2% to about 4% carbon black masterbatch, and from about 0.5% to about 2% antioxidant masterbatch.

10. The wiring harness wrap of Claim 9, wherein the backing comprises from about 60% to about 70% low density polyethylene, from about 25% to about 35% of the second polymer, from about 2% to about 3% carbon black masterbatch, and from about 0.5% to about 1.5% antioxidant masterbatch.

11. The wiring harness wrap of Claim 10, wherein the backing comprises about 65% low density polyethylene, about 30% of the second polymer, about 2% carbon black masterbatch, and about 1% antioxidant masterbatch.

12. The wiring harness wrap of Claim 1, wherein the adhesive layer has a thickness of from about 0.5 mils to about 5 mils.

13. The wiring harness wrap of Claim 1, wherein the backing has a thickness from about 3 mils to about 7 mils.

14. The wiring harness wrap of Claim 1, wherein the rubber-based adhesive is selected from the group consisting of natural rubber, ethylene- propylene rubbers, diene terpolymers, butyl rubber, and styrenic block copolymers.

15. The wiring harness wrap of Claim 1, wherein the ethylene- acrylic copolymers are selected from the group consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate and ethylene-acrylic elastomers.

16. A halogen-free wiring harness wrap for a wiring system of a motor vehicle, the wrap comprising: a backing having two opposing sides comprising from about 30% to about 95% low density polyethylene, from 5% to about 60% of a second polymer, from 1% to about 5% carbon black masterbatch, from 0.5% to about 5% antioxidant masterbatch, wherein the second polymer is selected from the group consisting of ethylene-acrylic copolymers, ethylene-acetate copolymers, ethylene-acrylic acid copolymers, and elastomers; and a rubber-based adhesive coated on at least one side of said backing

17. The wiring harness wrap of Claim 16, wherein the rubber-based adhesive is selected from the group consisting of natural rubber, ethylene propylene rubbers, diene terpolymers, butyl rubber, and styrenic block copolymers.

18. A wiring harness wrap for a wiring system of a motor vehicle, the wrap comprising: a backing having two opposing sides comprising from about 30% to about 95% low density polyethylene, from 5% to about 60% of ethylene- methyl acrylate copolymer containing from about 20% to 22% methyl acrylate, from 1% to about 3% carbon black masterbatch, from 0.5% to about 3% antioxidant masterbatch; and a rubber-based adhesive disposed on one side of the backing wherein the adhesive is a styrene-isoprene-styrene block copolymer.

19. A method for making a halogen-free wiring harness wrap for a wiring system of a motor vehicle, the method comprising the steps of: blending from about 30% to about 95% low density polyethylene, and from about 5% to about 60% of a second polymer selected from the group consisting of ethylene-acrylic copolymers, ethylene-acetate copolymers, ethylene-acrylic acid copolymers, and elastomers to form a molten low- density polyethylene mixture; extruding the molten low-density polyethylene mixture from an extruder onto a first nip and between a top and a center roll; forming a backing sheet having two opposing sides comprised of the mixture on the center roll; and coating one side of the backing sheet with a rubber-based adhesive by extruding a rubber-based adhesive onto a second nip and between the center roll and a bottom roll thereby calendering the rubber-based adhesive onto the backing sheet forming an adhesive layer.

20. The method of Claim 19, wherein the mixture comprises from about 45% to about 85% low density polyethylene, and from about 5% to about 45% of the second copolymer.

21. The method of Claim 19, wherein the rubber-based adhesive is selected from the group consisting of natural rubbers, thermoplastic rubbers, and elastomer ic polymer rubbers.

22. The method of Claim 19 wherein the rubber-based adhesive is selected from the group consisting of natural rubber, ethylene-propylene rubbers, diene terpolymers, butyl rubber, and styrenic block copolymers.

23. The method of Clam 19, wherein the mixture further comprises from about 0.5% to about 5% carbon black masterbatch, and from about 0.5% to about 5% antioxidant masterbatch.

24. The method of Claim 23, wherein the mixture further comprises from about 1% to about 5% carbon black masterbatch, and from about 0.5% to about 3% antioxidant masterbatch.

25. The method of Claim 24, wherein the mixture comprises from about 45% to about 85% low density polyethylene, from about 5% to about 45% of the second polymer, from about 2% to about 4% carbon black masterbatch, and from about 0.5% to about 2% antioxidant masterbatch.

26. The method of Claim 25, wherein the mixture comprises from about 60% to about 70% low density polyethylene, from about 25% to about 35% of the second polymer, from about 2% to about 3% carbon black masterbatch, and from about 0.5% to about 1.5% antioxidant masterbatch.

27. The method of Claim 26, wherein the mixture comprises about 65% low density polyethylene, about 30% of the second polymer, about 2% carbon black masterbatch, and about 1% antioxidant masterbatch.

28. The method of Claim 19, wherein the adhesive layer has a thickness of from about 0.5 mils to about 5 mils.

29. The method of Claim 19, wherein the backing sheet has a thickness from about 3 mils to about 7 mils.

30. The method of Claim 19, wherein the ethylene-acrylic copolymers are selected from the group consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate, and ethylene-acrylic elastomers.