Abstract: A method of forming a twisted pair of wires for use with Ethernet-based networks. At least two wires are extruded with a cross-linked polyolefin insulating composition marketed under the registered trademark, EXRAD®. The wires are twisted together with a consistent lay length to form a cable. The cable is irradiated to become thermoset. Electrical properties of the extruded wire are controlled during the extrusion step and concentricity of the wire and surrounding insulation is also monitored and controlled. The cable can be jacketed to provide greater mechanical protection.

Abstract: A flexibility testing apparatus for wire or cable. Two circular, rotatable gears are mounted to a frame, one gear being a drive gear and the other being a driven gear. The driven gear is coplanar with the drive gear and the drive gear teeth are enmeshed with the driven gear teeth. Two rods are connected to the mounting holes of the drive gear and the wire or cable is attached to the rods using barrel end clamps for flexing. The driven gear can be rotated at different speeds by an electric motor or a pneumatic driving device.

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: Insulation compounds are described that have been formulated for use in a refrigeration environment. The materials consist of crosslinkable compounds made from ionomer (EAS), polyether block amide (PEBA), polybutyleneterephthalate (PBT) homo- or copolymers, and/or polyvinylidenefluoride (PVDF). The insulation compounds are intended for use as wire insulation and in the fabrication of gaskets and liners. The compounds show superior resistance to refrigerants such as HCFC-22, HCFC-123, and HFC-134a. Crosslinking provides resistance to creeping under heat and pressure.

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 shielded wire and cable article capable of meeting stringent aerospace specifications and requirements, particularly those pertaining to low weight and high temperature. The article generally consists of an inner conductive core of one or more wires that can be twisted or braided and which can be individually insulated. The conductive core is surrounded by one or more thin layer(s) of insulation about which the shielding of this invention is overlaid. The shielding is made of a woven, braided or served mesh or woven yarn of metal-coated high-performance fibers. The fibers of the mesh or yarn are characterized by high-tensile strength and flexibility and are operative at high temperatures, equal to or exceeding 150.degree. C. When the fibers themselves are braided, the resulting mesh can be braided even more tightly about the interior insulation surface than can conventional meshes.

Abstract: This invention features an assembly that creates a strong bond connection between a conductive polymeric element of a cable, such as a polymeric conductive core or polymeric conductive shield layer, and an electrical connector. The invention features two components: a newly styled connector, and an intermediate sleeve. The newly styled connector is made of an inner, concave, bullet-shaped recess that fits within an outer, deformable shell. The intermediate sleeve joins the polymeric element of the cable and the electrical connector. The sleeve consists of two sections. The first section has a solid, convex, bullet-shaped nose portion that fits into the concave, bullet-shaped recess located in the connector. The two bullet-shaped male and female surfaces mate with each other; they are metallic, so that they are easily solderable.

Abstract: The present invention features a new "filter line" cable having a temperature-enhancement jacket layer composed of, in various forms, a Teflon layer or fused Teflon/Kapton layers. The filter line cable has a conductive core having a primary insulation layer. Over the primary insulation is a filtering layer made up, at least in part, of ferromagnetic particles (ferrite or magnetite) within a polymeric matrix such as Viton, a fluorinated elastomeric polymer. These ferromagnetic particles may or may not be metal-coated. In addition, they may also be "spherical", to enhance the filtering effect. The filtering layer provides the "filter line" protection against internal RFI and microwave interferences traveling down the wire.

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: 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: The present invention features a new "filter line" cable of very thin construction. The thinner cable has a reinforcing mesh layer that lends physical strength to the otherwise thinner, weakened cable. Additionally, the reinforcing mesh provides grounding and some shielding. The reinforcing mesh layer is made of a thin metal wire or metal-coated 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 metal-coated ferromagnetic particles of ferrite or magnetite dispersed within a polymeric matrix such as Viton, a fluorinated elastomeric polymer. The ferromagnetic particles may be "spherical", to enhance the filtering effect. The filtering layer provides the "filter line" protection against internal RFI and microwave interferences traveling down the wire. Over the filtering layer is a layer of metal wire or metal-coated fibers, woven or served into a mesh.

Abstract: The present invention is a method of fabricating a wire and cable article capable of meeting stringent aerospace specifications and requirements, particularly that of low weight. The article generally comprises an inner conductive central core of one or more metal-coated fibers. The conductive core is preferably comprised of silver-coated aramid fibers having a silver coating of greater than 30 wt. % of the fiber, and generally several hundred weight percent thereof. The silver is coated upon aramid fibers to provide a cable having approximately half the weight and approximately 15 times the tensile strength of cables having equivalent resistance and/or equivalently sized cores of silver plated copper. The metal coating of the inventive process is accomplished in two steps: (a) a high tensile strength fiber comprising nylon, aramid, etc., is first plated with a first layer of metal such as copper, silver, etc.; and then (b) electrochemically plated with a second layer of metal.

Abstract: The present invention features a new shield material useful in the fabrication of shielded wire or cable articles. The conductive core of the wire and cable is layered with a shielding wrapping tape, foil or film. A shielding insulation compound can also be extruded over the conductive wire or cable core. Wire and cable articles containing the new shield material have an extended interference frequency attenuation range resulting from the improved shield layer. The shield material contains shaped ferrite particles dispersed within a polymeric binder, such as a fluorocarbon polymer. The shaped particles are generally spherical.

Abstract: The present invention features a shielded wire and cable article capable of meeting stringent aerospace specifications and requirements, particularly that of low weight. The article generally comprises an inner conductive core of one or more wires that can be bare or individually insulated, and that can be straight, twisted or braided within the core. The core can also comprise a multicore consisting of a plurality of core members. The conductive core is surrounded by one or more thin layer(s) of insulation about which the shielding of this invention is applied. The shielding comprises a braided or served mesh or woven yarn of metallically coated fibers, characterized by high tensile strength and flexibility. Where the fibers themselves are braided, the resulting mesh can be braided more tightly about the interior insulation surface than can conventional meshes.

Abstract: The present invention features a new shield material useful in the fabrication of shielded wire or cable articles. The conductive core of the wire and cable is layered with a shielding wrapping tape, foil or film. A shielding insulation compound can also be extruded over the conductive wire or cable core. Wire and cable articles containing the new shield material have an extended interference frequency attenuation range resulting from the improved shield layer. The shield material contains metal-coated magnetic particles dispersed within a polymeric binder, such as a fluorocarbon polymer. Other particles of metal such as copper, silver, nickel, manganese, zinc, or silver-coated copper in combination with metal coated and non-coated ferrites and magnetites dispersed within the polymer matrix may also be part of the blend formulation. The shielded wire or cable attenuates both RFI/EMI and microwave/radar interferences.

Abstract: The present invention features a new type of filter line cable. The new filter line in one embodiment thereof, comprises a cable having a conductive core member. A first insulation layer is disposed over the conductive core member. A first shielding layer of ferrite particles dispersed within a polymeric matrix is then overlayed the first insulation layer. A second insulation layer is then disposed over the first shielding layer. A second shielding layer of braided or served metallic mesh overlays the second insulation layer. A jacket layer overlays the second shielding layer and comprises a cross-linked, polymeric matrix containing approximately between 10 wt. % and 35 wt. % carbon black.

Abstract: The present invention features a shielded wire and cable article capable of operating more effectively in high power environments. The article generally comprises an inner conductive core of one or more wires that can be twisted or braided and which can be individually insulated. The conductive core is surrounded by one or more thin layer(s) of insulation about which conventional, braided or served mesh shielding is applied. The shielding effectiveness is improved in accordance with this invention by the addition of a layer of conductive polymer material above or below the braided or served mesh.

Abstract: The invention features in synergistic combination a new chemistry for fabricating wire and cable insulation and heat-shrinkable tubing and an irradiation process for providing the insulation with both increased tensile strength and increased elongation.The chemistry utilizes a polycondensation-type process wherein a hydrophobic olefinic terpolymer base material having 3% or less carboxyl groups and a hydrophilic flame retardant filler material containing hydroxyl groups is linked to a silicone material containing silanol groups.The insulation is further characterized by an oxygen index in excess of 50.0, resulting from high loadings of the fire retardant filler material, generally in excess of 200 parts by weight of the total material weight.