Abstract: Winding wire articles may include a conductor formed into a predefined shape having at least one bend. Additionally, a plurality of cavities may be formed within the conductor. Insulation may also be formed around the conductor.

Abstract: A continuously transposed conductor (CTC) cable may include a plurality of electrically insulated strands arranged in first and second stacks with the plurality of strands successively transposed between the first and second stacks. The plurality of strands may include at least one strand having a plurality of component strands that are arranged in third and fourth stacks with the plurality of component strands successively transposed between the third and fourth stacks. Each of the components strands may include a conductor and insulation formed at least partially around the conductor.

Abstract: Insulated winding wire articles and associated formation methods are described. An insulated winding wire article may include a conductor and optional base insulation formed around the conductor. The conductor may be formed into a predefined shape having at least one bend, such as a U-shaped bend. A coating comprising parylene may be formed around the conductor and any base insulation.

Abstract: Insulated winding wire articles and associated formation methods are described. An insulated winding wire article may include a conductor and optional base insulation formed around the conductor. The conductor may be formed into a predefined shape having at least one bend, such as a U-shaped bend. A coating comprising parylene may be formed around the conductor and any base insulation.

Abstract: Insulated winding wires and associated methods for forming winding wires are described. A winding wire may include a conductor and insulation formed around the conductor. The insulation may provide a partial discharge inception voltage greater than approximately 1,000 volts and a dielectric strength greater than approximately 10,000 volts. Additionally, the insulation may be capable of withstanding a continuous operating temperature of approximately 220° C. without degradation. The insulation may include at least one base layer formed around an outer periphery of the conductor, and an extruded thermoplastic layer formed around the base layer. The extruded layer may include at least one of polyetheretherketone (PEEK) or polyaryletherketone (PAEK).

Abstract: Continuously transposed conductor (“CTC”) cables are described. A CTC cable may include a plurality of electrically insulated strands connected in parallel at their ends. Additionally, each strand may include one or more conductors and an extruded insulation layer formed at least partially around the one or more conductors.

Abstract: An insulated winding wire may include a conductor and insulation formed around the conductor. The insulation may include a base insulation layer formed around the conductor and having a first dielectric constant (?1). The insulation may further include an extruded thermoplastic layer formed around the base insulation layer and having a second dielectric constant (?2). The extruded thermoplastic layer may include (i) at least one polymer comprising a ketone group and (ii) at least one fluoropolymer. A ratio of the dielectric constant (?2) of the extruded thermoplastic layer to the dielectric constant (?1) of the base layer at 250° C. may be less than or equal to approximately 1.0.

Abstract: Insulated winding wires and associated methods for forming winding wires are described. A winding wire may include a conductor and insulation formed around the conductor. The insulation may provide a partial discharge inception voltage greater than approximately 1,000 volts and a dielectric strength greater than approximately 10,000 volts. Additionally, the insulation may be capable of withstanding a continuous operating temperature of approximately 220° C. without degradation. The insulation may include at least one base layer formed around an outer periphery of the conductor, and an extruded thermoplastic layer formed around the base layer. The extruded layer may include at least one of polyetheretherketone (PEEK) or polyaryletherketone (PAEK).

Abstract: Cables incorporating discontinuous shielding elements are described. A cable may include at least one twisted pair of individually insulated conductors, and a shield element may be positioned adjacent to the at least one twisted pair. The shield element may include a plurality of segments positioned along a longitudinal direction of the cable. Each segment may include a respective dielectric substrate with electrically conductive material formed on the substrate, and each segment may be electrically isolated from the other segments. A respective overlap may be formed between adjacent segments along a shared longitudinal edge. Additionally, a jacket may be formed around the at least one twisted pair and the shield element.

Abstract: Cables incorporating discontinuous shields are described. A cable may include at least one twisted pair of individually insulated conductors, and a shield may be formed around the at least one twisted pair. The shield may include a plurality of segments positioned along a longitudinal direction of the cable. Each segment may include electrically conductive material, and each segment electrically isolated from the other segments. Additionally, a respective overlap may be formed between adjacent segments along a shared longitudinal edge. A jacket may be formed around the at least one twisted pair and the shield.

Abstract: Continuously transposed conductor (“CTC”) cables are described. A CTC cable may include a plurality of electrically insulated strands connected in parallel at their ends. Additionally, each strand may include one or more conductors and an extruded insulation layer formed at least partially around the one or more conductors.

Abstract: Insulated winding wires and associated methods for forming winding wires are described. A winding wire may include a conductor and insulation formed around the conductor. The insulation may provide a partial discharge inception voltage greater than approximately 1,000 volts and a dielectric strength greater than approximately 10,000 volts. Additionally, the insulation may be capable of withstanding a continuous operating temperature of approximately 220° C. without degradation. The insulation may include at least one base layer formed around an outer periphery of the conductor, and an extruded thermoplastic layer formed around the base layer. The extruded layer may include at least one of polyetheretherketone (PEEK) or polyaryletherketone (PAEK).

Abstract: A system of rollers can transfer fluid from a reservoir to an electrically conductive wire feeding past the reservoir. The system can include a first cylinder that contacts the reservoir and rotates to pick up fluid from the reservoir. A second cylinder can contact the first cylinder and rotate. Fluid can transfer between the first cylinder and the second cylinder. The second cylinder can contact the feeding wire such that the second cylinder applies the fluid to the wire as the wire feeds past the second cylinder. Accordingly, two rotating cylinders can cooperatively transfer fluid from the reservoir to the moving wire.

Abstract: A system for manufacturing wire having a mill and a finishing station configured to receive the wire output from the mill in a continuous fashion. The mill has first and second dies and first and second capstans. The first die is configured to receive a wire having a first cross-sectional area and to reduce the cross-sectional area of the wire as it passes through the first die. The first capstan is configured to receive the wire from the first die and apply a first force on the wire. The second die is configured to receive the wire from the first capstan and to further reduce the cross-sectional area of the wire as it passes through the second die. The second capstan is configured to receive the wire from the second die and apply a second force on the wire. The wire exits the mill having a second cross-sectional area that is smaller than the first cross-sectional area, and is finished by the finishing station.

Abstract: A buffer tube for use in a fiber optic cable is disclosed. The buffer tube has a flexural modulus greater than about 180 kpsi and less than about 370 kpsi, which results in a buffer tube having good crush resistance and flexibility. A particularly useful buffer tube material is an alloy of polypropylene and polyphenylene oxide, which may contain solid fillers.

Abstract: A hybrid data communications cable includes optical fibers and insulated electrical conductors. The cable includes an elongated filler member having a central portion, walls extending radially from the central portion and a conduit running the length of the filler member. The optical fibers are enclosed within the conduit, and at least one insulated electrical conductor is separated from another insulated electrical conductor by one or more walls of the filler member. The cable further includes a jacket that encloses the filler member and the insulated electrical conductors.

Abstract: A magnet wire insulation designed to withstand voltage wave shapes present in inverter driven motors for a sustained period of time is disclosed. A large surface area inorganic oxide, e.g., fumed silica, may be added into the magnet wire insulation for providing improved resistance to insulation degradation. Alternatively, a mixture of the large surface area inorganic oxide with a low resistivity oxide, e.g., chromium oxide, provides a greater improvement in resistance to insulation degradation. The present invention is particularly useful for extending the life of windings in a motor that is subjected to high voltage, steep wave shapes such as those found in inverter driven motors.

Abstract: A magnet wire insulation designed to withstand voltage wave shapes present in inverter driven motors for a sustained period of time. A large surface area inorganic oxide, e.g., fumed silica, may be added into the magnet wire insulation for providing improved resistance to insulation degradation. Alternatively, a mixture of the large surface area inorganic oxide with a low resistivity oxide, e.g., chromium oxide, provides a greater improvement in resistance to insulation degradation. The present invention is particularly useful for extending the life of windings in a motor that is subjected to high voltage, steep wave shapes such as those found in inverter driven motors.

Abstract: An improved wire and cable packaging system for use with a spool wound with wire rotatable about a spiral-wrapped paper tube includes a container and a unitary insert, disposable in the container, both made of cardboard. The container includes a pair of retaining flaps and a pay-out slot for dispensing the wire. The insert is adapted to fit inside the container and is provided for receiving and supporting the tube when assembled. The insert includes a base with a pair of end walls extending vertically from opposing ends of the base. The end walls each having a support flap extending therefrom that is foldable about bend lines to a vertical position, adjacent the end walls, for improving support strength. The insert includes a pair of support flutes centrally formed about each bend line to define a cradle for receiving the tube.

Abstract: A pallet assembly for transporting and de-spooling electrical wire packaged in different forms (on reels or in boxes and pails) is disclosed. The pallet assembly comprises a base and a first layer cover. The base has a number of depressions formed in its top surface, each capable of receiving packages having different cross sectional profiles (circular, square, rectangular, etc.). The first layer cover has a number of locator bosses extending downward from its bottom surface. While being shipped, the packages are secured in the depressions on the top surface of the base, and the first layer cover is disposed above the packages so that the locator bosses engage the packages. In addition, the pallet assembly may contain tubular shrouds for de-spooling wire reels directly off the pallet. All components of the pallet assembly are made from a thermoplastic material and are reusable.