Abstract: An electrical cable includes a plurality of conductors forming a conductor core, one or more insulation layers at least partially surrounding at least one of the plurality of conductors, an outer jacket surrounding the conductor core and a film applied to the exterior surface of the outer jacket. The film includes high visibility particles. Methods of forming electrical cables are also described herein.

Abstract: A coated electrical accessory includes a bare electrical accessory and a substantially inorganic and dried coating layer coating the bare electrical accessory. The coating layer includes a heat radiating agent and a binder. When the coated electrical accessory is tested in accordance with ANSI CI 19.4-2004 with an amount of imparted current, the coated electrical accessory exhibits an operating temperature that is less than an operating temperature of a bare electrical accessory tested in accordance with ANSI CI 19.4-2004 with the same amount of imparted current. Methods are also provided.

Abstract: A method is provided for preparing a wire for installation of a terminal. The method comprises removing an insulating layer from a conductor to expose a portion of a conductor. The method further includes attaching a conductive foil layer to a portion of the exposed portion of the conductor by applying pressure to the conductive foil layer. Terminated wires are also provided.

Abstract: A cable separator comprising a preshaped article having a longitudinal length, wherein said preshaped article is substantially entirely formed of a foamed polymer material having a glass transition temperature greater than 160° C. and being halogen-free is provided. A data communications cable comprising a plurality of conductors and the cable separator of the present invention, wherein said cable separator separates the plurality of conductors is provided. A method of manufacturing a cable comprising the separator of the invention is also provided.

Abstract: A cable includes a jacket, a shielding tape, a pair of wires, an inner and outer jacket layer, and a separator. The shielding tape includes a substrate and a plurality of conductive shield segments disposed on the substrate. The pair of wires form a twisted pair. The inner and outer jacket layers are extruded onto inner and outer surfaces, respectively, of the substrate. The substrate, the inner jacket layer and the outer jacket layer are bonded together into a single layer that defines a circumference. Each of the conductive shield segments: extends only partially around the circumference of the single layer; is longitudinally spaced from each longitudinally adjacent one of the conductive shield segments; is radially spaced from, and overlaps a portion of, each immediately circumferentially adjacent one of the conductive shield segments; and is embedded in at least one of the inner jacket layer and the outer jacket layer.

Abstract: The present invention relates to a surface modified overhead conductor with a coating that allows the conductor to operate at lower temperatures. The coating is an inorganic, non-white coating having durable heat and wet aging characteristics. The coating preferably contains a heat radiating agent with desirable properties, and an appropriate binder/suspension agent. In a preferred embodiment, the coating has L* value of less than 80, a heat emissivity of greater than or equal to 0.5, and/or a solar absorptivity coefficient of greater than 0.3.

Abstract: A cable separator comprising a preshaped article having a longitudinal length, wherein said preshaped article is substantially entirely formed of a foamed polymer material having a glass transition temperature greater than 160° C. and being halogen-free is provided. A data communications cable comprising a plurality of conductors and the cable separator of the present invention, wherein said cable separator separates the plurality of conductors is provided. A method of manufacturing a cable comprising the separator of the invention is also provided.

Abstract: In one embodiment a matrix tape includes a support layer, a metallic layer composed of metallic segments attached to the support layer and a barrier layer attached to the support layer opposite the metallic layer. In another embodiment a matrix tape includes a support layer, a metallic layer composed of metallic segments attached to the support layer and a strength member attached to the metallic layer opposite the support layer. In a third embodiment a method of manufacturing a matrix tape includes providing a payout and an uptake reel. Dispensing a tape with a support layer and a metallic layer from the payout reel, ablating the metallic reel with a laser, attached at least one of a strength member or a barrier layer to the tape, and spooling the tape on the uptake reel.

Abstract: The present invention relates to materials for making cable jackets, particularly for riser and plenum cables. The materials provide low flammability and allow the cable to meet UL 910 or NFPA-262 or UL 1666 specifications. The composition contains polyvinyl chloride (PVC) resin, a plasticizer, ammonium octamolybdate, a molybdate compound, a stabilizer, a lubricant, aluminum trihydrate, and either i) metal oxide particles, ii) a polytetrafluoroehtylene (PTFE), iii) an intumescent compound, or iv) combinations thereof.

Abstract: Exemplary methods for manufacturing a wire and resultant wires are disclosed herein. The method includes extruding a receptor cross-linkable polymer that is substantially free of curing agent about a conductive core and extruding a donor polymer in association with a curing agent. The method includes disposing the donor polymer about the receptor polymer and conductive core to create a multi-layer wire pre-product. The method also includes heat curing a multi-layer wire pre-product to form a wire.

Abstract: Thermally conductive compositions exhibiting a thermal conductivity of 0.30 W/mK or more include a base polyolefin, a halogenated flame retardant, a non-halogenated flame retardant, and a flame retardant synergist. Cables include insulation and/or jacket layers formed of such thermally conductive compositions.

Abstract: A coating composition includes a fluoroethylene vinyl ether copolymer, a cross-linking agent, and water. The coating composition reduces the operating temperature of an overhead conductor by at least about 5° C. or more compared to a similar uncoated overhead conductor when the operating temperatures of each overhead conductor are measured at about 100° C. or higher and the coating composition is substantially free of solvent. Methods for making a coating composition and for making a coated overhead conductor are disclosed.

Abstract: A conductive composition can include a polyolefin base polymer, a high structure carbon black and a low structure carbon black. The conductive composition can exhibit two or more of a thermal conductivity of about 0.27 W/mK or more when measured at about 75° C., a volume resistivity of about 75 ohm-m or less when measured at about 90° C. and an elongation at break of about 300% or more. Cables having coverings formed of such conductive compositions and methods of making such cables are also described herein.

Abstract: A cable including a conductive composite core formed from braided carbonized fibers and fiberglass fibers. At least a portion of the fiberglass fibers are coated with magnetic material to suppress electromagnetic interference noise. Methods of forming such cables is also provided herein.

Abstract: A heat shield for use with cables in a nuclear environment can include a thermal insulator. The thermal insulator can have a low thermal conductivity and can be formed of a silica glass fiber material, an aerogel, or an aerogel-derived material. The heat shield can mitigate a 650° C. temperature spike caused by a severe accident condition. Cables including such heat shields can operate through a nuclear accident that causes an initial 650° C. temperature spike.

Abstract: A method is provided for preparing a wire for installation of a terminal. The method comprises removing an insulating layer from a conductor to expose a portion of a conductor. The method further includes attaching a conductive foil layer to a portion of the exposed portion of the conductor by applying pressure to the conductive foil layer.

Abstract: A cable assembly includes a conductor and a self-cleaning layer that surrounds the conductor and includes one or more of a photocatalyst and an electrocatalyst. Overhead high voltage electricity transmission lines are formed from these cable assemblies. Methods of reducing surface buildup on a cable are also provided.

Abstract: A data cable can include a plurality of insulated conductors twisted into pairs, an intumescent tape surrounding one or more of the insulated conductors, and a jacket. Each of the plurality of insulated conductors includes a conductor and an insulation layer. Data cables being fluoropolymer-free or halogen free are also described herein.

Abstract: The present invention relates to a method for making wire insulation that comprises the steps of providing a solid insulative material; adding a chemical foaming agent to at least one section of the solid insulative material; extruding the solid insulative material over at least one wire to create an insulated wire; and heating the insulated wire after extruding the solid insulative material and activating the chemical foaming agent in the at least one section of the solid insulative material to create at least one foamed section in the solid insulative material.

Abstract: A method for making a cable jacket that includes the steps of providing at least one shielding tape having a substrate formed of a substrate material, said substrate including at least one conductive segment; inserting the at least one shielding tape between first and second jacket layers of the cable jacket, each of said first and second jacket layers being formed of a jacket material; and co-extruding the at least one shielding tape with the first and second jacket layers, wherein the substrate material of the at least one shielding tape and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrate and first and second jacket layers bond together into a single layer wherein the at least one conductive segment is embedded in the single layer.