An assembly can include a housing that includes opposing ends, a longitudinal axis, an axial length defined between the opposing ends, a maximum transverse dimension that is less than the length and an interior space; circuitry disposed at least in part in the interior space; and a coated electrical conductor electrically coupled to the circuitry where the coated electrical conductor includes an electrical conductor that includes copper and a length defined by opposing ends, a polymeric electrical insulation layer disposed about at least a portion of the length of the electrical conductor, and a barrier layer disposed about at least a portion of the polymeric electrical insulation layer.

An insulation defect detection method for magnet wire coating includes: a running step of causing a magnet wire to run in a line direction; a first discharge detection step of detecting a first discharge by applying AC voltage to a measurement point on the running magnet wire; a second discharge detection step of detecting a second discharge by applying AC voltage to a measurement point on the magnet wire after the first discharge is detected; and a determination step of determining whether or not the magnet wire coating has an insulation defect by comparing the first discharge with the second discharge.

An insulation defect detection method for magnet wire coating includes: a running step of causing a magnet wire to run in a line direction; a first discharge detection step of detecting a first discharge by applying AC voltage to a measurement point on the running magnet wire; a second discharge detection step of detecting a second discharge by applying AC voltage to a measurement point on the magnet wire after the first discharge is detected; and a determination step of determining whether or not the magnet wire coating has an insulation defect by comparing the first discharge with the second discharge.

An insulated electric wire and a method of producing the electric wire are provided. The insulated electric wire includes: a copper wire; and an insulating coating formed on a surface of the copper wire by an electrodeposition method. A cross section shape of the insulated electric wire including the insulating coating is in a hexagonal shape, a chamfered part that suppresses swelling of the insulating coating is formed on each corner part of a hexagonal cross section of the copper wire, a length of the chamfered part is 1/3 to 1/20 of a length of a flat part of the hexagonal cross section, and a void ratio in a wound state is 5% or less.

A method for manufacturing an insulated conductive material includes applying a masking material to one or more regions of a conductive material. Regions of the conductive material other than the masked regions are coated. The regions are coated by electrically charging the conductive material with a first charge polarity, providing a medium of electrically charged insulating material particles that are charged with an opposite polarity, and passing the charged conductive material through the medium, whereby the insulating material particles bind areas of the conductive material and form an insulating film on areas of the surface other than the one or more regions. Afterwards, the insulating film is cured and a solvent is applied to the masking material to thereby remove the masking material. The cured insulated material film is substantially unaffected by the solvent.

A method for manufacturing an insulated conductive material includes applying a masking material to one or more regions of a conductive material. Regions of the conductive material other than the masked regions are coated. The regions are coated by electrically charging the conductive material with a first charge polarity, providing a medium of electrically charged insulating material particles that are charged with an opposite polarity, and passing the charged conductive material through the medium, whereby the insulating material particles bind areas of the conductive material and form an insulating film on areas of the surface other than the one or more regions. Afterwards, the insulating film is cured and a solvent is applied to the masking material to thereby remove the masking material. The cured insulated material film is substantially unaffected by the solvent.

An apparatus and method for modifying an aspect of an exterior polymer material or polymer type material of a linear substrate with a fluid. The apparatus include a variable exposure gap within which the linear substrate is exposed to the fluid. The width of the exposure gap is varied with the speed of the linear substrate traversing the exposure gap to maintain a constant exposure time of the linear substrate with the modifying fluid.

An apparatus and method for modifying an aspect of an exterior polymer material or polymer type material of a linear substrate with a fluid. The apparatus include a variable exposure gap within which the linear substrate is exposed to the fluid. The width of the exposure gap is varied with the speed of the linear substrate traversing the exposure gap to maintain a constant exposure time of the linear substrate with the modifying fluid.

An insulated conductor having a conductor and an insulating film provided on a surface of the conductor, in which the insulating film has a fluorine-containing resin composition layer including a cured product of a thermosetting resin and a fluororesin and a fluorine concentration gradient layer which is disposed between the conductor and the fluorine-containing resin composition layer. The fluorine-containing resin composition layer includes a cured product of a thermosetting resin and a fluororesin, and is provided with a concentration gradient in which a fluorine atom content decreases from the fluorine-containing resin composition layer side toward the conductor.

The invention relates to a method for manufacturing a cable bundle. At least one provided first cable is completely coated circumferentially on an outer side of the insulating sheath of the first cable with a hot-melt adhesive. In a further step, the first cable is positioned so that it touches a provided second cable over at least a partial length of the cables. In a further step, at least one local adhesive connection is produced between the first cable and the second cable along a partial length of the cables by locally melting the hot-melt adhesive on the first cable.