Method of manufacture of electrical wire and cable having a reduced coefficient of friction and required pulling force

• US 10,418,156 B1
• Filed: 09/07/2018
• Issued: 09/17/2019
• Est. Priority Date: 02/13/2012
• Status: Active Grant

• Current Assignee: Encore Wire Corporation
• Original Assignee: Encore Wire Corporation
• Inventors: Bigbee, Jr., William T., Griffin, Stephen S.
• Primary Examiner(s): Tso, Stanley
• Application Number:
  US16/125,591
• Time in Patent Office: 375 Days
• Field of Search: 174 30
• CPC Class Codes: B29C 2948/9278 Surface properties
• CPC Class Codes: B29C 2948/92942 Moulded article
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/03 characterised by the shape of the extruded material at extrusion
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/28 Storing of extruded material, e.g. by winding up or stacking
• CPC Class Codes: B29C 48/911 Cooling
• CPC Class Codes: B29C 48/919 using a bath, e.g. extruding into an open bath to coagulate or cool the material
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: B29K 2509/00 Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
• CPC Class Codes: B29K 2509/02 Ceramics
• CPC Class Codes: B29K 2509/08 Glass
• CPC Class Codes: B29K 2995/0007 Insulating
• CPC Class Codes: B29K 2995/0037 Other properties
• CPC Class Codes: B29K 2995/0039 Amorphous
• CPC Class Codes: B29L 2031/3406 : Components, e.g. resistors
• CPC Class Codes: B29L 2031/3462 : Cables
• CPC Class Codes: C08G 69/16 : Preparatory processes
• CPC Class Codes: C08K 3/36 : Silica
• CPC Class Codes: C08L 77/02 : Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08L77/10 takes precedence
• CPC Class Codes: H01B 13/0003 : for feeding conductors or cables
• CPC Class Codes: H01B 13/14 : by extrusion extrusion in general B29C48/00
• CPC Class Codes: H01B 13/141 : of two or more insulating layers
• CPC Class Codes: H01B 3/305 : Polyamides or polyesteramides
• CPC Class Codes: H01B 3/443 : from vinylhalogenides or other halogenoethylenic compounds
• CPC Class Codes: H01B 7/02 : Disposition of insulation
• CPC Class Codes: H01B 7/18 : Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring

Abstract

A process for manufacturing finished wire and cable having reduced coefficient of friction and pulling force during installation, includes providing a payoff reel containing at least one internal conductor wire; supplying the at least one internal conductor wire from the reel to at least one extruder; providing the least one extruder, wherein the at least one extruder applies an insulating material and a polymerized jacket composition over the at least one internal conductor wire, wherein the polymerized jacket composition comprises a predetermined amount by weight of nylon; and at least 3% by weight of a silica providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device; and, reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution.

Claims

1. A process for making a finished wire and cable, the process comprising:

supplying at least one internal conductor wire to at least one extruder;

providing the at least one extruder, wherein the at least one extruder applies an insulating material and a polymerized jacket composition over the at least one internal conductor wire, wherein the jacket composition comprises;

a predetermined amount by weight of nylon; and

at least 3% and less than 5% by weight of a predetermined amount of amorphous silica, wherein the nylon and silica are polymerized together without a pulling lubricant as an extrudable, pelletized compound;

providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device.

2. The process of claim 1, wherein the silica is synthetically produced.

3. The process of claim 1, wherein the at least 3% and less than 5% by weight of a predetermined amount of amorphous silica includes a range of 3%-4.5% by weight of amorphous silica.

4. The process of claim 1, wherein the step of providing the least one extruder further comprises:

providing a first extruder, wherein the first extruder applies an insulating material; and

providing a second extruder, wherein the second extruder applies the polymerized jacket composition.

5. The process of claim 4, wherein the insulating material is a polyvinylchloride (PVC) material.

6. The process of claim 1, wherein the temperature of the extruded insulating material and the polymerized jacket composition is lowered to a temperature of less than 85 degrees Celsius.

7. A process for making a finished wire and cable with an internal conductor, the process comprising:

providing an extruder, wherein the extruder applies an insulating material and a jacket composition over the internal conductor, wherein the jacket composition comprises;

a predetermined amount by weight of nylon; and

at least 3% and less than 5% by weight of a predetermined amount of amorphous silica, wherein the nylon and silica are polymerized together without a pulling lubricant as an extrudable, pelletized compound.

8. The process of claim 7 further comprising:

providing a cooling device for lowering the temperature of the extruded insulating material and the jacket composition and cooling the insulating material and the jacket composition in the cooling device.

9. The process of claim 8, wherein the temperature of the extruded insulating material and the polymerized jacket composition is lowered to a temperature of less than 85 degrees Celsius.

10. The process of claim 8 further comprising:

reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution.

11. The process of claim 7, wherein the silica is synthetically produced.

12. The process of claim 7, wherein the at least 3% and less than 5% by weight of a predetermined amount of amorphous silica includes a range of 3%-4.5% by weight of amorphous silica.

13. The process of claim 7, wherein the insulating material is a polyvinylchloride (PVC) material.

14. A process for making a finished wire and cable, the process comprising:

providing a payoff reel containing at least one internal conductor wire;

supplying the at least one internal conductor wire from the reel to first extruder;

providing the first extruder, wherein the least one extruder applies a first insulating material;

providing a second extruder, wherein the second extruder applies jacket composition over the at least one internal conductor wire and insulating material, wherein the jacket composition consisting essentially of;

a predetermined amount by weight of nylon; and

at least 3% and less than 5% by weight of a predetermined amount of amorphous silica, wherein the nylon and silica are polymerized together as an extrudable, pelletized compound;

providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device; and

,

reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution.

15. The process of claim 14, wherein the silica is synthetically produced.

16. The process of claim 14, wherein the at least 3% and less than 5% by weight of a predetermined amount of amorphous silica includes a range of 3%-4.5% by weight of amorphous silica.

17. The process of claim 14, wherein the predetermined amount by weight of nylon includes predetermined amount by weight of Nylon 6.

18. The process of claim 14, wherein the finished wire and cable includes Thermoplastic High Heat-resistant Nylon coated wire and cable.

19. The process of claim 14 further comprising:

providing a third extruder, wherein the third extruder applies a second insulation material over the first insulation and prior to the application of the jacket composition.

20. The process of claim 19, where the second insulation material is the same insulating material as the first insulating material.