Abstract: The invention pertains to multi-layer polymeric formulations for protecting or insulating metallic objects, and, more particularly, to an integrated, tri-layer, thin-wall insulation composite, for use in a high temperature, automotive-wire article. The tri-layer design comprises an inner layer of a fluoropolymer, polyether sulfone, polyether-ketone, polyetherimide, or thermoplastic polyester; a middle layer comprising a polyolefin; and an outer layer comprising a fluoropolymer. The inner and outer layers serve to protect the middle polyolefinic layer from degradation.

Abstract: The present invention features a high-temperature, automotive-wire article having a thin wall construction and an operative temperature of at least 135 degrees Centigrade. The wire article is made of an inner core of copper that is surrounded by a single layer of insulation, the latter of which includes an integral composite of two insulations. The inner layer of the composite consists of a fluorocarbon material; the outer layer of the composite is made of an irradiated, cross-linked polyolefin material. The outer layer may be irradiation cross-linked with between approximately 60 to 400 kGy, and preferably between 100 and 200 kGy. The inner and outer layers can optionally be adhesively bonded together or thermal fused together using a meltable resin, in order to form a single layer. The total wall thickness of the composite is less than approximately 0.5 mm.

Abstract: The present invention features a high-voltage, high-temperature cable article for use with electric motors, coils, transformers, generators and power supplies. The cable article has a conductive core member overlaid with an intermediate, semiconductive layer and an outer, insulative jacket layer. The intermediate, semiconductive layer can be a carbon-impregnated polymer such as a carbon-impregnated polyethylene; a carbon-impregnated, ethylene-propylene-diene terpolymer (EPDM); semiconductive nylon tape; semiconductive PTFE (polytetrafluoroethylene) tape; semiconductive fabric tape; or a semiconductive extruded fluorocarbon. The temperature rating of the cable article is at least approximately 150.degree. C.; the voltage rating can be in a range of approximately between 1,000 to 15,000 volts. The wall thickness of the semiconductive layer can range from approximately 2 to 20 mils. The outer, insulative jacket layer can be a cross-linked polyolefin, an elastomeric or a thermoplastic elastomer material.

Abstract: The present invention features a surge-protected cable for use in the wire leads and wire-wound stators of electrical motors. The cable of the invention is of the "filter line" type. This invention reduces failures in the stator windings of variable frequency drive (VFD) motors by attenuating peak voltages and transient voltage spikes. The "filter line" type of cable insulation prevents "dirty" power from unabated travel along the axis. This invention's type of filter line cable features a core member of one or more strands of conductive material overlaid with a primary insulation layer containing ferrites and/or magnetites; this layer is then further overlaid with a flame-retardant insulation jacket layer made of high-temperature material. Both the primary insulation and the outer jacket layer are cross-linked.

Abstract: The present invention features a new lead wire for use with class F motors, coils and transformers. The new motor lead wire has the UL-required temperature rating of at least 150.degree. C. and a voltage rating of approximately 600 volts. The lead wire is characterized by a thinner and less costly insulative construction. The motor lead wire has a conductive core member that is overcoated with a primary insulation layer of polyolefin. The polyolefin layer is of a reduced thickness, generally below the standard 30 mils. The polyolefin insulation thickness can be reduced by half, to about 15 mils. This reduced insulation layer is then protected with a jacket of polyvinylidene fluoride or a polyvinylidene fluoride copolymer having an approximate maximum thickness of 0.005 inches. The primary insulation is cross-linked and stabilized with zinc salt of methylmercaptobenzimidazole and a hindered phenol oxidant.

Abstract: An insulation system for electrical conductors is provided. The insulation system has a layer of polymer selected from ethylene-tetrafluoroethylene copolymer, ethylene-chlorotrifluoroethylene copolymer and ethylene-tetrafluoroethylene terpolymer surrounding the conductor. This layer of polymer is irradiation crosslinked with from 3 to 20 megarads of high energy ionizing irradiation. Bonded to the surface of the irradiation crosslinked layer of polymer is a polyimide coating. The insulation is a high temperature, flame resistant system having a combination of properties useful in the aircraft industry as airframe and hookup wire.