Flexible cable with structurally enhanced conductors
In an electrical cable of the type having an outer sheath enclosing a conductor assembly comprising a plurality of insulated conductors disposed within a binder, the binder having a crush resistance for protecting the insulated conductors, an improvement in which a strength enhancer is mixed within the conductor insulation such that the binder can be removed without decreasing a crush resistance of the electrical cable.
1. An electrical cable having an outermost metallic sheath, the electrical cable comprising:
a conductor assembly including a bare grounding conductor and at least an insulated conductor disposed within the outermost metallic sheath,
the insulated conductor consisting of a single surrounding layer without an additional protective covering about the single surrounding layer, the single surrounding layer comprising a strength enhancer mixed therein for maintaining a crush and impact resistance of the single surrounding layer of the conductor when surrounded by the outermost metallic sheath, the strength enhancer including a lubricant, the single surrounding layer having the strength enhancer mixed therein being in direct contact with the outermost metallic sheath substantially along the length of the conductor and the outermost metallic sheath, the strength enhancer comprising a high molecular weight silicone oil having a concentration by weight of at least 9%;
the combination of the single surrounding layer and the strength enhancer mixed therein replacing any further protective covering between the conductor and the outermost metallic sheath such that the single surrounding layer as part of the conductor maintains the crush and impact resistance as required by UL 1569 second edition, revision of Sep. 10, 1998 without the electrical cable having the further protective covering between the conductor and the outermost metallic sheath.
2. The electrical cable of claim 1 , wherein the single surrounding outer layer comprises an extruded nylon polymer containing the strength enhancer mixed within.
3. The electrical cable of claim 2 , wherein the extruded polymer is nylon.
4. The electrical cable of claim 1 , wherein the bare grounding conductor is in direct contact with the outermost metallic sheath.
5. An electrical cable comprising:
a metallic outer sheath conductively contacting a bare grounding conductor disposed within the metallic outer sheath;
an insulated conductor consisting of a single outer layer without an additional protective covering between the single outer layer and the metallic outer sheath, the single outer layer having a lubricant mixed therein, the outer layer of the insulated conductor remaining in direct contact with the metallic outer sheath, and substantially along the length of the insulated conductor and the metallic outer sheath,
the lubricant including 0.25-0.85% of erucamide and a stearyl erucamide such that the electrical cable maintains the crush and impact resistance requirements of UL 1569 second edition, revision of Sep. 10, 1998 without any additional cover between the insulated conductor and the metallic outer sheath.
6. The electrical cable of claim 5 , wherein the outer layer comprises an outer region and an inner region, the outer region having the lubricant and a thickness to increase the crush and impact resistance of the conductor.
7. The electrical cable of claim 5 , wherein the strength enhancer comprises an erucamide applied on the outer layer.
8. The electrical cable of claim 5 , wherein the strength enhancer comprises a silicone oil and the silicone oil is initially applied on the outer layer.
9. An apparatus for protecting an electrical cable assembly including one or more insulated conductors and a bare grounding conductor, each insulated conductor consisting of a single outer surrounding layer, the apparatus comprising:
an outermost metallic sheath surrounding the electrical cable assembly; and
the one or more insulated conductors, in which each single outer surrounding layer is in direct contact with the outermost metallic sheath substantially along the length of the electrical cable assembly and the outermost metallic sheath, each single outer surrounding layer incorporating a strength enhancer formed of a high molecular weight silicone oil having a concentration by weight of at least 9% or a lubricant material including 0.25-0.85% of erucamide and a stearyl erucamide and mixed in an amount such that the outermost metallic sheath and the electrical cable assembly meet the crush and impact resistance requirements in UL 1569 second edition, revision of Sep. 10, 1998 without any additional layer.
10. The apparatus of claim 9 , wherein the apparatus includes a bare grounding conductor in direct contact with the outermost metallic sheath.
11. An electrical cable having a metallic outer sheath, the electrical cable comprising a conductor assembly including a bare grounding conductor and at least an electrically insulated conductor, the electrically insulated conductor being a Type XHHW consisting of a surrounding layer consisting of a cross-linked polyethylene material
and a strength enhancer mixed therein, the strength enhancer formed of a lubricant including a high molecular weight silicone oil having a concentration by weight of at least 9% or is between 0.25-0.85% of erucamide and a stearyl erucamide to maintain a crush and impact resistance of the conductor assembly when surrounded by the metallic outer sheath meeting the requirements of UL 1569 second edition, revision of Sep. 10, 1998 without requiring an additional protective covering between the surrounding layer and the metallic outer sheath,
the single surrounding layer, comprising the cross-linked polyethylene material and the strength enhancer mixed therein, being in direct contact with the metallic outer sheath and substantially along the length of the electrically insulated conductor and the metallic outer sheath.
12. The electrical cable of claim 11 , wherein the strength enhancer comprises an erucamide applied on the surrounding layer.
13. An electrical cable having a metallic outer sheath, the electrical cable comprising:
a conductor assembly, including a bare grounding conductor and at least an electrically insulated conductor contacting the bare grounding conductor, the electrically insulated conductor being a Type THHN consisting of a surrounding layer, the surrounding layer consisting of an outer portion of a nylon material around an inner portion of a polyvinylchloride material, and
a strength enhancer mixed in the outer portion, the strength enhancer formed of a lubricant in an amount to maintain a crush and impact resistance of the conductor assembly when surrounded by the metallic outer sheath meeting the requirements of UL 1569 second edition, revision of Sep. 10, 1998 without requiring an additional protective covering between the surrounding layer and the metallic outer sheath, the strength enhancer including a high molecular weight silicone oil having a concentration by weight of at least 9% or is between 0.25-0.85% of erucamide and a stearyl erucamide; and
the surrounding layer comprising the strength enhancer mixed therein being in direct contact with the metallic outer sheath, and substantially along the length of the conductor and the metallic outer sheath.
14. The electrical cable of claim 13 , wherein the strength enhancer comprises an erucamide and the erucamide is applied on the surrounding layer.
15. The electrical cable of claim 13 , wherein the strength enhancer comprises a silicone oil and the silicone oil is applied on the surrounding layer.
16. The electrical cable of claim 13 , wherein the strength enhancer comprises an erucamide and the erucamide is mixed within the surrounding layer.
17. The electrical cable of claim 13 , wherein the strength enhancer comprises a silicone oil and the silicone oil is mixed within the surrounding layer.
18. An electrical cable having an outermost metallic sheath, the electrical cable comprising:
a conductor assembly including a grounding conductor and at least an insulated conductor disposed within the outermost metallic sheath, the insulated conductor consisting of a single surrounding layer without an additional protective covering about the single surrounding layer, the single surrounding layer comprising a strength enhancer mixed therein for maintaining a crush and impact resistance of the insulated the conductor when surrounded by the outermost metallic sheath, the strength enhancer including a lubricant mixed therein and in direct contact with the outermost metallic sheath substantially along the length of the conductor and the outermost metallic sheath, the strength enhancer comprising a high molecular weight silicone oil having a concentration by weight of at least 9% or is between 0.25-0.85% of erucamide and a stearyl erucamide;
the combination of the single surrounding layer and the strength enhancer replacing any further protective covering between the conductor and the outermost metallic sheath such that the single surrounding layer as part of the conductor maintains the crush and impact resistance as required by UL 1569 second edition, revision of Sep. 10, 1998 without the electrical cable having the further protective covering between the conductor and the outermost metallic sheath.
19. An electrical cable having a metallic outer sheath, the electrical cable comprising:
a conductor assembly having a grounding conductor and at least one electrically insulated conductor contacting the grounding conductor, the at least one electrically insulated conductor being a Type THHN consisting of a surrounding layer, the surrounding layer consisting of an outer portion of a nylon material around an inner portion of a polyvinylchloride material,
a strength enhancer mixed in the outer portion, the strength enhancer formed of a lubricant in an amount to maintain a crush and impact resistance of the at least one conductor when surrounded by the metallic outer sheath meeting the requirements of UL 1569 second edition, revision of Sep. 10, 1998 without requiring an additional protective covering between the surrounding layer and the metallic outer sheath, the strength enhancer including a high molecular weight silicone oil having a concentration by weight of at least 9% or is between 0.25-0.85% of erucamide and a stearyl erucamide; and
the surrounding layer comprising the strength enhancer mixed therein being in direct contact with the metallic outer sheath, and substantially along the length of the at least one conductor and the metallic outer sheath.