Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a plurality of ingredients for a polymeric insulation material and process the plurality of ingredients to facilitate polymerization of the polymeric insulation material within the extruder. An application assembly in fluid communication with the extruder may apply the polymeric insulation material onto a wire. A curing device may then cure the polymeric insulation material.

Disclosed are cable types, including a type THHN cable, the cable types having a reduced surface coefficient of friction, and the method of manufacture thereof, in which the central conductor core and insulating layer are surrounded by a material containing nylon or thermosetting resin. A silicone based pulling lubricant for said cable, or alternatively, erucamide or stearyl erucamide for small cable gauge wire, is incorporated, by alternate methods, with the resin material from which the outer sheath is extruded, and is effective to reduce the required pulling force between the formed cable and a conduit during installation.

The present invention relates to a wire or cable comprising a conductor coated with an insulation composition, wherein said insulation composition comprises: i) a polyethylene copolymer having a melting point of 105° C. or less; and ii) a hindered amine light stabiliser (HALS) comprising at least one 2,2,6,6-tetramethyl-piperidinyl group present in an amount of 0.5 to 1.5 wt %.

An automotive communications cable includes a cable jacket, a pair of twisted conductors disposed within the cable jacket, and two or more insulating strands disposed within the cable jacket. The two or more insulating strands include a central insulating strand disposed between a first conductor in the pair of twisted conductors and a second conductor in the pair of twisted conductors.

A shielded electrical ribbon cable includes adjacent first and second longitudinal conductor sets where each conductor set includes two or more insulated conductors. The first conductor set also includes a ground conductor that generally lies in the plane of the insulated conductors of the first conductor set. At least 90% of the periphery of each conductor set is encompassed by a shielding film. First and second non-conductive polymeric films are disposed on opposite sides of the cable and form cover portions substantially surrounding each conductor set, and pinched portions on each side of each conductor set. When the cable is laid flat, the distance between the center of the ground conductor of the first conductor set and the center of the nearest insulated conductor of the second conductor set is σ1, the center-to-center spacing of the insulated conductors of the second conductor set is σ2, and σ1/σ2 is greater than 0.7.

A shielded electrical ribbon cable includes adjacent first and second longitudinal conductor sets where each conductor set includes two or more insulated conductors. The first conductor set also includes a ground conductor that generally lies in the plane of the insulated conductors of the first conductor set. At least 90% of the periphery of each conductor set is encompassed by a shielding film. First and second non-conductive polymeric films are disposed on opposite sides of the cable and form cover portions substantially surrounding each conductor set, and pinched portions on each side of each conductor set. When the cable is laid flat, the distance between the center of the ground conductor of the first conductor set and the center of the nearest insulated conductor of the second conductor set is σ1, the center-to-center spacing of the insulated conductors of the second conductor set is σ2, and σ1/σ2 is greater than 0.7.

An opto-electrical cable may include an opto-electrical cable core and a polymer layer surrounding the opto-electrical cable core. The opto-electrical cable core may include a wire, one or more channels extending longitudinally along the wire, and one or more optical fibers extending within each channel. The opto-electrical cable may be made by a method that includes providing a wire having a channel, providing optical fibers within the channel to form an opto-electrical cable core, and applying a polymer layer around the opto-electrical cable core. A multi-component cable may include one or more electrical conductor cables and one or more opto-electrical cables arranged in a coax, triad, quad configuration, or hepta configuration. Deformable polymer may surround the opto-electrical cables and electrical conductor cables.

An opto-electrical cable may include an opto-electrical cable core and a polymer layer surrounding the opto-electrical cable core. The opto-electrical cable core may include a wire, one or more channels extending longitudinally along the wire, and one or more optical fibers extending within each channel. The opto-electrical cable may be made by a method that includes providing a wire having a channel, providing optical fibers within the channel to form an opto-electrical cable core, and applying a polymer layer around the opto-electrical cable core. A multi-component cable may include one or more electrical conductor cables and one or more opto-electrical cables arranged in a coax, triad, quad configuration, or hepta configuration. Deformable polymer may surround the opto-electrical cables and electrical conductor cables.

The invention relates to power cable polymer composition which comprises a single site polyethylene (SSPE), a power cable, for example, a high voltage direct current (HV DC), a power cable polymer insulation, use of a polymer composition for producing a layer of a power cable, and a process for producing a power cable.

A winding wire having a stranded wire formed by twisting a plurality of element wires whose a copper wire having a wire diameter of 0.05 to 0.5 mm and an extrusion coating layer coating the plurality of the element wires, wherein at least one of the element wires has a magnetic layer on an outer circumference of the copper wire, and the thickness of the extrusion coating layer is 40 to 400 μm;
as well as a coil and a transformer using the winding wire.