Process for manufacturing a power cable includes: providing a power cable core having an electric conductor; providing a copper foil; providing a protective strip over the power cable core, the protective strip having a radially inner and outer surface and being made of copper with a coating; folding the copper foil around the power cable core so as to bring two longitudinal copper foil rims to contact one to the other; welding the two contacted longitudinal copper foil rims thus obtaining a copper sheath in form of a tube with a welding seam; reducing the diameter of the copper sheath to put it into direct contact with the power cable core and the protective strip; heating the protective strip and the copper sheath at a temperature higher than the melting temperature of the coating of the strip so that the coating fuses in the welding seam.

Process for manufacturing a power cable includes: providing a power cable core having an electric conductor; providing a copper foil; providing a protective strip over the power cable core, the protective strip having a radially inner and outer surface and being made of copper with a coating; folding the copper foil around the power cable core so as to bring two longitudinal copper foil rims to contact one to the other; welding the two contacted longitudinal copper foil rims thus obtaining a copper sheath in form of a tube with a welding seam; reducing the diameter of the copper sheath to put it into direct contact with the power cable core and the protective strip; heating the protective strip and the copper sheath at a temperature higher than the melting temperature of the coating of the strip so that the coating fuses in the welding seam.

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.

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.

In various embodiments, a non-circular electrical cable having a reduced pulling force attributable to the exterior surface of an outer sheath, and method of producing the same is provided. In various embodiments, an outer sheath of the cable may comprise a first and second sheath layer, the second sheath layer being located external to the first sheath layer, and comprising a nylon material configured to reduce the pulling force necessary for installing the cable. In various embodiments, the first sheath layer may be extruded using a tube extrusion method into a substantially circular shape, and the second sheath layer may be extruded using a pressure extrusion methods onto the exterior surface of the first sheath layer while maintaining the at least substantially circular shape of the sheath. The sheath may then be pulled onto the surface of a plurality of conductors to form the non-circular electrical cable.

In various embodiments, a non-circular electrical cable having a reduced pulling force attributable to the exterior surface of an outer sheath, and method of producing the same is provided. In various embodiments, an outer sheath of the cable may comprise a first and second sheath layer, the second sheath layer being located external to the first sheath layer, and comprising a nylon material configured to reduce the pulling force necessary for installing the cable. In various embodiments, the first sheath layer may be extruded using a tube extrusion method into a substantially circular shape, and the second sheath layer may be extruded using a pressure extrusion methods onto the exterior surface of the first sheath layer while maintaining the at least substantially circular shape of the sheath. The sheath may then be pulled onto the surface of a plurality of conductors to form the non-circular electrical cable.

A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

A seal mold divided structure for combination cable disclosed comprises the following structures: a first cable and a second cable separated from the combination cable; a connector provided at the end of the first cable; a division molding portion that molds the division part between the first cable and the second cable and keeps the first cable and the second cable separated from each other; a connector molding portion that molds the connection part between the connector and the first cable; and a protect tube, with its ends respectively fixed to the division molding portion and the connector molding portion to protect the first cable and prevent inflow of a molding compound.

A seal mold divided structure for combination cable disclosed comprises the following structures: a first cable and a second cable separated from the combination cable; a connector provided at the end of the first cable; a division molding portion that molds the division part between the first cable and the second cable and keeps the first cable and the second cable separated from each other; a connector molding portion that molds the connection part between the connector and the first cable; and a protect tube, with its ends respectively fixed to the division molding portion and the connector molding portion to protect the first cable and prevent inflow of a molding compound.