The present disclosure provides insulated electrical conductors, e.g., wires, and methods for producing such insulated electrical conductors to combat partial discharge by enhancing bond strength between the electrical conductor and a base insulating thermoplastic layer (e.g., including a PAEK). Such insulated electrical conductors can include: an electrical conductor; an insulating coating on at least a portion of a surface of the electrical conductor; and an oxide layer between the electrical conductor and the insulating coating. Methods for producing such insulated electrical conductors can involve extrusion of an insulating polymer onto the electrical conductor under ambient atmosphere and a subsequent heat treatment step, which can also be conducted under ambient atmosphere.

An insulating composition comprising a polymer resin, a nanoclay, and one or more nanofillers. The insulating composition has a thermal conductivity of greater than about 0.8 W/mK, a dielectric constant of less than about 5, a dissipation factor of less than about 3%, and a breakdown strength of greater than about 1,000 V/mil. The insulating composition has an endurance life of at least 400 hours at 310 volts per mil.

A system and method for enhanced magnet wire insulation is described. A method of making an enhanced magnet wire insulation suited for an electric submersible motor application includes drawing copper magnet wire to size, cleaning the copper magnet wire, pulling the copper magnet wire through a polyimide wrap machine to produce wrapped copper magnet wire and placing the wrapped copper magnet wire around a spool, heating the wrapped magnet wire by unspooling the wrapped magnet wire through a tube comprising an induction coil, removing moisture from the heated, wrapped copper magnet wire by creating at least a partial vacuum inside the tube, redrawing the wrapped copper magnet wire through an extrusion mold after moisture is removed, applying molten PEEK to the wrapped copper magnet wire to produce enhanced magnet wire, and winding the enhanced magnet wire into an induction motor to be used to operate an electric submersible pump.

Adhesive compositions are described that significantly improve the adhesion of polymer overmold compositions to metal substrates in polymer-metal junctions. The adhesive compositions include one or more poly(aryl ether) polymers, where each of the poly(aryl ether) polymers is, independently, a poly(aryl ether sulfone) polymer or a poly(aryl ether ketone) polymer. The overmold composition includes at least one poly(aryl ether ketone) polymer. Polymer-Metal junctions can be formed by, for example, dip-coating, spin-coating, extruding, or injection molding the adhesive composition and/or the overmold composition onto the metal substrate. Desirable applications settings for the polymer-metal junctions described include, but are not limited to electrical wiring.

A technique facilitates construction and operation of a power cable which may be used to deploy an electric submersible pumping system downhole into a wellbore. The power cable is constructed to provide structural support of the electric submersible pumping system while also providing electric power to the electric submersible pumping system when located downhole in the wellbore. The power cable comprises at least one conductor and a plurality of layers selected and arranged to ensure long-term support and delivery of electrical power in the relatively harsh downhole environment.

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.

A method for producing a binder resin by a reaction of a cellulose derivative, a polyvinyl acetal, and a bonding agent that has in the molecule at least two functional groups that can react to hydroxyl groups in the polyvinyl acetal and the cellulose derivative. In the production method, the content of the bonding agent is at least double the molar quantity of whichever has the greater number of moles between the polyvinyl acetal and the cellulose derivative. The produced binder resin is favorable in a coating paste such as a conductive paste, and causes an improvement in film quality such as the smoothness and denseness of a coating film formed by the paste.

An insulated wire, containing: a rectangular conductor; and a thermoplastic resin layer on the rectangular conductor, wherein an adhesion strength between the thermoplastic resin layer and the rectangular conductor for a pair of sides of the rectangular conductor opposed to and an adhesion strength between the thermoplastic resin layer and the rectangular conductor for the other pair of sides of the rectangular conductor opposed to are different from each other.

An insulation wire includes a conductor, a first insulating layer formed in an outer surface of the conductor, and a second insulating layer formed in an outer surface of the first insulating layer. In the insulation wire, the first insulating layer is a thermoplastic resin layer that is made of polyphenylene sulfide or polyether ether ketone, and the second insulating layer is a thermosetting resin layer.

The present invention relates to a poly(arylene ether) resin composition and a cable coated with the same. More particularly, the present invention relates to a poly(arylene ether) resin composition, including 20 to 40% by weight of a poly(arylene ether) resin, 15 to 35% by weight of a low-molecular weight styrene-based block copolymer having a weight-average molecular weight of 90,000 g/mol or less, 10 to 30% by weight of a high-molecular weight styrene-based block copolymer having a weight-average molecular weight of 95,000 g/mol or more, 1 to 20% by weight of a flame retardant, and 0 to 20% by weight of an additive.

In accordance with the present invention, a poly(arylene ether) resin composition having superior flame retardancy, tensile strength, flexibility, extrusion processability, elongation, and appearance characteristics and a cable coated with the same are provided.