Abstract: Exemplary methods for manufacturing a wire and resultant wires are disclosed herein. The method includes extruding a cross-linkable polymer that is substantially free of curing agent about a conductive core, then adding a curing agent to the extruded wire pre-product, then heat-curing the extruded wire pre-product.

Abstract: A coated conductor, such as an insulated electrical wire, is formed by a method that includes a specific poly(arylene ether) composition and an extrusion coating apparatus in which molten poly(arylene ether) composition flows through helical channels en route to covering the previously uncoated conductor. There is a synergy between the use of the helical channels and the poly(arylene ether) composition. Specifically, coated conductor formed using the helical channels and the poly(arylene ether) composition exhibits improved resistance to temperature and humidity variations compared to coated conductor formed using the same poly(arylene ether) composition and so-called heart-sleeve channels. This synergy is not seen with alternative insulation compositions, such as those based on poly(vinyl chloride) and polyethylene.

Abstract: A Drain wire led out from the interior to the exterior of a shielded wire is covered with a heat shrinkable tube made of an insulating resin or with a rubber tube including silicon or EPDM (ethylene-propylene rubber). A water-stop agent is penetrated between the element wires of the drain wire in the heat shrinkable tube or the rubber tube. In addition, A boundary portion between a terminal connected to an end of the drain wire and the heat shrinkable tube is covered with a rubber stopper.

Abstract: A wire capable of conducting electrical current has a polymer core and a coating layer surrounding the core. The coating layer, which may be, for example, gold or copper, conducts electrical current and the core provides strength so that the wire is able to withstand bending and breakage. Among other things, the polymer core wire is useful for connecting an integrated circuit to a lead frame or substrate.

Abstract: The present invention relates to a partially-crystalline copolymer comprising tetrafluoroethylene, hexafluoropropylene in an amount corresponding to HFPI of from about 2.8 to 5.3, and preferably from about 0.2% to 3% by weight of perfluoro(alkyl vinyl ether), said copolymer having less than about 50 ppm alkali metal ion, having a melt flow rate of within the range of about 30±3 g/10 min, and having no more than about 50 unstable endgroups/106 carbon atoms and which can be extruded at high speed onto conductor over a broad polymer melt temperature range to give insulated wire of high quality.

Abstract: A method of coating metal wire with extrudate using an extrusion system. The method includes the steps of advancing the metal wire through an extrusion die of the extrusion system and extruding molten extrudate over the metal wire as the metal wire is advanced through the extrusion die. Image data is generated, using one or several electronic cameras, concurrently with the advancing, and extruding to provide visual feedback indicative of the concentricity or non-concentricity of extrudate surrounding the metal wire as the metal wire exits the extrusion die.

Abstract: A process for printing conductive metal markings directly on a substrate under an ambient condition, including the steps of synthesizing or providing conductive the ink on a substrate to form conductive metallic nanoparticles into an ink; and printing the ink on a substrate to form conductive metallic markings on the substrate. The printed conductive metallic markings may form wires that behave as resonant RFID antenna applications.

Abstract: Techniques for making nanowires with a desired diameter are provided. The nanowires can be grown from catalytic nanoparticles, wherein the nanowires can have substantially same diameter as the catalytic nanoparticles. Since the size or the diameter of the catalytic nanoparticles can be controlled in production of the nanoparticles, the diameter of the nanowires can be subsequently controlled as well. The catalytic nanoparticles are melted and provided with a gaseous precursor of the nanowires. When supersaturation of the catalytic nanoparticles with the gaseous precursor is reached, the gaseous precursor starts to solidify and form nanowires. The nanowires are separate from each other and not bind with each other to form a plurality of nanowires having the substantially uniform diameter.

Abstract: Provided are low-melt polyimides and poly(amic acids) (PAAs) for use in repair of electrical wire insulation, flat or ribbon wire harnesses, and flat surfaces comprised of high-performance polymers such as inflatables or solar panels applications. Also provided are methods and devices for repair of electrical insulation.

Abstract: An FEP pellet having a volatile content of 0.2% by weight or less. The FEP pellet satisfies the following requirements (i) and (ii) when used to form a insulating material coating a core wire by extrusion coating at a coating speed of 2,800 ft/min.: (i) an adhesive strength between the insulating material and said core wire of 0.8 kg or more; and (ii) an average number of cone-breaks in the insulating material of one or less per 50,000 feet of the coated core wire.

Abstract: An insulating varnish includes a polyamide-imide resin including a repeat unit represented by Formula (1) below derived from a synthesis reaction between a resin component (X) and a diisocyanate component (Y). The resin component (X) is derived from a synthesis reaction between a diamine component including aromatic diamines including g a divalent aromatic group (R) including three or more aromatic rings, and an acid component in the presence of an azeotrope solvent. The diisocyanate component (Y) includes a 2,4?-diphenylmethane diisocyanate (Y1) and a 4,4?-diphenylmethane diisocyanate (Y2). In Formula (1), R denotes the divalent aromatic group including three or more aromatic rings, and m and n denote an integer of from 1 to 99.

Abstract: Disclosed is a method for fabricating an electric cable for nuclear power plants, comprising: pre-heating a conductor wire; melting a PEEK (poly ether ether ketone) material and extruding the PEEK material in the direction of the conductor wire, to form an insulator such that the insulator coats the surface of the conductor wire; and cooling the insulator quickly.

Abstract: A production method for a headline sonar cable (20, 120) that exhibits a high breaking-strength and lighter weight than a conventional steel headline sonar cable. Producing the headline sonar cable (20, 120) is characterized by the steps of: a. providing an elongatable internally-located conductive structure (34, 134) that is adapted for data signal transmission; and b. braiding a strength-member jacket layer (52) of polymeric material around the structure (34, 134) while ensuring that the structure (34, 134) is slack when surrounded by the jacket layer (52).

Abstract: Techniques for nitridation of copper (Cu) wires. In one aspect, a method for nitridation of a Cu wire is provided. The method includes the following step. The Cu wire and trimethylsilylazide (TMSAZ) in a carrier gas are contacted at a temperature, pressure and for a length of time sufficient to form a nitridized layer on one or more surfaces of the Cu wire. The Cu wire can be part of a wiring structure and can be embedded in a dielectric media. The dielectric media can comprise an ultra low-k dielectric media.

Abstract: The invention concerns a method for fireproofing a coating of a data and/or power transmitting cable by incorporating at least one fire-retardant agent in said coating. The invention is characterized in that said incorporation is performed after the manufacture of said coating and is carried out using a supercritical fluid.

Abstract: Methods are provided of producing a heater cable. An electrical conductor is coated with a preceramic resin. At least a portion of the coated electrical conductor is deployed into a operational location. The preceramic resin is pyrolyzed while the portion of the coated electrical conductor is in the operational location to convert the preceramic resin into a ceramic insulator disposed to electrically insulate the electrical conductor from the sheath.

Abstract: A method of depositing a solute (34) on a metal thread (4), comprising the steps of: depositing a liquid solution (3), formed from a volatile solvent and said solute (34), on the thread (4); and then rapidly raising the temperature of the thread (4) to a temperature above the vaporization temperature of the solvent so as to vaporize the solvent placed in contact with the surface of said thread (4) and to form vapour bubbles (32) which, by expanding, generate a pressure pulse that ejects the liquid (33) remaining on the periphery of the thread.

Abstract: A process is described for manufacturing gas diffusion electrodes, which process comprises: (a) treating an area of a pre-shrunk porous hydrophobic substrate so as to restrict the slurry deposited in step b) to the said area, preferably by forming a well in the area and/or treating the substrate in the area to render it less hydrophobic, e.g. by plasma treating the area; (b) dispensing a slurry of catalyst onto the said area, (c) removing liquid from the dispensed slurry, (d) treating the dried slurry to remove organic materials and e) cutting the catalyst and the underlying portion of substrate from the rest of the substrate.

Abstract: A method for producing an aqueous absorptive polymer-containing resin composition in which a resin composition is doped with an aqueous absorptive polymer includes causing the aqueous absorptive polymer to absorb and be swollen by water beforehand, and milling and microparticulating the water-absorbed and -swollen absorptive polymer at an ultrasonic flow pressure of not less than 50 MPa.

Abstract: Methods of manufacturing insulated wires are provided. In an embodiment, by way of example only, a method includes drawing a conductive wire through a first pad to apply a layer of a first slurry onto the conductive wire, the first pad comprising a chamois leather material and including the first slurry disposed on the chamois leather material, wherein the first slurry comprises a first dielectric precursor material and a first binder having an organic component and heat treating the conductive wire to form the insulated wire.

Abstract: Dispersion of sol-derived nano-alumina in an organic solvent mixture containing a 1,2-diol with simple agitation. A thixotropic solution is obtained at 20% alumina in ethylene glycol, while a low viscosity (<100 cps) solution is possible for a 20% alumina in (1:1, N-methylpyrrolidone-ethylene glycol) solution. Alumina particles are de-agglomerated with minimal agitation. The resulting solution or resin solution is stable to settling and re-agglomeration. The nano-alumina dispersion solution can then be mixed with an imide coating to provide for a wire coating to give the wire improved abrasion, COF, and corona resistance.

Abstract: A conductive wire includes a plurality of thermoplastic filaments each having a surface, and a coating material having a plurality of carbon nanotubes dispersed therein. The coating material is bonded to the surface of each thermoplastic filament. The thermoplastic filaments having the coating bonded thereto are bundled and bonded to each other to form a substantially cylindrical conductor.

Abstract: A process for producing a cable, such as, for medium-tension or high-tension power transmission or distribution, having at least one coating layer made of a thermoplastic polymer material. The process includes at least the following steps: (a) extruding a thermoplastic material of at least one thermoplastic polymer and at least one dielectric liquid; (b) passing the thermoplastic material through at least one static mixer; and (c) depositing and shaping the thermoplastic material around a conductor belonging to the cable so as to obtain a layer of thermoplastic coating on the conductor.

Abstract: Cable comprising at least one conductor and at least a fire resistant coating layer including a composition comprising: (a) at least an organic polymer having a combustion temperature range comprised between a minimum value T1 and a maximum value T2; (b) at least a glass frit; (c) at least an inert compound; wherein:—said inert compound (c) has a softening point or a melting temperature of not less than 1000° C.;—said glass frit (b) reaches a viscosity of between 107 poise and 108 poise in a selected temperature range including the combustion temperature range of said organic polymer (a), said selected temperature range being such that said glass frit (b) flows over said inert compound (c) and the burned organic polymer (a) so as to form a solid char fire resistant coating layer.

Abstract: Methods are provided for producing an attrition-resistant, flexible, insulated wire well-suited for use in a high temperature operating environment. In one embodiment, the method includes the steps of providing a conductor, preparing a dielectric coating, applying the dielectric coating over the conductor, and curing the coated conductor. The dielectric coating includes an organic binder, a dielectric material, and an inorganic lubricant.

Abstract: Techniques for making nanowires with a desired diameter are provided. The nanowires can be grown from catalytic nanoparticles, wherein the nanowires can have substantially same diameter as the catalytic nanoparticles. Since the size or the diameter of the catalytic nanoparticles can be controlled in production of the nanoparticles, the diameter of the nanowires can be subsequently controlled as well. The catalytic nanoparticles are melted and provided with a gaseous precursor of the nanowires. When supersaturation of the catalytic nanoparticles with the gaseous precursor is reached, the gaseous precursor starts to solidify and form nanowires. The nanowires are separate from each other and not bind with each other to form a plurality of nanowires having the substantially uniform diameter.

Abstract: A bonding or superfine wire is provided made of copper, with a gold enrichment on the surface thereof, in particular in an amount corresponding to a coating of at most 50 nm. The wire may be bonded by the ball/wedge method, has a copper-colored appearance, and the ball thereof after flame-off has a hardness of less than 95 according to HV0.002. In order to produce the bonding or superfine wire, a copper wire is coated with gold or a copper-gold alloy or gold is introduced into the surface of the copper wire. The wires are bonded to a semiconductor silicon chip.

Abstract: A method for the formation of a diffusion barrier layer on a surface of at least one fuel cell interconnect structure is described. The interconnect structure is usually formed from ferritic stainless steel, and includes chromium. The method includes the step of coating an austenite phase-stabilizer on the interconnect surface, and then heating the coated surface. The heat treatment transforms the microstructure of the surface region of the interconnect, from a substantially ferritic body-centered cubic (BCC) phase to a substantially austenitic face-centered cubic (FCC) phase. The diffusion rate of chromium through the FCC phase is relatively low. Thus, the formation of a thick layer of chromium oxide can be minimized, leading to better fuel cell performance. Related fuel cells and fuel cell stacks are also disclosed.

Abstract: Method for passivating non-radiatives recombination centres of a ZnO specimen in which magnesium is deposited on at least one surface of the ZnO specimen, and annealing of the specimen on which magnesium is deposited is performed in an oxidizing atmosphere. ZnO specimen thus obtained.

Abstract: A method for enhancing the dielectric properties of an electrical cable segment having a central stranded conductor encased in a polymeric insulation jacket and an interstitial void volume in the region of the conductor, including filling the interstitial void volume with a dielectric property-enhancing fluid at a pressure below the elastic limit of the polymeric insulation jacket, and confining the fluid within the interstitial void volume at a residual pressure greater than about 50 psig, with the pressure being imposed along the entire length of the segment but below the elastic limit of the polymeric insulation jacket. Preferably, the residual pressure is sufficient to expand the interstitial void volume along the entire length of the cable segment by at least 5%.

Abstract: A method for selecting components for a mixture to be injected into an interstitial void volume adjacent to a central stranded conductor of an electrical cable segment having the central conductor encased in a polymeric insulation jacket to enhance the dielectric properties of the cable segment. The method includes selecting an anticipated operating temperature for the cable segment to be used in selecting the components for the mixture to be injected into the interstitial void volume of the cable segment and selecting a minimum desired time period to be used in selecting the compounds for the mixture to be injected during which the dielectric properties of the cable segment are to be enhanced by the mixture. Next, first, second and third components for the mixture are selected to provide the cable segment with a reliable life at the selected operating temperature spanning first, second and third time periods, respectively.

Abstract: A hydrated water-absorption polymer containing resin composition includes a liquid cross-link curable resin composition, and a water-absorption polymer dispersed in the liquid cross-link curable resin composition. The water-absorption polymer is preliminarily hydrated and swollen. The water-absorption polymer before being hydrated and swollen includes an average particle diameter of not more than 10 ?m. The water-absorption polymer includes an amount of water absorption of 10 to 100 g/g.

Abstract: Certain embodiments of the present technology provide a cable comprising a conductor and a cable layer. The cable layer comprises a polypropylene material. The cable layer and/or the polypropylene material comprise a crystalline fraction crystallizing in the temperature range of 200 to 105° C. determined by stepwise isothermal segregation technique. The crystalline fraction comprises a part, wherein, during subsequent melting at a melting rate of 10° C./min, the part melts at or below 130° C. and the part represents at least 20 percent by weight of the crystalline fraction. In certain embodiments, the part melts at or below the temperature T=Tm?3° C., wherein Tm is the melting temperature of the cable layer and/or the polypropylene material, and the part represents at least 45 percent by weight of the crystalline fraction. Certain embodiments provide methods and processes for manufacturing the cable described above and herein.

Abstract: A manufacturing apparatus of conductive fiber is provided. The manufacturing apparatus includes a spinning unit, a conductive wire supply unit, and an insulating material supply unit. The spinning unit has at least one spinneret. The spinneret has a wire lead-in portion and a liquid lead-in portion connected with the wire lead-in portion. The liquid lead-in portion has a containing space and a capillary, and the wire lead-in portion is disposed in the containing space. The conductive wire supply unit is connected with the wire lead-in portion to lead a conductive wire through the capillary. The insulating material supply unit is connected with the liquid lead-in portion to supply a liquid insulating material to the containing space. The liquid insulating material is covered on the surface of the conductive wire passing through the capillary.

Abstract: Flexible insulated wires for use in a high temperature environment are provided. In an embodiment, the wire includes a conductor and a coating over the conductor. The coating is formulated from a dielectric material and an organic binder having an organic component, wherein the organic component has been substantially decomposed from the coating during manufacture. The flexible insulated wire may be incorporated into a component. Methods of forming the flexible insulated wire are also provided.

Abstract: A filament, heat shield, supporting base comprised of SiC with ceramic insulators and top plate that together form an effusion assembly for use in the vacuum evaporation, molecular beam epitaxy, and ultra high vacuum deposition of epitaxial materials. The effusion assembly used together with a crucible and source material allow for the vacuum evaporation of species above 1250° C. when quantities of reactive gaseous species such as oxygen, sulphur, or reactive nitrogen are present in the deposition chamber. The relative chemical inertness of SiC even at elevated temperatures allows the SiC filament assembly to be used at high temperature especially in the presence of oxygen for the high purity epitaxial nucleation and growth layered electronic materials including semiconductors, metals, oxides, dielectric multilayer stacks, sulfides and oxides.

Abstract: A metallic glass-coated microwire has controllable surface porosity. The porosity is achieved by etching the metallic glass-coated microwire or other shapes of glass-coated bodies with acid after annealing to produce a multi-phase glass coating. Porous metallic glass-coated microwires are found to make superior PCR machines, which find use in a variety of in vivo, biochemical, and chemical sensors. Advantageously, the PCR apparatus is smaller, less expensive to construct than conventional units. It readily carries out in vivo passive or active operations.

Abstract: A method for producing an insulated wire having a cross section of a desired shape, in which a conductor having a cross section of a desired shape is coated with an insulating film, which method comprises: supplying a raw conductor while passing through a rolling unit composed of at least one pair of rolling rolls that are capable of freely rotating without a drive mechanism and that have a desired shape, thereby forming a conductor having a cross section of a desired shape; and coating the conductor with an insulating film.

Abstract: Methods and apparatus for the deposition of a source material (10) are disclosed. An atomizer (12) renders a supply of source material (10) into many discrete particles. A force applicator (14) propels the particles in continuous, parallel streams of discrete particles. A collimator (16) controls the direction of flight of the particles in the stream prior to their deposition on a substrate (18). In an alternative embodiment of the invention, the viscosity of the particles may be controlled to enable complex depositions of non-conformal or three-dimensional surfaces. The invention also includes a wide variety of substrate treatments which may occur before, during or after deposition. In yet another embodiment of the invention, a virtual or cascade impactor may be employed to remove selected particles from the deposition stream.

Abstract: The present invention provides a process and an apparatus for the preparation of a motor coil by which a longitudinally wound motor coil, so called, can be easily prepared. First, a molded product 10 comprising a column part 11, and a fin part 12 projected in the form of flat plate from an outer peripheral surface 11A, 11B, 11C, 11D of the column part to an outer side in a radial direction of the column part and helically continuing in an axis direction of the column part at predetermined intervals along the outer peripheral surface of column part is prepared. The column part 11 of the first molded product is punched out in an axis direction of the column part with retaining the fin part 12 to remove the column part, and the fin part 12 having helical shape left after the removal is coated with an insulating film.

Abstract: A novel polymer coated magnet wire that includes an insulating polymeric coating on only one facet thereof. Such a magnet wire can be conventionally wound using current transformer manufacturing processes but can be produced at significantly lower cost due to the almost 75% reduction in the volume of insulating polymeric material applied to the magnet wire core as compared to similar prior art such products. The method provides for the application of the insulating polymeric coating to only a single minor axis facet of the magnet wire core through the use of custom dies and a modified manufacturing process.

Abstract: On a surface of a glass cloth adhered a mica layer sheet, a mixture of inorganic particles having a thermal conductivity of at least 5 W/mK, a resin, and a solvent is applied to form a layer of the mixture of the inorganic particles, the resin, and the solvent; the layer of the mixture is reduced in thickness using a doctor blade, followed by pressurizing to form a high thermally conducting layer; the mica layer sheet on which the high thermally conducting layer is disposed is cut to obtain a mica insulating tape; and the mica insulation tape is wound around a coil conductor. As a result, an insulated coil that is excellent in the voltage endurance characteristics and has a high thermal conductivity is manufactured.

Abstract: The method for hardening electro-insulating materials is characterised by the utilization and/or co-utilization of near-infrared radiation (NIR) having a wavelength of 500 nm to 1400 nm. NIR also enables very fast hardening of the component surface even with pure thermally hardenable impregnating material and further provides good hardening of thick layers located deep inside said layers. Combined hardening, for example, NIR and UV light, is also possible.

Abstract: The invention relates to a process for manufacturing a conductor bar comprising a number of partial conductors, with the following steps: A: manufacturing the partial conductors, B: applying at least one insulating layer to the partial conductors, in each case with the following substeps: B1: coating the regions to be insulated of the partial conductor with a plastics powder, B2: sintering this powder layer by melting the plastic and at least partially curing the plastic to form an insulating layer, the sintering being carried out in such a way that at least one outer insulating layer is not completely cured, C: assembling a number of insulated partial conductors to form a conductor bar, D: sintering the insulating layers of the partial conductors while simultaneously pressing the partial conductors against one another in the assembled conductor bar, the plastic in the case of the not completely cured insulating layers at least partially melting and being squeezed out between the partial conductors, and the

Abstract: A method for producing an insulated wire having a cross section of a desired shape, in which a conductor having a cross section of a desired shape is coated with an insulating film, which method comprises: supplying a raw conductor while passing through a rolling unit composed of at least one pair of rolling rolls that are capable of freely rotating without a drive mechanism and that have a desired shape, thereby forming a conductor having a cross section of a desired shape; and coating the conductor with an insulating film.

Abstract: The invention relates to a transparent substrate coated on at least one of its faces with a polymer layer deposited under vacuum. This polymer layer is provided with an adhesion prelayer of organic or organoinorganic nature. The invention also relates to the process for manufacturing such a coated substrate and to its applications.

Abstract: In a method for producing electrical cables coated with cross-linked polyethylene, a polyethylene granulate is mixed with a liquid silane-containing cross-linking agent, the granulate thus prepared is melted in an extruder and extruded onto the electrical cable, and the extruded coating is cross-linked in the presence of water or steam. A mixture of granular material of a polyethylene homopolymer and a polyethylene copolymer is coated with the cross-linking agent. The copolymer content in the coating on the cable is between 1 and 8% by weight.

Abstract: Process for preparing an electrical cable comprising at least one conductor and at least one layer of extruded insulating coating, which includes: coating, by extrusion, the conductor with a polymeric composition comprising a polyethylene, a radical initiator and at least one unsaturated carboxylic acid of general formula (I) in free form: in which: R1 represents H or CH3; n represents 0 or 1; said unsaturated carboxylic acid being present in an amount of between 0.0006% and 0.25% by weight, said amount being expressed as the weight content of —COOH groups relative to the total weight of the polymeric composition; heating the conductor thus coated so as to obtain cross-linking of said polymeric composition.

Abstract: The invention discloses a process for producing a high-quality insulation on a conductor or conductor bundle of rotating electrical machines, in which, in successive immersion passes in a fluidized-bed sintering tank, internal corona-discharge protection, insulation and external corona-discharge protection are applied, in each case with layer thicknesses of ≦0.2 mm. The sintering and curing take place at temperatures of approx. 200° C., so that it is possible to use materials which satisfy the demands which are imposed on the insulation of conductors or conductor bundles of this type for rotating electrical machines. Furthermore, the production process, in particular the layer thickness selected for the individual layers, ensures that the individual layers are free of defects, so that it is impossible for there to be any partial discharges, which would otherwise lead to damage to the insulation.

Abstract: A wire showing satisfactory electrical insulation, mechanical strength, wear resistance, crosslinking properties and appearance may be obtained by coating a conductor with an ethylene/&agr;-olefin copolymer whose density, melt flow rate, decane soluble matter content, melting point and melt tension are controlled to particular ranges. The copolymer may be used singly or in combination with high-pressure low-density polyethylene. Such copolymer provides a coated layer showing tensile strength of not less than 15 MPa, tensile elongation of not less than 400% and taper wear amount of not more than 15 mg. Furthermore, if the resin pressure in the extruder is adjusted to a particular range, high-speed extrusion becomes possible with a smooth apparent coated layer.