A method of forming a conductive portion in an insulating material. The insulating material includes carbon and at least one other constituent. The method includes exposing the insulating material to ions to preferentially remove the other constituent.

In one aspect, the present invention relates to a communications cable, which comprises a support separator providing a plurality of channels for receiving transmission media, said support separator comprising a first polymeric material, at least one optical fiber disposed in one of said channels, at least an electrical conductor capable of carrying at least about 10 watts of electrical power disposed in another one of said channels, an insulation at least partially covering said electrical conductor, a jacket surrounding said support separator and said transmission media, said jacket comprising a second polymeric material. In some embodiments, the first and second polymeric materials can be the same material, and in other embodiments, they can be different materials.

A method for forming magnet wire with improved partial discharge performance may include providing a conductor, forming a first layer of polymeric enamel insulation formed around the conductor, and forming a second semi-conductive layer around the first layer. Forming the second layer may include providing a base polyamic acid and complexing filler particles with the base polyamic acid. The polyamic acid may be applied around the first layer, and the filler particles may migrate towards an outer surface of the second layer. The polyamic acid may be cured to form a semi-conductive enamel layer, and at least sixty percent by weight of the filler particles may be positioned within an outer half of the second layer following the migration.

An electric winding assembly includes a conductor core having a first end and an opposing second end, an insulation layer overlying the conductor core, and a conductive shield layer overlying the insulation layer. The conductive shield layer includes an insulative carrier circumferentially surrounding the insulation layer and a conductive layer disposed on the insulative carrier, the insulative carrier formed from a material having a thermal rating greater than 180 C., the conductive shield layer having a surface resistivity between 1.5 and 10 ohms per square.

The disclosure provides a resin composition and a manufacturing method thereof. The resin composition includes a resin carrier, conductive carbon black, and graphene. The carbon black and graphene are dispersed in the resin carrier. Based on a total weight of the resin composition, the resin carrier accounts for 93 wt % to 97 wt %, the conductive carbon black accounts for 1 wt % to 3 wt %, and the graphene accounts for 2 wt % to 4 wt.

A method of manufacturing a corrosion-resistant wireline cable includes embedding a first layer of armor wires onto a core cable using a heated carbon fiber reinforced polymer. A second layer of carbon fiber reinforced polymer is then extruded to envelop the first layer of armor wires. In one method, a layer of virgin or colored polymer is extruded over the second layer, and a second layer of armor wires is embedded through the virgin or colored polymer, displacing it to envelop the outer armor wires. In another method, each wire in the second armor layer is coated with virgin polymer before being embedded into the second carbon fiber reinforced polymer layer. The assembly is then heated to cause the virgin polymer to migrate outward, forming an outermost layer. In both methods, a final jacket layer is applied over the exterior to complete the cable. The resulting cable provides corrosion resistance and mechanical reinforcement.