An insulated electric wire includes a conductor comprising twisted elemental wires and an insulation covering. The insulated electric wire includes an exposed portion in which the insulation covering is removed from the outer surface of the conductor, and a covered portion in which the insulation covering covers the outer surface of the conductor. The exposed portion and the covered portion are adjacent with each other along a longitudinal axis of the insulated electric wire. A density of the conductive material per unit length is higher in the exposed portion than in the covered portion. The elemental wires are twisted in both the exposed portion and the covered portion including an area that is positioned away from the exposed portion by at least a distance corresponding to a length of the exposed portion. Gaps between the elemental wires of the exposed portion are filled with a sealant.

A sealed cable assembly includes a jacket enclosing a plurality of insulated wires. Each insulated wire includes a bare wire covered by surrounding insulation, and a cable plug or connector is electrically connected with the bare wires. A sealant surrounds the insulated wires in an air gap between the jacket and the insulated wires in a location at or near the cable plug or connector, and the sealant fills the air gap at the location to prevent or reduce fluid loss through the cable in an immersion cooling system. The cable assembly can also be sealed at an in-between section away from the cable plug or connector. The cable assembly is wrapped with a weatherproof film or tape at the location of the sealing to further prevent or reduce fluid loss through the cable.

A sealed cable assembly includes a jacket enclosing a plurality of insulated wires. Each insulated wire includes a bare wire covered by surrounding insulation, and a cable plug or connector is electrically connected with the bare wires. A sealant surrounds the insulated wires in an air gap between the jacket and the insulated wires in a location at or near the cable plug or connector, and the sealant fills the air gap at the location to prevent or reduce fluid loss through the cable in an immersion cooling system. The cable assembly can also be sealed at an in-between section away from the cable plug or connector. The cable assembly is wrapped with a weatherproof film or tape at the location of the sealing to further prevent or reduce fluid loss through the cable.

Provided are methods for extending the life of in-service electrical cable having polymeric insulation, comprising injecting a dielectric enhancement fluid composition into the cable, wherein the composition comprises: (a) one or more organoalkoxysilane functional additives (voltage stabilizer-based, hindered amine light stabilizer (HALS)-based, and/or UV absorber-based); and (b) a catalyst suitable to catalyze hydrolysis and condensation of (a), the injected composition providing for rapid initial permeation of (a) into the insulation, and extended retention of subsequent condensation products of (a) in the insulation. Additionally provided are innovative silyl functional ferrocenes (e.g., containing a ferrocene moiety and a silyl function hydrolysable to silanol) having utility as functional voltage stabilizing additives in the methods.

An insulated electric wire includes: an exposed portion and a covered portion including the insulation covering, and further includes a water-stopping portion wherein a water-stopping agent is placed over the exposed portion, and part of the covered portion and is adjacent to the exposed portion. The water-stopping portion continuously has: an inter-elemental-wire filling area filled with the water-stopping agent in gaps between conductor elemental wires; an exposed-portion-outer-circumferential area wherein the water-stopping agent covers an outer circumference of the conductor; and a covered-portion-outer-circumferential area wherein the water-stopping agent covers an outer circumference of the insulation covering. In a subject region that is a part of the exposed-portion-outer-circumferential area and is other than a region closer to the covered-portion-outer-circumferential area with a larger outer diameter due to a thickness of the insulation covering, a difference between a maximum and minimum outer diameter is not greater than 12% of the minimum outer diameter.

An insulated electric wire includes: an exposed portion and a covered portion including the insulation covering, and further includes a water-stopping portion wherein a water-stopping agent is placed over the exposed portion, and part of the covered portion and is adjacent to the exposed portion. The water-stopping portion continuously has: an inter-elemental-wire filling area filled with the water-stopping agent in gaps between conductor elemental wires; an exposed-portion-outer-circumferential area wherein the water-stopping agent covers an outer circumference of the conductor; and a covered-portion-outer-circumferential area wherein the water-stopping agent covers an outer circumference of the insulation covering. In a subject region that is a part of the exposed-portion-outer-circumferential area and is other than a region closer to the covered-portion-outer-circumferential area with a larger outer diameter due to a thickness of the insulation covering, a difference between a maximum and minimum outer diameter is not greater than 12% of the minimum outer diameter.

A wire harness including: an electric wire; a first tube that is made of a metal and covers an outer circumference of the electric wire; a braided wire that is formed by braiding conductive strands into a tubular shape, is attached to an outer circumferential surface of the first tube, and covers an outer circumference of a drawn-out portion of the electric wire, the drawn-out portion being drawn out from an end of the first tube; and a second tube that is made of a metal.

A wire harness including: an electric wire; a first tube that is made of a metal and covers an outer circumference of the electric wire; a braided wire that is formed by braiding conductive strands into a tubular shape, is attached to an outer circumferential surface of the first tube, and covers an outer circumference of a drawn-out portion of the electric wire, the drawn-out portion being drawn out from an end of the first tube; and a second tube that is made of a metal.

A waterproof seal for electrical assemblies wherein an outer sheath of an electrical cable is removed to expose the wires and the insulation is removed from the wires to form a window of exposed electrical conductor, the electrical conductors being maintain apart from each other and contained in a cover that may comprise a connector, an epoxy applied to the electrical conductors to fill in all the space in and around the electrical conductors and the cover to form a waterproof seal that prevents water from wicking past the waterproof seal via an interior of the electrical cable.

A waterproof seal for electrical assemblies wherein an outer sheath of an electrical cable is removed to expose the wires and the insulation is removed from the wires to form a window of exposed electrical conductor, the electrical conductors being maintain apart from each other and contained in a cover that may comprise a connector, an epoxy applied to the electrical conductors to fill in all the space in and around the electrical conductors and the cover to form a waterproof seal that prevents water from wicking past the waterproof seal via an interior of the electrical cable.