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.

In order to increase the adhesion of an insulating coating (2) to an electric conductor (1), preferably of copper or aluminum, an insulated electric conductor comprising an electric conductor (1), preferably made of copper or aluminum, with an insulating coating (2) is proposed according to the invention, wherein the insulating coating (2) either comprises at least one insulating layer (3) made of thermoplastic material, or the insulating layer (3) and a plastic-containing intermediate layer (4, 5), obtainable by a method in which the electric conductor (1) is placed under a protective gas atmosphere and is bombarded with ions of the protective gas in a gas plasma in order to remove an oxide layer formed on a surface of the electric conductor (1) and/or to increase the surface energy of the electric conductor (1), and subsequently either the at least one insulating layer (3) or, in the case that the coating (2) comprises the plastic-containing intermediate layer (4, 5), at least the plastic-containing intermediate layer (4, 5) is applied directly to the surface of the electric conductor (1) under a protective gas atmosphere.

Example implementations include an insulated wire and a preparation method thereof, a coil and an electronic/electrical device. A bonding layer containing PEEK nano-powder is arranged between a conductor and a PEEK resin insulating layer, and a bonding agent for forming the bonding layer contains organic solvent, polyamide-imide resin and PEEK nano-powder material which are mixed.

A power cable for an electric submersible pump (ESP) includes an electrical conductor in the power cable; an elastomeric insulation layer around the electrical conductor; a fluoroplastic barrier layer around the elastomeric insulation layer; and a bonding layer between the elastomeric insulation layer and the fluoroplastic barrier layer, the bonding layer formulated to prevent a dielectric breakdown of the power cable and a rapid gas decompression breakdown of the power cable.

A cooling system (100) for cooling a cable (10). The system (100) comprises: at least one fixed cooling channel (20), which is arranged downstream of an extrusion head (EH); and at least one multi-pass apparatus (30), which in turn comprises a set of fixed pulleys (32, 33, 34), and a fixed, motor-driven capstan (35) designed to wind the cable (10). The system (100) is characterized in that the multi-pass apparatus (30) comprises a movable pulley (36) designed to translate along vertical guides (39A, 39B). The movable pulley (36) and the vertical guides (39A, 39B) are contained in a cooling device (56) for cooling the cable (10).

The present invention relates to a fire-resistant cable comprising at least one electrically insulating composite layer based on at least one cementitious material and at least one starch, and the process for manufacturing same.

An electrical cable includes a plurality of conductors forming a conductor core, one or more insulation layers at least partially surrounding at least one of the plurality of conductors, an outer jacket surrounding the conductor core and a film applied to the exterior surface of the outer jacket. The film includes high visibility particles. Methods of forming electrical cables are also described herein.

A particular method includes using a helical forming tool to make helical grooves on an insulating jacket of a conductive length, such as a wire. A gear may rotate a forming mechanism, such as a protrusion, around the insulating jacket to form the helical grooves. The helical grooves are formed to limit bending of the insulated wire.

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.