A method of manufacturing a wiring harness assembly includes the steps of forming a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, forming an opening in the substrate located and sized such that a section of the plurality of electrically conductive wires is exposed within the opening, disposing a support segment within the opening, securing a connector segment including a plurality of terminals to the support segment, and placing the plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.

A process produces an electrical line which extends in the longitudinal direction and the line has a line core and an outer shell. In a continuous shaping process, individual shell portions of the outer shell are formed successively by surrounding the line core with a curable plastic substance. In at least one portion, the outer shell is produced having a cross-sectional geometry which can be varied in the longitudinal direction of the line.

A power cable can include a conductor; an insulation layer disposed about the conductor where the insulation layer includes a first polymeric material; and a shield layer disposed about the insulation layer where the shield layer includes a second polymeric material where a solubility parameter of the first polymeric material is less than a solubility parameter of the second polymeric material.

Magnet wire including extruded insulation formed from multiple layers of different materials is described. A magnet wire may include a conductor and insulation formed around the conductor. The insulation may include a first layer of extruded thermoplastic insulation formed around the conductor and a second layer of extruded thermoplastic insulation formed around the first layer of extruded thermoplastic insulation. The first layer may be formed from a first polymeric material having a first thermal index, and the second layer may be formed from a second polymeric material having a second thermal index higher than the first thermal index.

An electric cable for improving flexibility of an insulating resin portion of the electric cable expressed by a secant modulus value is provided. In an electric cable 10a in which an outer periphery of a conductor 11 made of wires with diameters from 0.15 to 0.5 mm and having a cross-sectional area of 20 mm.sup.2 or more is covered with an insulating resin 12 including a flame retardant, a ratio of an electric cable diameter to a conductor diameter is from 1.15 to 1.40, and a secant modulus of the insulating resin 12 is from 10 to 50 MPa.

A fire-resistant coaxial cable is described in which the dielectric between the central conductor and outer coaxial conductor can ceramify under high heat. The dielectric is composed of a ceramifiable silicone rubber, such as that having a polysiloxane matrix with inorganic flux and refractory particles. An outer wrap of ceramic fiber yarn surrounds the outer conductor and continues to insulate it from the outside if a low smoke zero halogen jacket burns away. Embodiments include those with durable corrugated outer conductors or flexible braided outer conductors. Methods of testing and installation are described.

A high-speed transmission line includes a first shielded layer, a first insulating layer, a conductor layer, a second insulating layer and a second shielded layer sequentially attached to each other. The conductor layer includes plural first conductors and plural first conductors interspersed with each other, and the first conductor has a round cross section and is made of a round copper wire capable of increasing the signal transmission speed and extending the scope of application of the transmission line of a flexible cable.

A coaxial cable includes a conductor, an electrically insulating member provided over a periphery of the conductor, a shielding layer composed of served shields formed by helically wrapping a plurality of metal wires around the electrically insulating member, and a sheath provided around the shielding layer. The electrically insulating member includes indentations on portions of its surface to be brought into contact with and mated to the metal wires respectively. The shielding layer includes portions in respective circumferential directions of the plurality of metal wires being brought into contact with the electrically insulating member are mated to the indentations, respectively, on the electrically insulating member, and adjacent ones of the metal wires in a circumferential direction of the shielding layer are in surface contact with each other.

A thermoplastic composition includes an aromatic poly(ketone), a poly(etherimide), and a reactive additive, wherein each component is present in a particular amount as defined herein. The thermoplastic composition can be useful in an insulating layer disposed over a conductor wire to form an electrical wire. Articles including the thermoplastic composition can be particularly useful in applications including an electrical device component, a railway vehicle component, an auto-mobile component, a marine vehicle component, a construction component, construction component, a building component, or an aircraft component.

An insulated electrically conductive element, including at least one inner electrically conductive element and at least one outer insulating element, and to a method for producing such an insulated electrically conductive element.