Abstract: A communications cable is provided having at least one elongate electrical conductor surrounded by a layer of insulating material, said layer comprising a foamed fluorinated polymer formed using a liquid or solid blowing agent having a vaporization temperature at ambient temperature of between about 140.degree. F. and about 700.degree. F. The elongate electrical conductors can be provided as at least one pair of twisted wires, each wire thereof surrounded by a layer of insulating material comprising the foamed fluorinated polymer. The communications cable includes insulated wires which possess a layer of foamed fluorinated polymer insulating material having uniform thickness and electrical properties along the length of the wire. In addition, the fluorinated polymer can be applied on the conductor in a relatively thin layer which minimizes the amount of fluorinated polymer material used to insulate the individual conductors.

Abstract: There is disclosed an insulated wire having an extrusion-coating insulating layer provided on the outer surface of a conductor directly or via some other layer, or provided on the peripheral surface of a multicore wire composed of conductor cores or insulated cores that are collected together, wherein the extrusion-coating insulating layer is made of a resin mixture to be extrusion-coated, which comprises 100 parts by weight of a resin (A) comprising a polyethersulfone resin, as an essential component, and, optionally, a polyetherimide resin, and 10 to 100 parts by weight of a resin (B) comprising at least one resin selected from polycarbonate resins, polyarylate resins, polyester resins, and polyamide resins.

Abstract: A communications cable is provided having at least one elongate electrical conductor surrounded by a layer of insulating material, said layer including a chemically blown fluorinated polymer having a melting point of greater than about 480.degree. F. The elongate electrical conductors may be provided as at least one pair of twisted wires, each wire thereof surrounded by a layer of insulating material including the chemically blown fluorinated polymer. The fluorinated polymer is preferably a high melting fluorinated polymer and is chemically blown by a blowing agent such as the barium salt of 5-phenyltetrazole. The communications cable includes insulated wires which possess a layer of foamed fluorinated polymer insulating material having uniform thickness and electrical properties along the length of the wire. The fluorinated polymer can be applied on the conductor in a relatively thin layer which minimizes the amount of fluorinated polymer material used to insulate the individual conductors.

Abstract: A high speed data transmission cable comprises a pair of primary cables positioned adjacent to each other along their lengths with each primary cable including a pair of generally parallel conductors coupled together and surrounded by insulation. A shield layer surrounds each primary cable along its length to isolate the primary cables from each other. The primary cables and corresponding shield layers are twisted together around a center axis and form a double helical structure, thereby providing improved transmission characteristics in the high speed data transmission cable.

Abstract: A communication cable includes a first plurality of twisted pairs of electrical conductors, wherein each electrical conductor is surrounded by a layer of plenum rated insulation. The cable also includes a second plurality of twisted pairs of electrical conductors, wherein one conductor of each pair is surrounded by a layer of plenum rated insulation and the other electrical conductor is surrounded by a layer of non-plenum rated insulation. In an alternate embodiment, a communication cable includes a plurality of twisted pairs of electrical conductors, each pair having a first insulating material about one of the electrical conductors and a second insulating material about the second electrical conductor.

Abstract: An electrically conductive composite article is provided having a polytetrafluoroethylene fibril matrix and a predetermined volume. The electrically conductive composite article comprises electrically conductive particles, and electrically nonconductive, energy expanded hollow polymeric particles. The volume percent of the electrically conductive particles is at least 20 volume percent. The electrically conductive composite article is continuously electrically conductive throughout its entire structure. Accordingly, electric current freely flows through the composite article due to the low resistivity of the article. The electrically conductive composite article may additionally include an elastomer material disposed within the article in a discontinuous fashion.

Abstract: An abrasion-resistant fluoropolymer mixture comprising(A) from 75 to 99% by weight of a fluorocarbon polymer(B) from 1 to 25% by weight of an oxidized polyarylene sulfide and, based on the sum (A)+(B),(C) from 0 to 15% by weight of a filler,is used for the production of feed pipes for Bowden cables which are pressure-resistant and abrasion-resistant.

Abstract: There is disclosed a communications cable having a cable jacket and a first pair of twisted wires disposed within the jacket, each wire thereof having a conductor surrounded by a first insulating material. A second twisted pair of wires is disposed within the jacket and has a twist lay length different from that of the first twisted pair. Each wire of the second twisted pair has a conductor surrounded by an insulating material. The insulating material of the first twisted pair differs in a physical property from the insulating material of the second twisted pair, the physical property of the insulating material of the second pair being correlated with the physical property of the insulating material of the first twisted pair and with differences in twist lay length of the first and second twisted pairs so that the phase delay of the twisted pairs is matched. There is also provided a communications cable having more than two twisted pairs.

Abstract: Insulated wires and cables, especially local area network (LAN) cables, in which the conductors are covered by foamed insulation made from a composition containing an ECTFE polymer having a crystallinity of at least 50% by weight, and, dispersed in the ECTFE polymer, particles of a PTFE polymer having a crystallinity of at least 50%, the ratio by weight of the ECTFE polymer to the PTFE polymer being 1:1 to 9:1.

Abstract: An insulating material comprised of a benzimidazole-based polymer layer and a fluorine-containing rubber layer. This material is heat-resistant and is especially useful for use in electric wires. To manufacture such wires, a varnish solution is prepared by dissolving partially polymerized benzimidazole-based polymers in a solvent, then adding a polymerization initiator thereto. Subsequently, an electric wire is soaked in the solution and heated to cross-link the benzimidazole-based polymers. By repeating this procedure, the electric wire is coated with any desired thickness of a benzimidazole-based polymer layer. This coated wire is further coated with a fluorine-containing rubber layer to obtain a heat-resistant electric wire that is also resistant to dielectric breakdown.

Abstract: There is disclosed an insulating composition comprising a mixture of a polyolefin, such as polyethylene or polypropylene, and a partially fluorinated copolymer such as ethylene-chlorotrifluoroethylene (ECTFE) or ethylene-trifluoroethylene (ETFE) in an amount from about 3.0% to about 50% by weight polyolefin. Such mixture may be used as either a solid or foamed insulation over a metallic conductor in a plenum-type communications cable. Such an insulation has been found to have improved mechanical and electrical properties over insulations consisting of 100% ECTFE or ETFE. Specifically, the insulation exhibits improved elongation performance and lower dielectric constant and dissipation factor values. These insulated wires may be used in the transmission of electronic signals, such as voice, data or video, and possess unique properties in electrical, fire safety and cost performance.

Abstract: A low pair count high performance, TIA/EIA 568 Category 5 plenum rated cable has a core made up of a plurality of twisted pairs of conductors, each conductor being insulated with a tetrafluoroethylene/hexafluoropropylene copolymer material, and a single twisted pair of conductors wherein each conductor is insulated with a high density polyethylene material. The core is surrounded and enclosed in a jacket of a plasticized copolymer of ethylene and clorotriflouoroethylene material.

Abstract: In order to provide a coil type high-voltage resistive wire having a lower resistance than and a noise preventing performance similar to a prior art resistive wire while maintaining an inductance level without increasing a diameter and a winding pitch of a resistance wire, a core (3) consists essentially of a center reinforcing core (1) which is obtained by twisting three aramid fibers of 1000 denier and a ferrite core (2) having an outer diameter of 1.3 mm or smaller which is obtained by extruding a mixture of resin or rubber base and ferrite powder around the center reinforcing core (1). A resistance wire 5 made of a copper-nickel alloy wire having a diameter of 35 to 55 .mu.m and an electrical resistivity of 5 to 35 .mu..OMEGA..cm is wound around the core 3 at a pitch of 10000 winds/m or larger in a direction normal to the longitudinal axis of the core (3), so that the resistance value of the resistance wire (5) as a conductor can be set at 4 to 7 k.OMEGA./m.

Abstract: A telecommunications cable having a cable core in which each conductor is surrounded by an individual dual layer insulation of an inner layer of flame retardant polyolefin and an outer layer of fluorinated ethylene propylene. The cable is for plenum chamber usage in which smoke is to be minimized. Although the flame retardant polyolefin is a known smoke generating substance which does not satisfy plenum test smoke requirements, its use in this structure is entirely suitable for plenum chamber use because little or no smoke is actually generated as the outer layer protects the inner layer from combustion.

Abstract: A composite of a thermoplastic copolymer of tetrafluoroethylene and perfluoro(propyl vinyl ether), and a porous membrane of polytetrafluoroethylene, at least a portion of the thermoplastic copolymer being dispersed within the pores of the porous polytetrafluoroethylene. The composite is useful as insulation for wire and cable.

Abstract: Amorphous tetrafluoroethylene copolymers having a hexafluoropropylene content up to 29 mol % with the hexafluoropropylene units being uniformly distributed throughout the copolymer.

Abstract: A fluorocarbon copolymer-insulated wire comprising, around a conductor, an insulating layer made of a composition comprising an ethylene-tetrafluoroethylene copolymer and an unsintered tetrafluoroethylene-propylene copolymer, which is resistant to heat, abrasion and oil, and improved in flexibility. The wire can be efficiently installed in a narrow space in various equipments and enables easy wiring work.

Abstract: The present invention is an improved jacketing material for all forms of electro-magnetic energy conductors. The jacket material of the present invention comprises a silicone material that is imbibed into a porous polymer, such as expanded polytetrafluoroethylene, to produce a flexible and durable composite. When applied as a cable jacket, the composite material of the present invention produces dramatic improvement over the use of silicone alone, especially in the areas of load sharing, resistance to fatigue from repeated flexure, and resistance to harsh environmental conditions. The ability of the material of the present invention to withstand repeated autoclave cycles without compromise makes it particularly suitable for cable jacketing in bio-medical applications.

Abstract: A communication cable includes a plurality of twisted pairs of electrical conductors, each electrical conductor being surrounded by a layer of plenum rated insulation. The cable also includes at least one additional twisted pair of electrical conductors, each electrical conductor thereof being surrounded by a layer of non-plenum rated insulation.

Abstract: Porous expanded polytetrafluoroethylene material having a microstructure of nodes interconnected by fibrils wherein a surface of the material has been modified to have increased hydrophobicity as indicated by having a water droplet roll-off angle of less than about 10 degrees in comparison to a typical roll-off angle of greater than about 12 degrees for the unmodified material. Under magnification, the surface morphology may be indistinguishable from that of the unmodified precursor material. The modification is preferably done by exposing the surface to radio frequency gas plasma discharge with a reactive etching gas for a lengthy amount of time such as about ten minutes. If surface etching is continued beyond a time adequate to produce the highly hydrophobic behavior, then the surface morphology includes the appearance of broken fibrils.

Abstract: A multistranded conductor consists of a central bundle of nine strands of small diameter wire (insulated or non-insulated) in a twisted configuration and a series of six outer bundles each being of similar construction, the six outer bundles being equispaced as to each other and circumscribing around the central bundle and being covered with an outer electrically insulating protective covering.

Abstract: An electrical cable for use in submersible well pumps in oil and gas well environments is provided having an electrical conductor core which is surrounded by an insulating layer of cross-linked polyethylene. A barrier layer surrounds the cross-linked polyethylene insulating layer. The barrier layer is impermeable to oil and other liquid hydrocarbons, but is permeable to low molecular gases. The barrier layer is preferably formed from a fluoropolymer and is surrounded by a polymeric protective layer. An adhesive layer attaches the barrier layer to the insulating layer.

Abstract: An insulated cable which combines good roundness and good strippability includes one or more insulated conductors, an inner lining of polymeric tape wrapped around the conductors, and an outer jacket of polymeric insulation melt extruded around the inner lining. The level of adhesion between the inner lining and the conductors is less than the level of adhesion between the inner lining and the outer jacket. The insulated cable is particularly useful in anti-lock braking systems. A process for making the cable is also disclosed.

Abstract: An electrical cable for a submersible well pump is provided which is resistant to attack by hydrogen sulfide and which is less susceptible to damage from expanding gases during decompression. The electrical cable has a central copper conductor core. The conductor core is surrounded by a layer of electrical insulation material of either thermosetting or thermoplastic material. Surrounding the insulation material is a polymeric, low permeable layer having a hydrogen sulfide permeability rate which is substantially lower than the insulation material. A metal tape layer, such as lead tape, surrounds the low permeable layer. One or more conductor cores together with the insulation, low permeable layer and metal tape layer can be embedded in an elastomeric jacket and provided with an outer metal armor to provide a single electrical cable.

Abstract: Laminar structures having a polyimide core layer, inner fluorinated ethylenepropylene copolymer (FEP) layers, intermediate polytetrafluoroethylene homopolymer (PTFE) and fluorinated ethylenepropylene copolymer (FEP) blend layers and outer fluorinated ethylenepropylene copolymer (FEP) layers for use in the form of narrow tapes as an insulating wire or cable wrap.

Abstract: The cable includes a conductive coating layer disposed on an internal dielectric and surrounded by a conductive screen. The cable is characterized in that said conductive coating is a conductive silicone coating and in that the dielectric is treated and therefore has an adapted surface tension value greater than a value typically in current use, therefore directly giving said silicone coating layer a small level of adherence to said treated dielectric and thereby rendering it peelable.Applicable to cables having operating temperatures of the order of 250.degree. C. and high noise immunity.

Abstract: A light-weight, but strong and cut-through resistant electrical insulation tape, which is a laminate of porous polytetrafluoroethylene and polyetheretherketone. Also described are insulated wires and coaxial cables using the electrical insulation tape.

Abstract: A new insulation system comprising film coated, copper magnet wires covered under NEMA Standards No. MW1000, insulated with single or multiple layer(s) of extruded TEFLON.RTM. (any color) fluorocarbon resin insulation to meet the government or safety agency promulgated performance and construction requirements.

Abstract: A bundled conductor manufactured by bundling a plurality of small diameter conductors 1, or a bundled conductor 2 manufactured by giving an extremely rough twisting pitch, which is 20 times or more larger than an outer diameter of said bundled conductor, to the bundled conductor is formed. Then, an insulating layer 3 comprising 3 layers 3a, 3b and 3c, each comprising a heat-resistant plastic film, is arranged around the bundled conductor above. A required voltage resistance characteristics is provided and maintained by any 2 of the aforesaid 3 insulating layers, and each of the 3 insulating layers described above is independent respectively and can be separated from other ones.

Abstract: A resin-insulated cable includes electrical conductors arranged in parallel with each other, two insulating resin tapes coating the conductors and a porous insulating resin tape faced with one of the insulating resin tapes and having a printed surface which is in contact with the one of the insulating resin tapes.

Abstract: A bundled conductor manufactured by bundling a plurality of small diameter conductors 1, or a bundled conductor 2 manufactured by giving an extremely rough twisting pitch, which is 20 times or more larger than an outer diameter of said bundled conductor, to the bundled conductor is formed. Then, an insulating layer 3 comprising 3 layers 3a, 3b and 3c, each comprising a heat-resistant plastic film, is arranged around the bundled conductor above. A required voltage resistance characteristics is provided and maintained by any 2 of the aforesaid 3 insulating layers, and each of the 3 insulating layers described above is independent respectively and can be separated from other ones.

Abstract: Ribbon cables have lower capacitance, higher impedance, and faster propagation velocities with microporous fibril thermoplastic dielectric insulation, because they have great amounts of air adjacent to the conductors and the improved electrical performance is due in part to the improved crush resistance. Crystallizable thermoplastic polymers having good fibril structure and crush resistance include polyolefins such as polypropylene and polymethylpentene. A layer of metal adhered to the dielectric insulation provides improved transmission line properties.

Abstract: A ribbon connector for use in an audio system as a speaker cable. The ribbon connector comprises two sets of flat conductors encapsulated in fluorinated ethylene polypropylene. Each of the sets is spaced apart from one another by a median strip of insulation. The median strip has a width greater than the thickness of the insulation between adjacent conductors in a set. This allows the sets to be separated from one another when a terminal is placed on each set. The conductors of a set function as a single conductor in that when used they are joined to a single terminal. The ribbon connector has enhanced capacitance and inductance characteristics compared to round twisted wire conductors.

Abstract: Commercially available coaxial cables have been used successfully in single shot electromagnetic launcher and other pulsed power applications. The use of a coaxial cable interface between power source and pulsed power load reduces external magnetic fields and also aids in standardizing the interface, enhancing inter-changeability between a variety of power supplies and loads. As pulsed power systems continue to become more energetic and as the importance of repetitive operation increases, the use of commercially available cables becomes impractical because of the large number required for appropriate energy transfer. The cable according to the invention overcomes many problems encountered in the use of conventional cables. It incorporates a large area, flexible conductor in both the current feed and current return path, and matches these conductor cross-sections to provide uniform current paths.

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: A method and apparatus for filling a jacketed signal conduit with a blocking material are provided. The blocking material is injected into the jacketed signal conduit such that the blocking material occupies space within the jacketed signal conduit not occupied by the signal conduit. The injected blocking material inhibits fluid intrusion and migration between the signal conduit jacket and the signal conduit.

Abstract: The present invention features a new "filter line" cable having a shield layer of metallized, high-tensile strength fibers. The filter line cable has a conductive core having a primary insulation layer. Over the primary insulation is a filtering layer made up of ferromagnetic particles (ferrite o magnetite) within a polymeric matrix such as Viton, a fluorinated elastomeric polymer. The filtering layer provides the "filter line" protection against internal RFI and microwave interferences traveling down the wire. A shield of metal-coated, high-tensile strength fibers (such as nylon, aramid, etc.) is woven or served to provide a flexible mesh layer of about 95% coverage; this is placed over the filtering layer. The shield layer provides protection against external EMI interference signals. An insulating-jacket layer is placed over the shield layer; it is made of materials such as Teflon, Kapton, fluorinated polyethylenes, carbon-filled fluorinated polyethylenes and combinations thereof, etc.

Abstract: A low loss coaxial cable has a central supporting rod of plastic, covered in metal and forming the inner conductor or core of the coaxial cable. An intermediate insulation made of a dielectric material surrounds the inner conductor and an outer metal conductor surrounds the intermediate insulation. The central rod is made of polytetrafluoroethylene (PTFE) having a relative density greater than or equal to 1.6. The intermediate insulation has a relative density less than 1.2 and the ratio of the density of the dielectric constituting the intermediate insulation divided by the density of the PTFE constituting the rod lies in the range of 0.15 to 0.75.

Abstract: A porous insulating resin tape is fed to an inner or outer surface of one of insulating resin tapes with which a plurality of electrical conductors of a flat cable are coated. Printing is performed on at least one surface of surface of the porous insulating resin tape, soaks into the pores of the porous insulating resin tape. The pores are sealed up when the tape is pressed by a heating/pressing rollers and then baked, and the ink is shut off from outside the pores. The printing can be clearly performed without being discolored.

Abstract: An insulated conductor having improved arc propagation resistant properties. The insulation consists of a first layer of a composite tape of polyimide between two layers of polytetrafluoroethylene. The second overlaying tape layer is unsintered polytetrafluoroethylene. Further disclosed is a process for manufacturing a sintered wire product having a tin plated electrical conductor.

Abstract: An elongate body insulated by means of an insulating covering, said covering being constituted by a tape (2) made of synthetic material taped around said body (1) and covered in a layer of varnish (11) made of synthetic material, the body being characterized in that the taping is such that there exists a groove (4) between the free edge (5) of any portion of a turn (3) that is not covered by the following turns and the uncovered surface (6) of the preceding turn, the width of said groove (4) lying substantially in the range 0% to 5% of the width of said tape (2) and being strictly greater than zero.

Abstract: A crush-resistant high signal propagation velocity coaxial cable insulated with a low-density expanded PTFE insulation surrounded by an extruded closed-cell polymer foam.

Abstract: A motion transmitting remote control assembly (10) for transmitting motion in a curved path including a liner (12) disposed within a conduit (16) and a motion transmitting core element (14) moveably supported by the liner (12). The liner (12) is made essentially of polytetrafluoroethylene (PTFE). The assembly (10) is characterized by the liner (12) further including poly(amide-imide) for increasing the strength and lubricity thereof. Preferably, the liner comprises 97 weight percent polytetrafluoroethylene and 3 weight percent poly(amide-imide).

Abstract: A multilayer circuit board is provided having an inner porous fluororesin layer containing electrical circuits, a ground conductor layer located adjacent the fluororesin layer on one side thereof and a power supply conductor layer located adjacent the fluororesin layer on the other side thereof, and a reinforcing, solid plastic dielectric layer adjacent each conductor layer and being external to the inner fluororesin layer. In an alternate embodiment, the multilayer circuit board may have a plurality of inner porous fluororesin layers, at least one fluororesin layer containing electrical circuits, and may have ground conductors and power supply conductors adjacent each fluororesin layer, and reinforcing, solid plastic dielectric layers on the outermost surfaces of the circuit board assembly. The ground and power supply conductor layers extend over the entire surfaces, respectively, of the inner fluororesin layers.

Abstract: Coaxial electric cable and simplified process for making it, wherein large gauge center conductor is wrapped with extruded strands of porous expanded polytetrafluoroethylene, drawn through a die to reduce diameter and voids, tape-wrapped with porous expanded polytetrafluoroethylene, sintered, and shielding and extruded jacketing applied.

Abstract: A ceramic filled fluoropolymer composite coaxial cable insulation and the coaxial cable made therefrom is presented. In accordance with the present invention, the coaxial cable insulation is comprised of 60-25% fluoropolymer that is fibrillatable, 40-75% ceramic filler and a void content which is effective to provide a dielectric constant of approximately less than 2.30. In a preferred embodiment of the present invention, the coaxial cable insulative composite comprises approximately 40 weight percent PTFE, 60 weight percent fused amorphus silica and a void volume percent of between 30 and 60. Also in certain preferred embodiemnts, the composite may include 1-4% by weight of microfiberglass filler and the ceramic filler may be coated with a silane coating. The provision of the void volume is an important feature of the present invention and acts to substantially lower the overall dielectric constant of the insulative composite.

Abstract: A plenum cable (20) includes a core (22) comprising at least one transmission medium such as a metallic conductor. The metallic conductor is insulated with a layer (27) of a plastic composition of material which includes a non-halogenated constituent such as, for example, a polyetherimide. Covering the insulated metallic conductor is a jacket (39) comprising a halogenated material such as a fluoropolymer. The cable exhibits excellent flame retardant properties as well as acceptable levels of corrosion and toxicity.

Abstract: A coaxial electric cable having a significant reduction in weight for equivalent electrical properties provided by wide spacing of braided or served shielding wires under metal foil, metal-laminated, or conductive tape shielding in a porous expanded polytetrafluoroethylene-insulated cable.

Abstract: A low smoke and flame-resistant fluoropolymer composition, useful as insulation in a plenum cable and comprised of a base polymer of ethylene units, tetrafluoroethylene and/or chlorotrifluoroethylene units, and fluorine-containing, non-telogenic termonomer units; a metal oxide; and a polytetrafluoroethylene drip suppressant.

Abstract: Wire for repairing or changing circuit elements such as printed circuits, has heat-resistant insulation surrounded by a hot-melt adhesive. The wire is attached to the surface of printed circuit boards easily by applying a hot iron to the adhesive layer on the wire and melting the adhesive which then adheres to the board surface. The coating is applied by passing insulated wire vertically through a length of molten adhesive and then through a die. Printed circuit board modifications can be made quickly and easily and at a relatively low cost.