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.

A resin composition, containing an ethylene-vinyl acetate copolymer (A); and 15 to 30 mass parts of a bromine-based flame retardant (B), 5 to 15 mass parts of antimony trioxide (C), 6 to 12 mass parts of a benzimidazole-based aging retardant (D), 2 to 4 mass parts of a phenol-based aging retardant (E), 2 to 4 mass parts of a thioether-based aging retardant (F), 0.5 to 2 mass parts of a copper inhibitor (G), and 3 to 6 mass parts of a crosslinking aid (H), with respect to 90 to 100 mass parts of the ethylene-vinyl acetate copolymer (A); a vehicle wire harness; and, a method of producing a vehicle wire harness.

There are provided a process for producing an electrical wire molded body comprising: step I of melting and kneading a polyethylene-based resin (a), a polypropylene-based resin (b), a block copolymer (c) of an aromatic vinyl-based compound and a conjugated diene-based compound and the like, and a silane coupling agent (g), and other components, to produce a silane crosslinkable flame retardant polyolefin (A); step II of melting and kneading a polymer selected from the components (a) to (c) and a silanol condensation catalyst (i), to produce a silanol catalyst rein composition (B); and step III of mixing the components (A) and (B), melt molding the mixture on a conductor and then crosslinking the molded body in the presence of water.

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.

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.

An electric wire protection member covering and protecting an outer periphery of an electric wire, the electric wire protection member includes an exterior member made of a flexible resin and having a tubular body in which peak portions and valley portions are alternately formed in an axial direction over a peripheral direction orthogonal to the axial direction, and a tubular bending restriction member accommodated in the exterior member and capable of bending in one direction with one side portion as an inner side. The bending restriction member includes a cut-out portion and a plurality of divided tubular portions connected by a connecting portion formed in the one side portion. The cut-out portion is inclined in the axial direction with respect to a radial direction of the bending restriction member.

An insulated wire includes a conductor including a copper material, and an insulation layer that is formed on an outer periphery of the conductor. A restoring temperature T.sub.B of the conductor is not more than 130 C. The restoring temperature T.sub.B is a temperature that is needed to restore a conductivity of the conductor after a coil processing to a conductivity of the conductor before the coil processing.

A self-bonding conductive wire and methods in which it is made and used. The wire comprises a conductor, an insulator, and a self-bonding outer coating. The self-bonding outer coating is a polyester polyether block copolymer. The insulator is an ethylene/tetrafluoroethylene copolymer, one or more layers of which may be used to insulate the conductor. The self-bonding capabilities of the wire may be activated by heating the wire, causing the outer coating to thermoplastically deform and fuse, allowing for the creation of self-supporting structures such as large bobbin-less coils. The use of the polyester polyether block copolymer for the self-bonding outer coating is superior to other materials, in which significant degradation of qualitative properties following self-bonding is observed, resulting in a superior self-bonding conductive wire.

The invention is related to a method of providing an insulated electric DC cable or DC termination or joint, the method comprising:providing a polymer based insulation system (11,12,13) comprising a compounded polymer composition (12), characterized by the step of:exposing the polymer based insulation system (11,12,13) to a heat treatment procedure while the outer surface of the polymer based insulation system (11,12,13) is covered by a cover (14) permeable to all the substances present in the polymer based insulation system (11,12,13) in a non-homogenous distribution, the permeable cover (14) having a melting and/or softening temperature greater than or equal to 120 C., thereby equalizing the concentration of the substances in the polymer based insulation system (11,12,13), the cable comprising a multi-wire conductor (10) that includes a central circular wire (101) that is surrounded by several layers of adjacent quadrangular wires (102).