Methods of manufacturing wire, wire pre-products and wires

Abstract

Exemplary methods for manufacturing a wire and resultant wires are disclosed herein. The method includes extruding a cross-linkable polymer that is substantially free of curing agent about a conductive core, then adding a curing agent to the extruded wire pre-product, then heat-curing the extruded wire pre-product.

1 . A method of manufacturing a wire, comprising:
 extruding a cross-linkable polymer, substantially free of curing agent, about a conductive core to form an extruded wire pre-product;   adding a curing agent to the extruded wire pre-product; and   heat curing the extruded wire pre-product.   
     
     
         2 . The method of  claim 1  wherein the conductive core comprises at least one of solid or stranded copper, nickel silver, beryllium, phosphor bronze, nickel, copper-clad aluminum, copper-clad steel, aluminium and steel. 
     
     
         3 . The method of  claim 1  wherein the conductive core comprises a semi-conductive material. 
     
     
         4 . The method of  claim 1  wherein extruding the cross-linkable polymer comprises disposing the cross-linkable polymer in direct contact with the conductive core. 
     
     
         5 . The method of  claim 1  wherein extruding the cross-linkable polymer comprises heating the cross-linkable polymer to a temperature of at least about 125° C. 
     
     
         6 . The method of  claim 1  wherein adding the curing agent comprises soaking the extruded wire pre-product in a bath containing curing agent for a time and at a temperature sufficient for curing agent to disperse into at least a portion of the cross-linkable polymer. 
     
     
         7 . The method of  claim 6  wherein the temperature of the bath is at least about 40° C. 
     
     
         8 . The method of  claim 6  wherein the time sufficient is at least about 20 seconds. 
     
     
         9 . The method of  claim 1  wherein the curing agent comprises a peroxide. 
     
     
         10 . The method of  claim 1  wherein the conductive core has a cross-sectional area of at least about 1.5 mm 2  and wherein heat curing comprises subjecting the extruded wire pre-product to a heightened temperature for time sufficient to form a wire including insulation capable of remaining intact following at least 1500 cycles of abrasion scrapes with a needle having a diameter of about 0.45±0.01 mm. 
     
     
         11 . The method of  claim 1  wherein the conductive core has a cross-sectional area of not greater than 0.22 mm 2  and wherein heat curing comprises subjecting the multi-layer wire pre-product to a heightened temperature for time sufficient to form a wire including insulation capable of remaining intact following at least 150 cycles of abrasion scrapes with a needle having a diameter of about 0.45±0.01 mm. 
     
     
         12 . The method of  claim 11  wherein the heightened temperature is at least about 125° C. and the time sufficient is at least about 30 seconds. 
     
     
         13 . The method of  claim 1  wherein the conductive core has a cross-sectional area of 0.35 mm 2  and about 0.5 mm 2  and wherein heat curing comprises subjecting the extruded wire pre-product to a heightened temperature for time sufficient to form a wire including insulation capable of remaining intact following an abrasion scrape with a 150 J garnet sandpaper with a length of about 250 mm that is exerted with an applied force of at least about 0.63N. 
     
     
         14 . A wire manufactured by the method of  claim 1 . 
     
     
         15 . A method of adding curing agent to an extruded wire pre-product, comprising:
 moving the extruded wire pre-product through a liquid bath comprising a curing agent for a time sufficient and at a temperature sufficient for curing agent to soak into at least a portion of at least one cross-linkable polymer in the extruded wire pre-product.   
     
     
         16 . The method of  claim 15  wherein the time sufficient is at least about 30 seconds and the temperature sufficient is at least about 40° C. 
     
     
         17 . The method of  claim 15  wherein the curing agent comprises a peroxide. 
     
     
         18 . An article of manufacture, comprising:
 an extruded wire pre-product on a heat curing manufacturing line, the extruded wire pre-product being substantially free of curing agent and the extruded wire pre-product having at least one insulative cross-linkable polymer about a conductive core.   
     
     
         19 . An article of manufacture, comprising:
 a heat-cured wire having a cross-linked polymeric insulative layer about a conductive core having a cross-sectional area of at least about 1.5 mm 2 , the insulative layer remaining intact following at least 1500 cycles of abrasion scrapes with a needle having a diameter of 0.45±0.01 mm or following an abrasion scrape with a 150 J garnet sandpaper with a length of about 200 mm that is exerted with an applied force of at least about 0.63N.   
     
     
         20 . An article of manufacture, comprising:
 a heat-cured wire having at least one polymeric insulative layer about a conductive core having a cross-sectional area of between about 0.35 mm 2  and about 0.5 mm 2 , the insulative layer remaining intact following at least 200 cycles of abrasion scrapes with a needle having a diameter of 0.45±0.01 mm or following an abrasion scrape with a 150 J garnet sandpaper with a length of about 250 mm that is exerted with an applied force of at least about 0.63N.