An insulated electric conductor includes a flat or round wire made of one or more electrically conductive materials, the flat or round wire having an exterior surface that is free of an oxide layer; and an insulating layer adhering directly to the oxide-layer-free exterior surface to form a coating around the oxide-layer-free exterior surface, the insulating layer being made of at least one thermoplastic material which provides electrical insulation. The flat or round wire is designed to conduct an electrical current.

A new dielectric material for a communication cable has a dielectric base with strength members embedded therein. By a new process, vacuum voids are formed in the dielectric base and at least partially contain or abut the strength members. The material is particularly well suited for a first dielectric tape, where the cable includes a first insulated conductor, the first dielectric tape and a second insulated conductor, with the first insulated conductor being twisted with the second insulated conductor with the first dielectric tape residing between the first insulated conductor and the second insulated conductor. The material is also suitable for a separator of the cable serving to separate twisted pairs from each other within the cable, as well as other components of the cable, such as an insulation layer of one or more of the insulated conductors of the twisted pairs.

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.

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a thermoset polymeric material and process the thermoset polymeric material to increase its pressure and temperature. An extrusion crosshead assembly in fluid communication with the extruder may receive the thermoset polymeric material and press extrude the thermoset polymeric material as insulation onto a magnet wire. A curing device may then cure the extruded insulation material.

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.

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.

A coaxial cable includes a conductor, an electrically insulating member provided over a periphery of the conductor, a shielding layer composed of served shields formed by helically wrapping a plurality of metal wires around the electrically insulating member, and a sheath provided around the shielding layer. The electrically insulating member includes indentations on portions of its surface to be brought into contact with and mated to the metal wires respectively. The shielding layer includes portions in respective circumferential directions of the plurality of metal wires being brought into contact with the electrically insulating member are mated to the indentations, respectively, on the electrically insulating member, and adjacent ones of the metal wires in a circumferential direction of the shielding layer are in surface contact with each other.

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.

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.

A dielectric isolator for a twisted pair cable includes a body formed as an elongate strip with a top surface, bottom surface, a first side edge and a second side edge. A first slot is formed in the first side edge and extends at least half way toward the center of the isolator. A second slot is formed in the second side edge and extends at least half way toward the center of the isolator. During cable manufacturing, first and second wedges open the first and second slots. First and second twisted pairs are inserted into the first and second opened slots, respectively. Third and fourth twisted pairs reside at the top and bottom surface, respectively. The isolator has the cost and reel storage savings of a flat separator tape, while simultaneously providing the internal crosstalk performance of the isolator.