Abstract: A high temperature pre-insulated pipe system is shown which can withstand conveyance temperatures in excess of 250° F. The pipe system includes a first and second length of insulated and jacketed pipe. Each pipe length includes an inner metal pipe having an interior surface and an exterior surface and having an envelope of foamed insulation surrounding the inner pipe exterior surface. A thermally protective coating layer is applied between the metal pipe exterior and the surrounding layer of foamed insulation. The thermally protective layer effectively lowers the interface temperature between the inner metal pipe and outer foamed layer to prevent disbondment of the outer foamed layer as the temperature of the inner pipe increases.

Abstract: A process for producing a rigid reticulated article involves coating a reticulated substrate which has open, interconnected porosity with a first dispersion comprising a ceramic or metal powder to form a first coating thereon; drying the coated reticulated substrate; contacting the coated reticulated substrate with one or more additional dispersions in succession to form one or more additional coatings thereon; drying the additional coatings between the steps of contacting; heating the coated reticulated substrate to pyrolyze organic components; and sintering the coated reticulated substrate to form a reticulated article, wherein each dispersion has a viscosity less than that of all preceding dispersions. A rigid reticulated article includes inner, intermediate and outer sintered layers of material in which the inner and outer layers are of different composition and the intermediate layer is a composite of the inner and outer layers.

Abstract: The present invention relates to low dielectric materials essential for a semiconductor having high density and high performance of the next generation, particularly to a process for preparing a porous interlayer insulating film having low dielectric constant containing pores with a size of a few nanometers or less. The present invention provides a process for preparing a porous wiring interlayer insulating film having very low dielectric constant for a semiconductor device comprising the steps of a) preparing a mixed complex of pore-forming organic molecules and a matrix resin, b) coating the mixed complex on a substrate, and c) heating the mixed complex to remove the organic molecules therefrom, thereby forming pores inside the complex.

Abstract: A method of confined synthesis of nanostructured material inside a mesoporous material. The method includes the step of providing mesoporous material having uniform and ordered mesopores. Next, a monolayer of charged functional group is attached on the pore surface of mesoporous host material by reacting with functional molecule. A oppositely-charged molecule is incorporated into the confined space of mesoporous material by either ion exchange or incipient wetness impregnation. Finally, the incorporated molecule is reduced or oxidized or further reacted with secondarily-incorporated molecule to form nanostructured material in mesoporous material.

Abstract: A method for producing an orthopaedic implant having enhanced fatigue strength. A forged implant substrate having an elongated stem is incorporated with a melting point lowering substance. Then, metal particles are sintered to the substrate, forming a porous layer on the substrate which enhances bone in growth or the mechanical interlock with bone cement. Advantageously, the sintering occurs at a lower temperature than if the substance were not incorporated into the substrate, which in turn results in an enhanced fatigue strength of the inventive implant. The fatigue strength of a forged or cast implant can also be improved by nitrogen diffusion hardening and/or thermally processing the implant after the porous coating is adhered by sintering. Further, the fatigue strength can be further improved by combining incorporating the melting point lowering substance with nitrogen diffusion hardening and/or aging treatment subsequent to sintering.

Abstract: A method for treating substrates including the steps of: providing a substrate; exposing said substrate to a plasma glow discharge in the presence of a fluorocarbon gas; maintaining said gas at a pressure between about 50 mTorr and about 400 mTorr; generating said plasma as a modulated glow discharge; pulsing said discharge at an on time of 1-500 milliseconds; pulsing said glow at an off time of 1-1000 milliseconds; maintaining said plasma glow discharge at a power density of 0.02-10 watts/cm2; and applying a hydrophobic coating to said substrate.

Abstract: The invention concerns a microporous diaphragm obtainable by filtering through a porous support, an aqueous dispersion free of asbestos fibres and titanate fibres, comprising organic fibres, at least a binding agent selected among halogenated polymers, at least a pore-forming agent and mineral particles with non-fibrous structure. The invention also concerns a combination comprising said diaphragm and a fibrous mat obtainable by filtration deposit through a porous support of a dispersion comprising fibres whereof part is electrically conductive, at least a binding agent selected among halogenated polymers, at least an electrolytic agent, at least a pore-forming agent. The invention further concerns the preparation of the diaphragm and the combination, and the use thereof to obtain an alkali metal hydroxide solution by electrolysis of aqueous alkali metal halide solutions.

Abstract: A method for manufacturing a filter utilizing a porous ceramic membrane as a separation film is provided, comprising the steps of substituting the air inside fine-pores of the porous substrate with a liquid, isolating the porous substrate face to be provided with a separation film, the other face of the porous substrate face not provided with the separation film, continuously feeding a film deposition slurry containing ceramic framework particles to allow the slurry to contact the face of the porous substrate to be provided with the separation film, applying a differential filtration pressure between the faces of the porous substrate, and depositing the slurry on the surface of the porous substrate. An organic polymer for endowing the deposition film with filtration resistance is added to the slurry.

Abstract: A method of manufacturing a composite wall with an open cell metal foam core layer bonded to an inner cladding layer and an outer cladding layer. The method involves: creating a core substrate of open cell gas permeable foam in a chosen shape; impregnating the open cell foam substrate with metal vapour and depositing a porous layer of metal on exposed internal and external surfaces of the substrate thereby forming the open cell metal foam core through metal vapour deposition; and forming the inner and outer cladding layers upon the metal foam core through spray application of metal or ceramic.

Abstract: A method for manufacturing a filter utilizing a ceramic porous membrane is provided, comprising the step of depositing a film deposition slurry containing ceramic framework particles on the surface of a porous substrate. The slurry contains an organic polymer for expanding gaps among the ceramic framework particles, and the micro-pore size of the porous membrane is controlled by adjusting the weight ratio between the framework particles and the organic polymer in the slurry, thereby enabling a porous membrane having a desired micro-pore size to be formed irrespective of the particle size of the framework particles.

Abstract: A method of fabricating a foamed metal structure using a powder supply of metal particles, comprising: (a) introducing the powder supply along with foaming agent particles into a propellant gas to form a gas/particle mixture stream; (b) projecting the mixture stream at a critical velocity of at least sonic velocity onto a metallic substrate to create a deposit of pressure-welded metal particles containing the admixed foaming agent; and (c) subjecting at least the coating of the substrate to a thermal excursion effective to activate expansion of the foaming agent while softening the metal particles for plastic deformation under the influence of the expanding gases.

Abstract: The present invention relates to a process for producing a porous layer adhering to a substrate, which comprises the steps:

Abstract: Chemical microreactors for chemical systhesis and their methods of manufacture are known, but have disadvantages such as extremely high manufacturing costs or poor flexibility for adaptation to various cases of application. These disadvantages are avoided by means of the microreactors and manufacturing methods according to the invention. The microreactors are characterized in that the reactors contain fluid ducts in at least one plane as well as feed and return lines for fluids, wherein the fluid ducts are defined by side walls of metal opposing each other and further side walls of metal or plastic extending between said side walls, and in which the planes are connected together and/or with a closure segment closing open fluid ducts by means of appropriate solder or adhesive layers. The manufacturing method is characterized by process sequences in which the individual reactor planes produced by means of electrolytic methods, are connected together by soldering or gluing.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: A method for producing an orthopaedic implant having enhanced fatigue strength. A forged implant substrate having an elongated stem is incorporated with a melting point lowering substance. Then, metal particles are sintered to the substrate, forming a porous layer on the substrate which enhances bone ingrowth or the mechanical interlock with bone cement. Advantageously, the sintering occurs at a lower temperature than if the substance were not incorporated into the substrate, which in turn results in an enhanced fatigue strength of the inventive implant. The fatigue strength of a forged or cast implant can also be improved by nitrogen diffusion hardening and/or thermally processing the implant after the porous coating is adhered by sintering. Further, the fatigue strength can be further improved by combining incorporating the melting point lowering substance with nitrogen diffusion hardening and/or aging treatment subsequent to sintering.

Abstract: The present invention relates to non-noble metal combustion catalyst for carbon monoxide comprising Cu—Al/Ce—Al complex oxides and aluminum oxide support. The catalysts comprise Ce—Al complex oxide and Cu—Al complex oxide successively loaded on the aluminum oxide support, wherein the loading weight ratio is 0.02-0.10 for Ce—Al—O/Al2O3 and 0.05-0.15 for Cu—Al—O/Al2O3, and the Cu—Al complex oxide is dispersed in cluster form on the surface of the aluminum oxide support pre-covered with high dispersed nanoparticles of the Ce—Al complex oxide. Furthermore, the present invention relates to a process for preparing the catalysts and their use as combustion promoter with high catalytic activity, high hydrothermal stability and ability of reducing NOx exhaust in the fluid catalytic cracking (FCC) process of petroleum refining.

Abstract: A spinning cone is positioned directly below a mixing head outlet to dispense and distribute a sticky mixture of polyurethane foam liquid chemical components. The mixing head and cone are reciprocated together across a longitudinally advancing metal strip to substantially uniformly distribute the mixture thereon. The procedure is practised in connection with the fabrication of overhead door insulated panels. In the prior art, plugging of dispensers would commonly occur within minutes, due to a build-up of adhering mixture on a surface followed by foaming. The spinning cone has dispensed satisfactorily for hours at a time.

Abstract: An inner syntactic foam insulator and an outer protective cover are co-extruded around a length of pipe. The protective cover is then rapidly solidified to retain the syntactic foam insulator in a desired shape about the length of pipe. The protective cover is preferably a thermoplastic or a thermosetting material. One technique for rapidly solidifying the thermoplastic protective cover is to bring the protective cover into contact with a liquid coolant (e.g., water). A thermosetting protective cover is rapidly solidified by heating the cover. According to another aspect of the invention, an inner syntactic foam insulator and an outer protective cover are co-extruded to provide an apparatus comprising the inner syntactic foam insulator encased by the outer protective cover. Advantageously, rapidly solidifying the protective layer provides a hard outer layer that protects the syntactic foam insulator as the insulator cures.

Abstract: AN EMI/RFI gasket with an open-celled foam substrate having a metal coating on its skeletal structure that is substantially deformable and recoverable. The gasket provides shielding effectiveness of greater than 40 dB.

Abstract: A method of forming a liquid-permeable asbestos-free diaphragm for use in an electrolytic cell (e.g., a chlor-alkali cell) is described. The method comprises, (a) forming a liquid-permeable diaphragm base mat of asbestos-free material on a foraminous structure (e.g., a foraminous cathode structure); (b) drawing through the base mat a topcoat slurry comprising an aqueous medium (e.g., deionized water), water-insoluble inorganic particulate material (e.g., attapulgite clay) and alkali metal polyphosphate (e.g., tetrasodium pyrophosphate decahydrate); and (c) drying the formed diaphragm. The inorganic material of the topcoat slurry is deposited on and within the diaphragm base mat.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: The present invention is a process for modifying the properties of a porous freeform fabricated part by increasing its density and reducing its porosity. The porosity and density of a freeform fabricated part are altered by packing the pores in a freeform part with an infiltrant, such as a preceramic polymer. The process includes drawing a vacuum on or pressurizing the freeform part while it is in an infiltrant bath, thereby forcing the infiltrant into the pores of the freeform part. After removing the densified freeform part from the infiltrant bath, the freeform part is subjected to a treating process, such that the infiltrant within the pores transforms to a ceramic or ceramic-containing phase to thereby increasing the density of the freeform part.

Abstract: There is provided a process for producing an acid-resistant membrane for separating a mixture, which is used for separation of a liquid and/or gas mixture by pervaporation, vapor permeation etc. The process for producing a membrane for separating a mixture comprises a step of carrying seed crystals of T-type zeolite on a porous support; a step of stirring an aqueous mixture containing a silica source, an alumina source, sodium ions, and potassium ions as the starting materials and then aging the mixture for a predetermined time and a step of immersing the porous support carrying the seed crystals in the aged mixture and then subjecting it to hydrothermal reaction to deposit T-type zeolite on the porous support. There can be provided the separation membrane on which chemical resistance such as acid resistance and alkali resistance as well as durability besides the molecular sieve ability of zeolite itself have been conferred.

Abstract: Fluorine-containing resin molded article including a molded article of a fluorine-containing resin composition containing 0.1 to 30% by weight of a carbon material, a surface of said molded article being fluorinated. The fluorine-containing resin molded article can be obtained by, after preparing molded article of a fluorine-containing resin composition containing 0.1 to 30% by weight of a carbon material, fluorinating the surface of the article with a reaction gas which comprises a compound containing fluorine atom. This fluorine-containing resin molded article has an antistatic property and non-tackiness.

Abstract: A method for forming a reactive medium for removing homogenous and heterogeneous impurities from a fluid is provided which includes forming a uniform oxide layer on all exposed surfaces of a porous metal substrate, depositing at least one layer of carbon on substantially all of the oxide layer formed on the porous metal substrate, depositing a precursor metal species on the carbon layer, and heating the porous metal substrate containing the carbon layer to form active sites on the carbon layer, wherein the active sites include at least partially deoxygenated metal species chemically bonded to the carbon layer. Also provided is a reactive medium for purifying a fluid, the reactive medium comprising a porous inorganic substrate, a layer including carbon and an oxide layer between the porous inorganic substrate and the layer including carbon. The reactive medium further comprises active sites including at least partially deoxygenated metal species, the active sites being bonded to the layer including carbon.

Abstract: A method of forming a liquid-permeable asbestos-free diaphragm on a cathode structure is described. The method comprises forming a liquid-permeable diaphragm base mat comprising fibrous synthetic polymeric material, e.g., polytetrafluoroethylene, on a cathode structure, e.g., a foraminous cathode; drawing a liquid slurry comprising an aqueous medium containing a wetting amount of surfactant and water-insoluble inorganic particulate material through the base mat, thereby to deposit said inorganic particulate material on and within the pre-formed base mat; and drying the resultant diaphragm at temperatures less than the temperature at which decomposition by-products of the surfactant are formed. The liquid slurry is substantially free of alkali metal halide and alkali metal hydroxide; and the inorganic particulate material comprises at least one oxide or silicate of a valve metal, e.g., zirconium oxide, having a median diameter of 0.

Abstract: A method of coating an ormocer (organically modified ceramic) on a phase separation surface of a roller of a phase separation apparatus to facilitate phase separation.

Abstract: A method of coating an ormocer (organically modified ceramic) on a phase separation surface of a filter of a phase separation apparatus to facilitate phase separation.

Abstract: An apparatus for drying a cellulosic fibrous structure. The apparatus comprises a micropore medium having pores therethrough. The pores are the limiting orifice in the air flow used in the drying process. The micropore medium has a relatively low pressure drop therethrough. This relatively low pressure drop advantageously reduces the energy costs used in drying, and/or allows for greater drying to be obtained at constant energy costs.

Abstract: The present invention is directed toward a new zeolite membrane which exhibits a columnar cross-sectional morphology and preferred crystallographic orientation comprising a porous substrate having coated thereon a mesoporous growth enhancing layer and a layer of columnar zeolite crystals on said mesoporous growth enhancing layer, and wherein said mesoporous growth enhancing layer comprises nanocrystalline or colloidal sized zeolites, nanocrystalline or colloidal zeolite and metal oxide, or nanocrystalline or colloidal zeolite and colloidal metal, or nanocrystalline or colloidal zeolite, colloidal metal and metal oxide, and wherein said mesoporous growth enhancing layer has interstices of about 20 to about 2000 .ANG., and wherein said columnar zeolite layer is a polycrystalline layer wherein 99.9% of said columnar zeolite crystals have at least one point between adjacent crystals that is .ltoreq.20 .ANG..

Abstract: A filtering cartridge made of compacted and sintered particles is manufactured from a powder consisting of chromium or a chromium alloy with at least 70% Cr by weight and a particle size of the chromium particles between 160 .mu.m and 500 .mu.m. Filtering cartridges of this type can be used advantageously, particularly in gas clarification for energy production by biomass gasification or coal gasification, in cracking processes in the petroleum industry, as well as for the production of melamine resin.

Abstract: A method for forming a reactive medium for removing homogeneous and heterogeneous impurities from a fluid is provided. The method includes forming a uniform oxide layer, depositing at least one layer of carbon, depositing a precursor metal species, and heating a substrate having the layer including carbon.

Abstract: A process for coating a substrate with diamond or diamond-like material including maintaining a substrate within a bed of particles capable of being fluidized, the particles having substantially uniform dimensions and the substrate characterized as having different dimensions than the bed particles, fluidizing the bed of particles, and depositing a coating of diamond or diamond-like material upon the substrate by chemical vapor deposition of a carbon-containing precursor gas mixture, the precursor gas mixture introduced into the fluidized bed under conditions resulting in excitation mechanisms sufficient to form the diamond coating.

Abstract: The invention relates to a foamable solid composition based on thermoprocessable perfluoropolymers comprising, homogeneously dispersed in the polymeric matrix, 0.05-20% by weight of a liquid fluoropolyether having molecular weight lower than 3,500 and 0.002-10% by weight of a nucleating agent. The composition results to be suitable for extruding foamed cables.

Abstract: A highly reliable rechargeable battery comprising an anode, a cathode, a separator positioned between said anode and said cathode, and an electrolyte or an electrolyte solution disposed so as to contact with said anode and said cathode, characterized in that said anode is provided with an anode active material-retaining body comprising (a) an electrically conductive material and (b) an insulating or semiconductor material having a property of allowing an ion dedicated for a battery reaction to pass through but not or substantially not allowing an anode active material deposited upon operating charging to pass through, and said anode active material-body having a number of pores distributed therein at a porosity rate of 10% or more.

Abstract: A method for preparing asbestos-free diaphragms for chlor-alkali electrolytic cells is described. The comprises establishing a liquid permeable diaphragm base mat of fibrous synthetic polymeric material and ion-exchange material on the cathode structure, treating the base mat with strongly alkaline aqueous alkali metal hydroxide having a concentration of from about 15 to about 40 weight percent, and providing a coating of inorganic particulate material on the base mat before the base mat has dried. Preferably, the base mat is coated with the inorganic particulate material using a slurry of the inorganic particulate material suspended in the strongly alkaline aqueous alkali metal hydroxide.

Abstract: Disclosed is a fixing roll, comprising a core metal, a heat resistant elastic layer formed to cover the circumferential outer surface of the core metal, and a surface layer formed to cover the circumferential outer surface of the heat resistant elastic layer, the surface layer being formed of a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer resin film of a double layer structure consisting of an inner layer having a volume resistivity of 10.sup.11 .OMEGA..cm or less and an outer layer having a thickness falling within a range of between 3 .mu.m and 50 .mu.m, and the entire thickness of the resin film falling within a range of between 20 .mu.m and 500 .mu.m.

Abstract: Asbestos-free diaphragms for chlor-alkali electrolytic cells are prepared by establishing a liquid permeable diaphragm base mat of fibrous synthetic polymeric material on the cathode structure, providing a coating of inorganic particulate material on the base mat, and treating the coated base mat with a nonionic or anionic surfactant. Preferably, the base mat is coated with the inorganic particulate material using a slurry of the inorganic particulate material suspended in an alkali metal halide brine solution containing the surfactant.

Abstract: A process for measuring the coating weight of a dried-in-place non-chromate polyacrylamide/surfactant based conversion coating is disclosed. An ammonium hexafluorotitanate tracer added to such a conversion coating was found to not adversely affect coating properties. The tracer was found to remain proportional to the polymer matrix when the coating was analyzed by X-ray fluorescence.

Abstract: A method of coating to produce a two-layer, vibration-absorbing and anti-corrosive, abrasion-resistant coating for rigid substrates, in particular for sheet metals in the underbody region of motor vehicles, for reducing the noise caused by impacting particles, comprises an inner layer, facing the substrate, of a polymer A and a plasticizer P.sub.1, and a covering layer of a polymer B and a plasticizer P.sub.2, such that either the polymers A and B have a different chemical composition and the polymer A is essentially incompatible with the plasticizer P.sub.2 and the polymer B is essentially incompatible with the plasticizer P.sub.1, or both layers contain essentially the same concentration of one plasticizer (P.sub.1 =P.sub.2), so that there is no risk of one layer being impaired by the plasticizer from the other layer.

Abstract: A caul screen is made with metal cable having a low twist level of between 1 and 5 turns per inch and where the cable is made with filaments that have been coated with brass; the cable is woven into a mesh to form the screen.

Abstract: Novel membranes comprise crystals of a zeo-type material carried by a porous support. The crystal growth of the zeo-type material is essentially continuous over the pores of the support and the zeo-type material is crystallized directly from and bonds directly to the support. Membranes may be prepared by immersing the support in a synthesis gel, crystallizing the gel, removing the support, and repeating these steps at least once.

Abstract: Gases such as hydrogen/hydrocarbon may be separated by a separating membrane of a Group VIII noble metal on a deposit of non-noble Group VIII metal which is supported on a porous silver or a porous carbon body.

Abstract: Reticulated ceramic or metal substrate coated with Cobalt compounds, noble metals or mixtures thereof are superior catalysts for the oxidation of ammonia to produce nitric oxide.

Abstract: A method of producing a flat, reinforced article with micro-openings is described wherein at least one reinforcing layer is applied to a basic layer. To be able to carry out such a method in an easy and inexpensive way, the following steps should be taken: Coating a prefabricated basic layer at both sides with a radiosensitive resist in such a way that the resist fills the micro-openings, irradiating the basic layer provided with the resist from one side in such a way that the radiation passes through the resist in the micro-openings, removing the resist from the basic-layer regions to be provided with the reinforcing layer, applying the reinforcing layer and subsequently removing the remaining resist.

Abstract: A method for manufacturing a Waffleline structure includes making holes in predetermined array pattern through a substrate material sheet, depositing layers of materials on the sheet until the holes are filled, machining the layers off a first side of the sheet to expose the substrate material, and etching the substrate material away, leavign a Waffleline structure having an array of mesas of the layers of material disposed on a base of the layers of material. The method may additionally include applying a mask to the first side of the sheet after the step of machining, and depositing further layers of material on a second side of the sheet opposite the first side following the step of applying the mask. The method may additionally comprise the steps of vapor blasting, chemically cleaning, or brushing the Waffleline structure following the step of etching.

Abstract: A coated roller for transportation and stretching of plastic film web during load unitization, and a process for preparation of the coated roller. A cylindrical metallic roller core is pitted by blasting, then primed, heated and immersed in a room-temperature liquid plastisol comprising vinyl particles dissolved in a plasticizer. The plastisol accumulates on the hot metal to a depth determined by immersion time. After removal, curing and cooling the coated core is machined by lathe to expose a cellular infrastructure and achieve a cylindrical coating coaxial with the core. The coated roller exhibits superior durability, resistance to tackifier additive buildup, and resistance to circumferential web slippage during web stretch between two rollers in a film path from a supply roll to a load being wrapped.

Abstract: A method for the uniform coating of honeycomb bodies with finely divided solid matter from a dispersion in an amount which is below that which arises during customary immersion. To this end, the honeycomb is flooded from below with dispersion, emptied after a dwell time and blown out. Filling time, filling amount, dwell time emptying time as well as the time between emptying and blowing out are measured in such a manner that in order to increase the separated amount of solid matter, filling time, dwell time, pumping-out time and the time between emptying and blowing out are increased but the filling amount is reduced.

Abstract: A method of applying a thermal barrier coat on an exposed side of a porous metal laminate which method includes the steps of spreading on the laminate an air-curable maskant to force maskant into the perforations in the exposed side, removing excess maskant from the exposed side so that maskant plugs remain in the perforations with tops generally coplanar with the exposed side, allowing the maskant to cure, directing sprays of bond coat and top coat incompatible with the maskant at the exposed side of the porous laminate to deposit a thermal barrier coat thereon but not on the maskant plugs, and removing the maskant plugs by thermal and chemical treatment or by chemical treatment alone.

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 coated 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 radiaiton 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.