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: A method of making a flexible coaxial cable is provided. The method comprises advancing a cable core comprising a conductor and an expanded foam dielectric surrounding the conductor along a predetermined path of travel, directing an elongate strip of copper onto the advancing cable core and bending the copper strip into a generally cylindrical form so as to loosely encircle the core. Opposing longitudinal edges of the thus formed copper strip are then moved into abutting relation and a longitudinal weld is formed joining the abutting edges to thereby form an electrically and mechanically continuous tubular copper sheath loosely surrounding the cable core. The cable core and the surrounding sheath are simultaneously advanced while the tubular sheath is deformed into an oval configuration loosely surrounding the core. The longitudinal weld of the advancing sheath is then directed against a scarfing blade and weld flash from the sheath is scarfed from the sheath.

Abstract: The invention relates to a coaxial high-frequency cable including an inner conductor, a dielectric material formed about the inner conductor, and an outer conductor formed about the dielectric material. According to the invention, the dielectric material is made from an expanded polymer blend compounded from two a-olefin polymers of different densities, whereby the polymer of the higher density forms the matrix of the polymer blend.

Abstract: A wire harness includes a plurality of wires encased in a continuous foam sheath. The sheath is mounted adjacent a first surface of a vehicle pillar. A trim panel secured to the pillar encloses the wire harness. Connectors on the trim panel pass through apertures through the sheath and snap-fit into apertures in the pillar.

Abstract: A wire harness for use on contoured, mounting surface includes individual wires bundled together. In an effort to protect these wires from mechanical wear, vibration, and water the wire harness is encased in foam. The foam is molded about the wire harness so that is surrounds the harness in the shape of the mounting surface. The foamed-in wire harness may have an elastic memory, so that it can be bent and resiliently recover to its molded shape.

Abstract: Foamed wire harnesses are provided with a jacket to protect the wires. The jackets are formed with convoluted structure to center the wires during foaming. The indented portions are spaced by full-sized portions. Also, the indented portions are noncontinuous in a circumferential direction. The non-indented portions provide protection to the encased wires by preventing movement of sheet metal or other components into the convoluted areas.

Abstract: The present invention is directed to a new foamed elastomer composition including elastomer, hollow fillers, and reinforced fillers for supporting the conducting wires in the test probes for wafer level testing and burn in and interposer connector applications. The thermally stable elastomer resin is mixed with hollow fillers and reinforced fillers before filling into the probe or connector mold with an array of elongated conducting wires, then is crosslinked by a crosslinking agent and a catalyst. The use of compressible hollow fillers to foam the elastomer has been successful to enhance the compliance and resilience, and to reduce the thermal expansion, density, and dielectric constant of the elastomer.

Abstract: A flexible coaxial cable includes a core including at least one inner conductor and a closed cell foam dielectric surrounding the inner conductor. The flexible coaxial cable also includes a tubular metallic sheath closely surrounding and preferably bonded to the core. The closed cell foam dielectric is a low density polyolefin foam and possesses improved electrical properties over conventional foam dielectrics. The coaxial cable has a velocity of propagation of greater than 90 percent of the speed of light but still maintains high flexibility and bending characteristics.

Abstract: A flexible coaxial cable includes a core including at least one inner conductor and a foam polymer dielectric surrounding the inner conductor. The flexible coaxial cable also includes an electrically and mechanically continuous tubular copper sheath closely surrounding the core and adhesively bonded to the core. A protective outer jacket surrounds the tubular metallic sheath and is adhesively bonded to the tubular metallic sheath to increase the bending properties of the cable. The bond peel strength of the adhesive bond between the polymer jacket and the sheath is no more than 36 lb./in to provide a coaxial cable having excellent bending characteristics and which can be easily stripped to provide an electrical connection between the coaxial cable and other conductive elements. The present invention also includes a method of making flexible coaxial cable.

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: A data communication cable for transmitting high frequency signals which includes at least one pair of conductors wherein each conductor is enclosed by a first inner layer of insulation and a second outer layer of insulation, and wherein the insulated conductors are enclosed by a jacket. The first inner layer of insulation is a polyolefin which may include a flame retardant and is in the form of an extruded expanded foam. The second or outer layer of insulation is a fluoropolymer and the jacket is a flame retardant and low-smoke PVC composition.

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: A high speed signal transmission cable including spaced, parallel conductors and an insulation layer comprising blown micro fiber web surrounding the conductors, preferably further including a layer of another dielectric material surrounding the microfiber material.

Abstract: A flexible lamp tube includes an elongated foam member, a metal wire, and an accordion plastic pipe. The foam member has a central bore extending through the length of the foam member. The metal wire extends through the central bore of the foam member. The accordion plastic pipe is sleeved around the foam member.

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 fire retardant cable for use primarily as a riser cable in buildings has a plurality of groups of twisted pairs of conductors arranged in a "honeycomb" structure. Each conductor comprises a metallic conducting member encased in a single layer of a non-flame retardant polyolefin material such as high density polyethylene. The groups of conductors are surrounded by a jacket of flame retardant poly(vinyl chloride) material.

Abstract: The invention relates to coating composition, coated articles of manufacture, and to the formation of the coated articles. The coating is an energy-beam set resin containing fluid containing heat-expandable, fluid-encapsulating hollow spheres in the resin. The coating of a substrate, such as a communication line material, is accomplished by coating the material with a resin mixture containing expandable spheres and then exposing the coated material to an energy-beam source for a period of time to cure the resin and expand the spheres. The coating is applied to at least one filament of a communication line material. Such filaments can be gathered into bundles which are first extrusion coated with a thermoplastic polymer before being coated with the resin mixture. The composition of the resin material can be varied by changing the volume percent of the hollow spheres present in the resin mixture.

Abstract: This invention relates to an article comprising a potted electrical component in a structure, wherein the electrical component is potted in a polyimide composition. The invention also relates to a method of potting electrical components comprising the steps of (1) adding a polyimide precursor to a structure including an electrical component, (2) curing the polyimide precursor to form a polyimide composition encapsulating the electrical component.

Abstract: A four-core balanced transmission cable of the present invention includes four insulated electric wires, a low dielectric center interposition member having a diameter 0.35 to 0.45 times as great as an external diameter of the insulated electric wire, a pressing winding material for compressedly winding the four insulated electric wires and the center interposition member and a covering member for covering an external circumference of the pressing winding material. Accordingly, the four-core balanced transmission cable of the present invention is thin, soft and light so as to meet the standards or requirements for a cabling system of a computer.

Abstract: The invention concerns an electrical winding with a conductor layer (14) which is sealed in an insulating layer (30) of polyethylene. The polyethylene has a degree of crosslinking of at least 60% and contains an anti-oxidant. The starting material used is a not yet crosslinked polyethylene to which a foaming agent is added so that, when heated to be crosslinked, during which it also melts, the polyethylene penetrates between the individual turns (20) in the conductor layer (14). The protective insulating layer (24) round the individual turns of the winding consists of a material which is stable at the crosslinking temperature.

Abstract: The invention relates to coating composition, coated articles of manufacture, and to the formation of the coated articles. The coating is an energy-beam set resin containing fluid containing heat- expandable, fluid-encapsulating hollow spheres in the resin. The coating of a substrate, such as a communication line material, is accomplished by coating the material with a resin mixture containing expandable spheres and then exposing the coated material to an energy-beam source for a period of time to cure the resin and expand the spheres. The coating is applied to at least one filament of a communication line material. Such filaments can be gathered into bundles which are first extrusion coated with a thermoplastic polymer before being coated with the resin mixture. The composition of the resin material can be varied by changing the volume percent of the hollow spheres present in the resin mixture.

Abstract: An electrical cable having a wire bundle core surrounded by a thermal protection sleeve, the thermal protection sleeve consisting of a sandwich structure of outer acrylic adhesive layer and a silicone foam core.

Abstract: An electrical cable having a wire bundle core surrounded by a thermal and chafe protection sleeve, the thermal and chafe protection sleeve consisting of a sandwich structure having an additional outer layer of fiberglass lacing tape and a fluorosilicone fuel resistant coating.

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 cable or discrete wires, having a layer of thermally stable, crush resistant, fibril microporous heat sealable thermoplastic crystallizable polymer dielectric surrounding said conductor. The thermoplastic dielectric having a void volume in excess of 70%, a propagation velocity of the insulated conductor greater than 85% the propagation velocity in air and the crush resistance being the recovery rate of the material after being under a 500 gram weight for 10 minutes greater than 92% of the initial thickness.

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 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: An electrical cable having a wire bundle core surrounded by a thermal protection sleeve, the thermal protection sleeve consisting of a sandwich structure of a laminate of silicone foam provided on both sides with an acrylic adhered layer of fiber glass, the sandwich structure having an additional outer layer of acrylic adhesive adhered silicone release liner material or fiber glass lacing tape.

Abstract: A process for producing an insulated electric wire, comprising the steps of coating around a conductor an energy radiation curable resin composition having heat expansible microspheres incorporated therein, and curing the energy radiation curable resin composition thus coating on the conductor by exposure to an energy radiation. The process also comprises the step of heating the energy radiation curable resin composition to expand the heat expansible microspheres in the energy radiation curable resin composition, thereby forming a high-porosity insulation layer on the conductor. An insulated electric wire comprises a conductor; an energy radiation curable resin composition layer having microspheres incorporated therein and surrounding the conductor, the outside diameter of the microspheres in the energy radiation curable resin composition layer being maximum in the vicinity of the conductor and decreasing gradually toward the periphery of the energy radiation curable resin composition layer.

Abstract: An electrical cable has a single yarn polyamide fiber strength member with a plurality of copper strands positioned adjacent thereto. An insulator jacket is extruded over the copper strands and the strength member to provide a insulated lead of high strength. A foam filler layer is extruded over a plurality of such leads, and a non-porous jacket is extruded over the foam filler layer, providing a light weight, flexible, high-strength, multi-lead cable, which is easily stripped by automated equipment.

Abstract: An electrically insulated conductor comprising an electrically conductive element surrounded by ultramicrocellular foamed polymer insulation having a void volume greater than about 75%, wherein the transmission speed of the insulated conductor is greater than 90% of the speed of light. Such insulated conductors are useful in computer and telecommunications applications.

Abstract: This invention relates to an expandable tape for use in making cables. The expandable tape comprises a carrier material carrying thermally expanding microcapsules therein or thereon. The invention also relates to the use of the tape in the manufacture of cables, and to the cables incorporating such tape.

Abstract: Shaped articles of cross-linked polymers comprising a first component having little or no cross-linking and high elongation, and a second component having a relatively high level of cross-linking and low elongation. Such articles are particularly useful in the form of electrical insulation, the first component being adjacent to a wire or other conductor. Preferably each of the components comprises a crystalline fluorocarbon polymer, especially an ethylene/tetrafluoroethylene copolymer. Such articles can be prepared by (1) melt-extruding a first polymeric composition which contains little or no cross-linking agent, and a second polymeric composition which contains a greater amount of cross-linking agent, (2) maintaining the two extrudates under conditions such that cross-linking agent migrates from the second to the first composition, and (3) cross-linking both compositions, preferably by radiation.

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: The present invention relates to a very small diameter shielded wire having low electric capacitance and high dielectric breakdown voltage.A shielded wire with polyethylene foam insulation has been widely used as interconnecting wires or cables between an antenna and a tuner of TV set, video equipments, computer equipments.However, the shielded wire with polyethylene foam insulation has shown a problem of lowering the dielectric breakdown voltage when the wall-thickness of the polyethylene foam insulating layer is less than 300 microns.The present invention has been achieved in order to solve the above described problem. That is to say, it has been found that the lowering of dielectric breakdown voltage can be remarkably reduced when the maximum diameter of bubbles within the polyethylene foam insulating layer are controlled less than a half times of the wall-thickness of the insulating layer, even though the wall-thickness of the insulating layer is less than 100 microns.

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 resin coating of a wire harness is shaped in the following manner. A laminated sheet formed by integrally laminating an outer skin sheet made of semi-hard resin and an unfoamed foamable sheet made of foamable resin material, is placed along a cavity wall surface of a shaping mold with the foamable sheet directed to the inside, a bundle of wires having terminals, connectors or the like attached to their opposite ends are disposed within a space defined by the laminated sheet, and by heating the shaping mold the foamable sheet is heated and foamed. A protective coating layer made of foamed resin and protective coating layer made of an outer skin sheet can be simultaneously shaped by the mold.

Abstract: A cable and method for making such cable is disclosed. The cable is especially suited for high frequency applications in which electrical attenuation and dissipation factor are of critical importance. The cable comprises a tubular outer conductor, and at least one inner conductor for transmission of electrical signals. Between the inner and outer conductor is a foamed dielectric material. This dielectric is formed from the extrusion of an olefin polymer or a fluoropolymer with a blowing agent gas. Sulfurhexafluoride (SF.sub.6), rather than environmentally unsafe chlorofluorocarbons, is used as a blowing agent to foam the dielectric.

Abstract: This invention provides a foam barrier which prevents substantial migration of plasticizer from a plasticized polymeric article, such as a PVC cable jacket, into a gel sealing material in contact with the article and prevents substantial migration of oil from the gel material into the article while not significantly interfering with the sealing contact between the gel material and the surface of the article.

Abstract: A reinforced coaxial electric cable having low dielectric constant and a layer of convoluted dielectric insulation placed between either center conductor and conductive shield, optional porous dielectric and shield, or shield and jacket. FEP convoluted dielectric and expanded polytetrafluoroethylene insulation.

Abstract: The invention relates to a robot arm with a work arm connected to it, a connector moved by motors for tools, workpieces, workpiece grippers or gripper change systems, whereby the motors are located at the end of the work arm opposite the connector, and are connected by output connections with gear wheels mounted in a swiveling axis of a swiveling head of the connector. To make such a robot arm flexible, and moreover to guarantee that the work arm is rigid, it is proposed that the axes (D,E,P) of rotation of the elements (work arm 2, swiveling head 23, connector 3) intersect at a common intersection point (A).

Abstract: A conductor wire with an inner layer of insulation of cellular polyolefin compound and an outer layer of polyvinylchloride. The polyvinylchloride includes a material compatible with the polyolefin and which bonds to the polyolefin to bond the layers together. The compatible material may be chlorinated polyethylene. In the insulated structure, the inner layer has a substantially continuous skin which is bonded to the outer layer. In a method of forming the insulation, the inner layer is maintained as a non-cellular structure which the outer layer is extruded onto it. This provides unbroken opposing surfaces of the layers which are bonded together and the integrity of the surface of the inner layer is maintained as the layer is formed into a cellular structure.

Abstract: A semi-foamed polyethylene tape for use in the molding of foamed jacket pethylene cables. After tumble mixing low density foaming polyethylene, ethylene vinyl acetate co-polymer and polyethylene color concentrate, the tape is extruded on a thermoplastic extruder having a maddox mixing screw that effectively mixes polyethylene compounds and a slot die with a suitable opening dimension. The tape is then quenched. By controlling manufacturing variables the tape is foamed to 40% to 50% of its maximum. The tape is then foamed to 100% maximum during the manufacturing of a cable assembly.

Abstract: A high speed electrical transmission line is provided comprising a signal conductor having an open cell, continuously porous, polymeric insulating material surrounding the conductor, the insulating material having a plurality of openings fused therein, the walls of the openings being solid, fused polymer which provide compressive strength for the otherwise highly compressible porous insulating material. The preferred polymer is expanded, porous polytetrafluoroethylene. The openings may be formed by a laser or by other means.

Abstract: This invention relates to the use of ethylene/tetrafluoroethylene (ETFE) or ethylene/chlorotrifluoroethylene (ECTFE) polymers to produce a foamed coating of insulation over wire and used as wire pairs for transmitting electronic signals, in which the foamed coating is surrounded by a protective jacket or skin made of one of the two polymers.

Abstract: A multi-conductor cable such as an electrical power cable, a signal-transmission cable or optical fiber cable, including a core made of a plurality of insulated conductors, a sheath surrounding the core, and a plurality of foamed plastic string fillers which fill the void space between the core and the sheath and between the insulated conductors.

Abstract: An electrical transmission line of the twisted pair of coaxial cable type is provided. One line has a center conductor, a porous plastic dielectric disposed around the outer periphery of the conductor, the dielectric having specific gravity of 0.5 or less, and having a plastic dielectric sheath disposed around the outer periphery of the porous dielectric, the outer sheath having a melting temperature which is 60% or less than the melting temperature of the porous plastic dielectric. The porous plastic dielectric may be in tape form helically wrapped around the conductor, preferably at a wrap angle of 20 degrees or less. The preferred porous dielectric is expanded polytetrafluoroethylene.

Abstract: A high performance controlled impedance low loss low attenuation cable having the characteristics of a shielded twisted pair cable is disclosed. The cable contains a plurality of pairs of associated conductors located in a single plane to give a low profile flat cable suitable for use in undercarpet wiring installations. The cable comprises a plurality of layers of extruded insulating material with a metal foil shield surrounding only associated pairs of conductors. Insulating material having different dielectric constants is employed in conjunction with the encircling foil shield to give the cable the characteristics of a conventional shielded twisted pair cable.

Abstract: A splice between two multiconductor cables is protected from ingress of water by a closure which is filled with an expanding foam sealant which provides pressure inside the closure sufficient to force the sealant into the interstices of the splice and the interstices between the conductors in the cable, which pressure is retained in the closure until the sealant cures or hardens.

Abstract: High strength, flexible compositions with improved mechanical properties at elevated temperatures for wire insulation coatings and other shaped articles used in hostile environments are disclosed, consisting of a high temperature fluorocarbon polymer, such as an ethylene-tetrafluoroethylene copolymer or the like, and from about 1% wt. to about 50% wt. of a polyvinylidene fluoride compound.