Multi-layer insulated conductor with crosslinked outer layer
First Claim
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1. An insulated conductor comprising:
- an elongate conductor; and
a two-layer insulation system havingan extruded first insulating layer comprising an aromatic thermoplastic material adjacent the elongate conductor, the first insulating layer having a thickness along its length of less than about 0.051 mm (0.002 inch); and
an extruded second insulating layer comprising a crosslinked fluoropolymer adjacent the first insulating layer,a volume of the first insulating layer being less than about 26% of a total volume of the insulation system.
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Abstract
An insulated conductor and method for making it are disclosed. The insulated conductor includes an elongate conductor and a two-layer insulation system. The two-layer insulation system has a first insulating layer including an aromatic thermoplastic material adjacent with the elongate conductor. The first insulating layer has a thickness along its length of less than about 0.051 mm (0.002 inch). The insulation system also includes a second insulating layer including a crosslinked fluoropolymer adjacent the first insulating layer. The volume of the first insulating layer is less than about 26% of the total volume of the insulation system.
25 Citations
20 Claims
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1. An insulated conductor comprising:
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an elongate conductor; and a two-layer insulation system having an extruded first insulating layer comprising an aromatic thermoplastic material adjacent the elongate conductor, the first insulating layer having a thickness along its length of less than about 0.051 mm (0.002 inch); and an extruded second insulating layer comprising a crosslinked fluoropolymer adjacent the first insulating layer, a volume of the first insulating layer being less than about 26% of a total volume of the insulation system. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. An insulated conductor comprising
an elongate stranded conductor having a diameter in the range of about 0.46 mm (0.0180 inch) to about 1.04 mm (0.041 inch); - and
a two-layer insulation system having an extruded first insulating layer comprising polyetheretherketone adjacent the elongate conductor, the first insulating layer having a substantially uniform thickness along its length in the range of about 0.013 mm (0.0005 inch) to 0.051 mm (0.002 inch); and an extruded second insulating layer comprising crosslinked poly(ethylene tetrafluoroethylene) adjacent the first insulating layer, the second insulating layer having a substantially uniform thickness along its length, a volume of the first insulating layer being less than 26% of the total volume of the first and second insulating layers and the total thickness of the insulation system being in the range of about 0.15 mm (0.006 inch) to about 0.18 mm (0.007 inch). - View Dependent Claims (14, 15, 16)
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17. A method for manufacturing an insulated conductor comprising:
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providing an elongate conductor;
thereaftermelt extruding an aromatic thermoplastic material onto an outer surface of the elongate conductor to create a first insulating layer having a substantially uniform thickness along its length of less than 0.051 mm (0.002 inch);
thereaftermelt extruding a compound comprising a fluoropolymer and a crosslinking agent onto an outer surface of the first insulating layer to create a second insulating layer overlying and in contact with the first insulating layer to provide an insulation system having a total thickness in the range of about 0.15 mm (0.006 inch) to 0.18 mm (0.007 inch), wherein a volume of the first insulating layer is less than about 26% by volume of the total volume of the insulating system; and
thereaftercrosslinking the second insulating layer. - View Dependent Claims (18, 19, 20)
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Specification