Specialty Cables

SEPTEMBER 2016

WIRE JOURNAL

®

INTERNATIONAL www.wirenet.org

EVENT PREVIEWS:

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

SEPTEMBER 2016

WIRE JOURNAL

Volume 49 | Number 9 | September 2016

INTERNATIONAL www.wirenet.org

Editorial . . . . . . . . . . . . . . . . . 6

FEATURES

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Industry Profile. . . . . . . . . . . 20 Patent Report . . . . . . . . . . . . 22 Asian Focus . . . . . . . . . . . . . 26 People. . . . . . . . . . . . . . . . . . 28 Fiber Watch . . . . . . . . . . . . . 30 Fastener Update . . . . . . . . . . 31 WAI News . . . . . . . . . . . . . . . 32 Chapter Corner . . . . . . . . . . . 41

IWCS preview . . . . . . . . . . . . . . 42 IWCS returns to Providence, Rhode Island, with a full technical program and a heightened connectivity presence.

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

Wire & Cable India preview

. . 50

Technical Papers . . . . . . 76-88

Organizers of Wire & Cable India report that the Indian market continues to offer much potential to the wire and cable industry, which in turn powers this event.

Products . . . . . . . . . . . . . . . . 90

Specialty cables . . . . . . . . . . . 58

Classified . . . . . . . . . . . . . . 102

This story presents comments from manufacturers of specialty cables as well as excerpts from a newly released study from Integer Research, and more.

Innovations . . . . . . . . . . . . . . 74

Career Opportunities . . . . . 102 Advertisers’ Index . . . . . . . 103

Next issue:

October 2016 • Manufacturing trends

TECHNICAL PAPERS Cellular polymers in cable extrusion: technology fundamentals and some case studies Horst Scheid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 IWCS Paper: Development of 2000-fiber Ultra-high Density Underground Cable Naoto Ito, Mizuki Isaji, Ken Osato, Masayoshi Yamanaka and Naoki Okada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Cover: A “special” overhead view of cutaway cables. Photo provided courtesy of James Monroe Wire & Cable Corp.

SEPTEMBER 2016 | 3

CONTENTS

®

INSIDE THIS ISSUE CONTENTS CONTENTS

Proton Products International/U.K.

At Interwire, Proton Products International showcased the company’s InteliSENS SL series speed and length gauges, which it noted are saving cable manufacturers serious money every day around the world.

IWCS: at 65, it’s still evolving 42 As cable manufacturers purchase raw materials by the ton and then sell by length, it’s extremely important to make sure that when you sell a reel ofDavid cable Kiddoo, at 1000 the president/ ft, its is not 1003 ft or 1005 ft, essentially giving away CEO of the IWCS 0.3% or 0.5% for free, which can be typical in many International Cable production facilities. The InteliSENS&SL Series gauges Connectivity are calibrated to 0.03%, and with noSymposium, moving parts to wear and non-contact operation eliminating slippage, reports that the we are extremely proud to work withevent our customers may be turnthis year, and provide a gauge that truly helps ing save65money and but it is far from improve profitability. a senior The DGK Series of gauges have nobeing moving parts and citizen.

In a per Q&A measure the diameter an amazing 10,000 times secin this preview, he ond, per axis. Available as either a dual- or triple-axis discusses the scope gauge, the Super Fast Processing Technology analyzes of the event, how up to 30,000 measurements per second display and it istopresented and communicate diameter, ovality, lumps and even theneckdowns. potential The company also showed a full range products for aof second event including spark testers, capacitance to gauges, lump and be held outside U.S.gauges and neck detectors, pre heaters, speed &the length

4 | WIRE JOURNAL INTERNATIONAL

the hugely popular combined Diameter and Flaw Detection Gage DGK SuperFast Series. ”We’d like to say a big ‘thank you’ to all who visited (us) at Interwire 2015.

India wire show is 1 of 4 events. 50

Wire &Latimer, Cable India, to Products. be held Oct. 5-7 at the Grant Proton Bombay Exhibition Center in Mumbai, will once again serve as without an industry springboard for exhibition the countryand andour full It was doubt our busiest region, with some 400 exhibitors from 25 countries team of agents and employees were on hand to take care expected to take part. The wire show will run concurof our customers.” Grant Latimer, managing director, rently with Tube India International, Metallurgy India g.latimer@protonproducts.com. and India Essen Welding & Cutting 2016.

JUNE 2015 | 73

EDITORIAL WIRE JOURNAL EDITORIAL

Advances on 2 WAI electronic fronts Electronics is part of just about any company’s business plans, and any business that employs it soon finds that there is no end line to cross. What one offers has to evolve, and change has to be made. That applies to the WAI, which this month is announcing two electronic steps forward, one for this magazine, the other for a newsletter.

Any subscriber of Wire Journal International can now request a digital version of the publication. In a way, this is not news as WAI has sent the digital issue to overseas international readers for some time because of the gap in delivery times.

Earlier this year at wirenet.org, WAI began offering new subscribers the opportunity to get the magazine in either the printed version, electronic version or both. Many people opted for both or just print, but some opted for just the digital version, a sign of the times, a representation that is likely to grow.

On one level, nothing has changed: it is still the same publication, although the digital version does offer more applications, such as links to live video, company websites and more. It also represents a member benefit as subscribers will get access to the current issue while WAI members will have access to digital issues for the last 10 years.

A second bit of news is that the electronic newsletter that had gone to WAI members for years will now be available to all WJI subscribers. Formerly known as the WAI Connection, it now is called Hard Wired. The newsletter, to be sent out 10 times a year, has a new look, one that includes videos, and no doubt it too will continue to evolve.

New ‘driver’ for Mexico ITC update WAI’s return this October to Monterrey, Mexico, to hold its third International Technical Conference there, just got a memorable addition: the Oct. 20 event tour will be of the nearby $1 billion Kia plant that opened in May. The massive highly automated facility should make for a very memorable tour. Just one more reason to consider attending. See the update on p. 32.

Steve Fetteroll WAI Executive Director

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I N T E R N A T I O N A L

®

Quality in its high-end form.

With passion, we develop future-oriented measuring and control devices for quality assurance of wires and cables, such as the LASER Series 6000. A high-end solution using non-contact CCD line sensor technology combined with pulse-driven laser light sources that ensures reliable data and perfect line control, for optimal quality and increased productivity.

– continuous non-contact diameter measurement with up to 5,000 measurements/sec and extremely high single value precision – integrated lump detection for demanding end products – Wi-Fi interface and SIKORA App for flexible diagnosis and connectivity – integrated display to have the measuring value at a glance

www.sikora.net/laserseries6000 Visit us from October 2-5, 2016 at the IWCS in Providence, RI, USA

CALENDAR

CALENDAR Sept. 26-29, 2016: wire China 2016 Shanghai, China. The 7th All China International Wire & Cable Industry Trade Fair will be held at the Shanghai New International Expo Center (SNIEC).

Contact: Messe Düsseldorf North America, tel. 312781-5180, info@mdna.com, www.mdna.com.

Oct. 2-5, 2016: 65th IWCS International Cable & Connectivity SymposiumTM Providence, Rhode Island, USA. See p. 42.

Oct. 5-7, 2016: Spring World 2016 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: CASMI Office, tel. 630-359-4273, info@casmi-springworld.org.

Oct. 5-7, 2016: Wire & Cable India Mumbai, India. To be held at the Bombay Convention & Exhibition Center. Contact: See wire China 2016.

May 8-10, 2017: Global Ferrous Rod & Wire Symposium Atlanta, Georgia, USA. This WAI event, to be co-located with Interwire 2017, focuses on ferrous rod and wire processes, www.wirenet.org.

May 9-11, 2017: Interwire 2017 Atlanta, Georgia, USA. This WAI event, which will be held at the Georgia World Congress Center, includes its trade show, technical programs and 87th Annual Convention, www.wirenet.org.

Oct. 3-5, 2017: Wire South America São Paulo, Brazil. To be held at the Imigrantes Exhibition & Convention Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Oct. 8-11, 2017: 66th IWCS International Cable & Connectivity Symposium Orlando, Florida, USA. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.

May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. This WAI event, to be held at the Gaylord Opryland Resort & Convention Center, includes its trade show, technical programs and 88th Annual Convention.

WIRE ASSOCIATION INTERNATIONAL EVENTS Sept. 29, 2016: Southeast Chapter 15th Annual Golf Tournament Conover, North Carolina, USA. To be held at the Rock Barn Golf and Spa. Contact Art Deming, tel. 252-955-9451, art.deming@nexans.com.

Oct. 18-20, 2016: ITC Monterrey Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this event will include technical presentations, a tabletop display and more. Contact: Steve Fetteroll, sfetteroll@wirenet.org.

See p. 32.

Oct. 6, 2016: Ohio Valley 13th Annual Golf Tournament Solon, Ohio, USA. To be held at the Grantwood Golf Course.

Contact: Mark MacKimm, markmackimm@gmail.com or Steve Fetteroll, sfetteroll@wirenet.org.

November 3, 2016: Midwest Chapter Tour & Meeting Fort Wayne, Indiana, USA Fort Wayne Metals and Presentation at Auburn Cord Duesenberg Automobile Museum

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May 8-10, 2017: Global Ferrous Rod & Wire Symposium Atlanta, Georgia, USA. See above.

May 9-11, 2017: Interwire 2017 Atlanta, Georgia, USA. See above.

May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. See above.

INDUSTRY NEWS

INDUSTRY NEWS Nexans to supply umbilical and accessories for Australian project Nexans will supply the umbilical and accessories to OneSubsea for use in the Greater Enfield development off the coast of Exmouth, Western Australia.

A press release said that the project, worth around 20 million euros, will be Nexans’ first to be installed in Australia. The umbilicals will be manufactured at Nexans’ plants in Halden and Rognan, and installed at a depth down to 915 m. To maximize the cost-effectiveness of the single unit umbilical, it will include both dynamic and static sections. Delivery is set for Jan. 2018.

“We are excited to expand our reach around the world and our strong relationship with OneSubsea,” said Dirk Steinbrink, Nexans Senior Executive Vice President, High Voltage & Underwater Cable Business Group. He said in the release that Nexans has pioneered the development of power umbilicals, “which are a cost-effective way of supplying power, control and other functions to the sea floor.”

Per the release, the Greater Enfield Project is a joint venture between Woodside Energy Ltd. and Mitsui E&P Australia Pty. Ltd. The oil field is 60 km from the Nexans will supply the umbilical and coast of Exaccessories for a OneSubsea project. mouth. The oil field will be developed using a 31-km subsea tie-back to the floating production storage and offloading (FPSO) facility. The six subsea production wells and six water injection wells are expected to produce around 69 million barrels of oil equivalent (MMboe). OneSubsea will supply subsea pumps for the project.

Nexans previously worked with OneSubsea on the Julia oil field project in the Gulf of Mexico, the release said.

Ecuador opens 1st FO cable plant A joint venture by Ecuador’s Holding Telconet and China’s Fiberhome Technologies has inaugurated the first-ever fiber-optic cable plant in Ecuador.

The plant is located in the southern province of Guayas,

Inauguration ceremonies are held for Ecuador’s first fiber optic cable plant.

Ecuador. Per a report in CHINADAILY Europe, the facility, named Latamfiberhome, was inaugurated at a ceremony that included Ecuador Vice President Jorge Glas; Wang Yulin, China’s ambassador to Ecuador; and other government figures as well as company executives.

This plant “strengthens cooperation between China and Ecuador,” Glas said, noting that this will also help to change the country’s production matrix. “Starting from today, we will be able to export fiber-optic cables made in Ecuador, with Ecuadorian talent and manpower as well as Chinese technology.”

The report said that the plant is projected to manufacture 1 million km of fiber-optic cable a year once it is fully operational in 2019. Ecuador, which currently imports cables worth $15 million a year, estimates that it will export some $20 million of cable a year, it said.

Cable Components Group announces it will start compounding this month Cable Components Group (CCG), a U.S. manufacturer of high performance plastic extruded products for markets that include wire, cable, fiber optic and more, announced that it will begin compounding at its plant in Pawcatuck, Connecticut.

CCG President Charles Glew explained that the move was prompted by his desire to manufacture “lightweighting” materials via chemical foaming.

That new direction, he said, was the motivation for a $3 million investment that will see the company become vertically integrated. He discusses this venture in more detail in Innovations, an occasional WJI section, that is on p. 74.

Got news? E-mail it to the WJI at editor@wirenet.org.

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The Prysmian Group reports that it will open two new plants for the production of telecommunications and data cables in Europe.

A press release said that the plants are being built as extensions on already-existing factories—in Slatina, Romania, and Presov, Slovakia—that will be opened in the coming months. Both plants will be the biggest in Europe for their category once they reach full capacity at the beginning of 2017. Official inauguration ceremonies will take place in early 2017 to celebrate “this significant event for the European cable industry.”

The release said that the Slatina factory started manufacturing energy cables in 1973, and optical fiber cables for backbone and access networks in 2009. After big investments in 2013-2014, the total yearly production

INDUSTRY NEWS

Prysmian to open 2 plants in Europe

Prysmian’s plant in Slatina, Romania, is one of two faciilities that are being expanded.

‘tis ‘the season’: Clinton presidential campaign takes to the shop floor Industry by and large does not garner much attention, but the shop floor does hold special appeal when there’s an election coming up, especially for a new U.S. presidential race. As part of her Continue Jobs Tour, Democratic presidential nominee Hillary Clinton and her running mate Tim Kaine have made the manufacturing rounds, which included the wire and cable industry.

Johnstown Wire Technologies was not scheduled to draw wire on Saturday, July 30, but the plant was open to provide a Clinton campaign-requested forum for the candidates. Accompanied

by Hillary’s husband/former President Bill Clinton, they got a tour of the steel wire factory from Jim Barber, general manager of operation services, who had performed that same chore once before when President Obama was running for his first term.

Barber said that the Clintons, Kaine, some campaign staffers, local and state representatives and lots of media representatives, arrived that afternoon and were there for several hours. The company has invited employees to sign up if they wanted to attend, and a number did. He said that Hillary spoke for about a half hour, the key focus being the need to find more jobs for the middle class.

One noteworthy aspect, Barber said, was that the Clintons got to meet with Johnstown Wire’s Nick Teeter, who had met the Clintons in the mid-1990s, when he was serving with the Marine Corps and assigned to presidential duty at the Camp David retreat in Maryland.

Less than a week later, Hillary Clinton covered the electrical side, when she toured Mojave Electric Co.

With the Clintons (from l-r) on July 30 are Johnstown Wire’s Nick Teeter (back turned)—Clinton running mate Tim Kaine— Ron Shaffer and Jim Barber.

Hillary Clinton touring Mojave Electric Co. in Las Vegas, Nevada, on Aug. 4, 2016.

SEPTEMBER 2016 | 11

INDUSTRY NEWS

capacity for optical cables grew to almost 4,500,000 fkm.

With Prysmian’s new investment of 22 million euros, the factory’s production capacity is predicted to reach 8,000,000 fkm.

The Presov plant produces copper data cables for multimedia solutions, with a current capacity of more than 600,000 km per year. After an investment of 21 million euros, production capacity for copper cables will be increased, and production of optical fiber cables for multimedia applications will be added.

Francesco Fanciulli, CEO Prysmian Group Central Eastern Europe, said that the Prysmian Group—one of the largest cable companies in Eastern Europe—has six production units based in Romania, Hungary, Slovakia and Czech Republic. “It is extremely significant that two centres of excellence in Europe for the production of telecom cables are located in Eastern Europe.”

Philippe Vanhille, senior vice president telecom business at Prysmian Group, said that the investments will “further reinforce the Group’s competitiveness in telecom’s fast-changing market.” He noted that the telecom market continues to evolve, with new players and services, as the evolution of broadband continues,especially in Europe. “For this reason, ... (we will continuously invest) in this strategic sector in order to offer innovative technological solutions for the development of telecom networks.”

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Primetals Technologies ships record unit for high-capacity Chinese rod mill Primetals Technologies reports that the company has produced the market’s highest capacity 250 mm ultra heavy-duty (UHD) roll unit for high-speed wire rod mills.

A press release said that the roll unit is part of the first phase of a high-speed wire rod mill upgrade for a major Chinese steel producer. The new roll unit, shipped in May from the company’s manufacturing center in Massachusetts, will be used as a finishing block in the mill, it said.

A photo of a Primetals Technologies roll unit.

Leoni was victim of electronic theft, 40 million euros stolen

products used in concrete reinforcement and similar value added markets, it said.

STM, a member of Italy’s ORI Group, was founded in 2000. At the STM website, the company notes that in recent years it has increased its manufacturing capacity to in excess of 50,000 tons per year. The STM product line includes Grade 250, Grade 270 and Grade 300 strand in both low and normal relaxation.

“We are excited to bring STM into the Keystone group and add PC strand to our product offerings,” said KCI CEO Chris Amstrong. “PC strand is complementary to

Germany’s Leoni AG reported that it was the victim of fraudulent activity on August 12, when liquidity—the equivalent of some 40 million euros of company funds—was transferred to accounts abroad.

A press release said that the funds were stolen by the use of falsified documents and identities and the use of electronic communication channels. “The Management Board immediately launched an investigation into the events and is currently assessing claims for damages and insurance claims.” The criminal activities, reported to authorities, have not affected the IT infrastructure or data security, it said.

“The extent to which the damage will affect the projected net income for the year cannot at present be assessed,” the release said. “The liquidity situation of the Leoni Group has not been adversely affected in any material way. The performance of Leoni’s operations is in line with the forecast.”

Keystone Consolidated has acquired Strand-Tech Martin Keystone Consolidated Industries, Inc., (KCI) announced that it has acquired Strand-Tech Martin, Inc., (STM) a producer of PC strand and industrial wire for the construction industry based in Summerville, South Carolina.

A press release said that a significant amount of the high-carbon steel rod feedstock for STM will be provided from KCI’s Keystone Steel & Wire (KSW) mill in Peoria, Illinois, which it noted has the flexibility to use third-party sources of steel rod as necessary. The KSW steel mill will provide STM an assured supply of steel rod that meets the requirements for customers’ projects requiring “made in the USA” materials, while shifting and increasing KSW’s productive rod capacity to SEPTEMBER 2016 | 13

INDUSTRY NEWS

As a high-speed finishing stand, the new roll unit’s 394 kN (40 long ton) separating force allows the customer to roll larger sizes at lower temperatures, enabling thermomechanical rolling in the wire rod mill at temperatures as low as 750°C, the release said. The mill is designed to roll at speeds up to 120 m/s and can roll sizes up to 28 mm in diameter.

This is the first major modernization of a rolling mill originally supplied in the late 1990s by Morgan Construction, a predecessor company of Primetals Technologies.

OMCG SpA Italy Erik A. Macs has been named

At Interwire, OMCG NorthofAmerica director sales forshowcased Wire and the company’s technology for wire, tube and strip forming Plastic Machinery Corp (WPM). projects in the formsHe of has systems with modular Servaxis more than 25 years of and Multislide forming capabilities thatand provide experience in wire cablesolutions to reduce costsmachinery critical to profi tability. sales at previous The company displayed its CNC Minimalist 6 model. sales and marketing positions ItGem features a feed that is very close to bend tools, which Gravure’s Derekfor Olsen with ErikMachinery, Macs, who is all Progressive Inc., reduces wirewinning torsionthe effect.

The which uses smiles after raffle for model, Red Sox ticketsand that were Fine International Corp., simple multi radii bend capability. donatedtooling,

by Gemhas Gravure.

Thermoplastics EngineeringThe Officials the contract signing for the new Sadui CNC unit was at shown with CAD to machine capability Corp. Prior to that, he had been Macs Arabian factory, which will produce high-voltage cable.

Group, which he noted were very gracious hosts, even that allows easy programming while the machine is in involved with ebeam crosslinked allowing competitors its facility. production.

It also usestoIGES and STEP file importwire materials atvisit Judd Wire; blown filmthat packA story research in TradeArabia News Service said the Past chapter leaders were recognized and ing to machine and machine controllers, viathe the2016 “Easy aging company manufacturing at Union Camp; extrusion andfor has signed an agreement with KAEC board, and officers, introduced. addition Fisher, the Program” that creates the program and can to simulate injection at In Dennison; and the molding purchase processing of a 9,000-sq-m plot located inTeflon Phase officers for 2016 include: Derek Olsen, Gem Gravure, forming with 3D animation on the screen.

It can indicate film heat and thermoforming research Onesealing of the Industrial Valley at KAEC. Thewith cable vice RichHe Goyette, EIS Cable, Co., ifAmerican therepresident; is any part and machine, factory, itinterference said, will bebetween the firstWire ofinits& kind in the Durafilm. has a degree mechanical all part of the simple and effective “What you see treasurer; and Michael Crouchley, Champlain Cable, economic city. engineering from Central New England College. Ais what you get” philosophy.

Other pluses include secretary.

Srubas is the past1991, president.

The board theWAI report said, manufactures fireproof strucmemberITG, of the since he was theother 2013remote wininternet machine diagnostics and controller program members are: Brian Carris Inc.;honors David cabling in Holden, the 450-750 andReels, 600-7,000 voltage ner of tural its Donnellan Memorial Award, which updating. ranges, as Apex; well asNick flex cables, gear and Plastics; gauging Braun, Teknor Roth, Pittsfield an individual’s contributions to the Association.

HeLori instrument connection cables and low-voltage cables.  Visit

also received the WAI’s President’s Award in 2014 for extraordinary volunteer service. He served two terms on the Association’s board of directors, and is still a member of its education, member relations and paper awards Australian courtmember finds of against Prysmian committees.

A former the board of directors A Federal Court has found that Italy’s Prysmian E of the New England Chapter of WAI, he servedCavi as that Sistemi Srl (Prysmian), engaged in cartel conduct in relabody’s president in 2000. He has also chaired the WAI’s tion to the supply of high-voltage land cables in Australia, Fundamentals of Wire Manufacturing program since in proceedings brought by the Australian Competition 2007, frequently serving as a course moderator andand Consumer Commission (ACCC). presenter. Based in Bristol, Connecticut, USA, Wire & An ACCC press release reported the following: The Plastic Corp. is a major supplier of used wire and cable Court found that Prysmian engaged in price fixing and equipment thatarrangement operates out of eightrelated warehouse locaexclusionary provisions to a 2003 tions in North America, including the Northeast, North invitation by Snowy Hydro Limited (Snowy Hydro) to OMCG America Bob Sears with the It was a North magical time atPresident the event...courtesy of a magician Carolina and Texas. tender for the supply of high-voltage land cables and company’s CNC 6 system. card tricks. with a bagfull of Minimalist seemingly impossible accessories. The Court found that Prysmian was a party to WAGO reported two personnel an agreement with other cable manufacturers supOMCG offers CNC systems forQuirk processing wire Parent, Breen Color; Mark Long, Wireand Company; additions.

Juliano Matias was pliers to “allocate” the tender to Prysmian and then gave forms from 0.040 in. toHarish 0.700Panchal, in. with Lloyd its unique, and Jim Stocking, Hitachi; & Bouvier; named national sales manager for effect to that agreement by providing pricing guidance to standard, eccentric bend head.

Complementary options Mike Canterino, so Fluoropolymer Resources, Inc.; Grant its competitors that they could submit higher amounts Canada.

He previously was nationavailable: robots, welding, grooving,John cold heading, Campbell, Multi/Cable Corporation; in an attempt to ensure that Prysmian won Rivers, thefor tender. al marketing manager Phoenix chamfering, threading, stamping and forming, assembly Fluorogistix LLC; and Patthat Harper, Hueson Corp.

Justice Besanko found the Snowy Hydro tender was Contact, where he instrumental and Multislide operations. For progressive strip forming “I amoflooking forward to serving as the chapter presipart a wider over-arching agreement between Japanese in developing projects, OMCG’s Servaxis and Multislide machines and European cable manufacturers and suppliers, which dent this year,” said regional Fisher, who talked about the value have blanking capacities upoftodeal120 ton and strip for the allocation high-voltage andwidth ofprovided the chapter’s scholarship program, and land the return to er networks to submarine +80 mm. www.omcg.com. various of the world.

As the Moheguncable Sunprojects infor June for WAI’s Operations Summitt a in range of parts part of this cartel arrangement, projects offered for tender industrial & Wire Expo 2016. “Being thecomhost chapter, we are were “allocated” to eitherU.S. the Japanese or the European SAMP USA, Inc. ponents and Matias hoping for a great turnout to showcase the talents and group of manufacturers and then to a particular compaThe as well as the SAMPSISTEMI Italy information of all theelectronics. event participants ny within that group.

That company would then provide company also named Joe Stirpe function and great things WAI does for the that industry and At Interwire, the SAMPSISTEMI of Italy’s “pricing guidance” to competitors todivision ensure other bids aswere its regional sales manager for its members.”

SAMP exhibited several machines, including the higher and increase the likelihood that the company upstate New York.

He has awin diverse allocated thethanked project would the tender.

Fisher also the following event sponDM80.2x8.22 (16 wire, 22 dies) multiwire line, the background in technical sales and “This is another example of the ACCC enforcing AustraBM-630-D + SV800 pay-off, the latter will be sors: Platinum: Carrismotorized Reels, James Monroe Wire & Stirpe business development with a focus lian cartel laws in relation to collusive arrangements made in operation during the show. Also single PVC horizontal Cable, MultiCable, Specialty Cablea and PolyOne; onoutside control electrical products of and Australia but Marketing, which have Wire the potential to affect extruder model TE60-25 for automotive application will be Gold: Quirk Wire, T&T & Plastic and applications.

Over the last several decades, he has Australian consumers and businesses,” ACCC Chairman displayed.

Machinery, Fluorgistix and Chemours; Silver: Breen held in business development and Rodleadership Sims said. position The DM80.2x8.22 represents the latest generation of Color Concentrates, Fluoropolymer Resources and The ACCC’s case against a French corporation, Nexans management at Siemens, Invensys Eurotherm and KJ SAMP multiwire design to improve production versatilS&E Polymers; Bronze: Amarak Automation SA,Specialty wasCorp. dismissed.

Justice Besanko found that a Nexans Electric Based in Germantown, Pennsylvania, ity, increasedNDC output and reducedJames energy consumption.

Associates, Technologies, Monroe, Joe as company wassuppliers part of thespring “over-arching” cartel agreement USA, WAGO pressure connection The line offers increased energy effi ciency and with a Snee Associates; Associates W. Hydro Gillies andas that NexansMossberg had interface been aware of automation the and Snowy well interconnect, and solutions power factor ≥ .95 enables the drawing line to have lower tender process.nHowever, ACCC had not established that Technologies. technology.

Nexans had made an arrangement or arrived at an under-

us at wire Düsseldorf — stand 11 D52 

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MARCH 2016 JANUARY 2016| |37 25

CHAPTER PEOPLE CORNER

INDUSTRY NEWS

This timely innovation will benefi t customEuropean household care busiers who make high volume and complex parts, as he just the money, she said. meant that people who had ness “It in Switzerland.

In 2002 NUMALLIANCE is was the in sole wire bending no obligation to believe me,CNC did.”

It was as if, beyond Director Internal Audit of machine manufacturer ableand toshe offer aancomplete range family, friends and mentors, had additional sup- of was appointed Director the welded wireP&G reinforcement currently manufactured equipment from simple 2D feed and form and harda huge tool by port team.

“That’s really who you are, and it made Treasury (Europe, Middle East, our Engineered Wire Products business, and also exploits bending solution for Africa) wire, tube, spring flat-stock. impact on myrecently life.” in 2004.

Heand joined Bekaert KSW’s completed significant upgrades to its arc There is no need to produce high volume and simple Theshop presentations wowed the approximately 130 attendas to Chief Financial Officerand and memand rod mill produce high-carbon cold-headed shape parts atbillet exotic destination.

Jobs are coming back, ofheartily the Bekaert Group Executive ees. They also applauded for 2015 President quality andber rod.” and multi-slide benders are the preferred solution.

2006,Texas, and took on additional based in in Dallas, produces steelsaid fabricated Robert KCI, Srubas, Times Microwave System, who it was now,products, OMCG, America had Nilson, wire industrial wire and rod. responsibility for wire the Specialized aUntil pleasure toItaly lead had the chapter through a year that saw a Germany had Biehler and France had Group Latour.

All those films activity platform.

As of 2013, highly successful tour of the Marmon R&D as well Humblet cam-driven mechanical multi-slide come with a major combines his responsibilities as as yetCable another factory good he chapter golf outing.

He introduced to isbewhy started in Saudi drawback: set up time.

That NUMALLIANCE CFO with those of Regional Operations Management the 2016 chaptertopresident, David Fisher, James Monroe Arabia produce high-voltage cable came with aLatin concept of servo driven camless multislide, ofWire Bekaert America.

Hewho holds a commercial engi&International Cable Corporation, also thankedreports the Marmon Trade Gateway Company that it able to harbor tooling inSchool an all-electric neering degree most from of theexisting Solvay Business of the will set up a high-voltage cable factory in Saudi Arabia’s environment.

The NUMASLIDE is yours to discover.

Brussels University.

The Bridon Bekaert Ropes Group is King Abdullah Economic City (KAEC). www.nummalliance.com. a joint venture between Bekaert and Ontario Teachers’ Pension Plan that combines the ropes and advanced cords businesses of Bekaert and Bridon.

OMCG North America U.S.

Report: global demand presses need for power cable, but ‘x’ factors exist Integration of renewable and distributed power resources in conventional grid infrastructure will have a major impact on the future development of the global power transmission towers and cables market, but according to “Power Transmission Towers and Cables Market - Global Industry Analysis, Size, Share, Growth Trends and Forecast 2015 - 2023,” a report issued earlier this year, there are some other factors to be considered.

A press release from Transparency Market Research (TMR) on the report said that the vast number of companies operating in the highly fragmented marketplace will benefit from the rising demand for “up gradation” of old or technologically outdated grid infrastructures. It notes that Asia Pacific is home to some of the largest vendors in the power transmission towers and cables market, including Sumitomo Electric Industries Ltd., KEC International Ltd., ShanDong Ding Chang Tower Co. Ltd., Nanjing Daji Iron Tower Manufacturing Co. Ltd., Zhejiang Shengda Steel Tower Co. Ltd., and Kalpataru Power Transmission Ltd. The release said that the mounting demand stems from the needs of a digitized world to have an uninterrupted and high quality electricity supply. “The vast rise in the global demand for electricity forms the backbone of the global power transmission towers and cables market. In addition to this factor, rapid industrialization and urbanization will be the major factors encouraging developments in the market in the next few years.”

The release said that the market “will be hampered to a certain extent” by the emergence of wireless power transmission technologies such as laser beaming and solar and magnetic resonant induction coupling in the next few years. “Known to minimize electrical energy losses and grant increased convenience of energy transfer, these technologies will see increased adoption from utilities looking for ways of achieving increased power efficiency. Adoption of these technol-

ogies will, to an extent, limit the need for overhead cables and above-ground power transmission towers.”

Per the report, the markets for power transmission towers and cables in developed regions will largely be driven by the vast and rapid changes in power flows and operating environment associated with the rising inclusion of renewable and distributed power resources in grid infrastructure. Additionally, the aging of grid components in these regions will also be a major driver of the power transmission towers and cables market.

In developing regions such as Asia Pacific and Africa, limitations in existing grid infrastructure will lead

SEPTEMBER 2016 | 15

INDUSTRY NEWS

standing in relation to that specific project.

A hearing on penalty and other relief sought by the ACCC against Prysmian will take place on a date to be fixed by the Court. In 2013, the Federal Court imposed a penalty of $1.35 million against a Japanese cable supplier, Viscas Corporation, for its part in this cartel conduct, following the filing of joint submissions and agreed facts.

INDUSTRY NEWS

Integer Research: top 100 wire and cable company list shows industry dip The global year in review for insulated wire and cable producers in 2015 is not going to be one of the more pleasant reads, but it certainly will be memorable.

Per the database for Top 100 Wire & Cable Producers: 2016 from Integer Research, to be released this month, the world’s top producers saw a 5% fall in revenues in 2015. There was a 15% decrease in total combined U.S. revenues for the top 10 insulated wire producers. The U.K.-based firm also saw a drop in the number of Chinese companies on the top 100 list, reversing what had been steady growth.

A press release said that 2015, overall, was tough, with leading emerging economies showing slower growth rates. While the European and North American markets have benefited from lower oil prices in some respects, this has not fed through to greater fixed investment and cable demand. In contrast to the total drop, the leading cable makers, Prysmian and Nexans, appear to have consolidated their positions in the last 12 months. Integer reports that while the final figures are still being checked to see who will end up holding the top spot in 2016 in terms of their sales and operations, Prysmian and Nexans have become truly global companies, with operations in North and South America, Europe, Africa and across all parts of Asia. Both companies have seen numerous challenges in some of their key markets, but initial results from Integer’s 2016 rankings do indicate signs of growth in their global operations and reach.

In recent years, the release said, Integer’s rankings have seen impressive flexing of Chinese industrial might as more than 30 cable makers made their way into the Top

16 | WIRE JOURNAL INTERNATIONAL

100. “Early analysis of the results in so far has seen many of these new Chinese entrants crash out of the Top 100, while several mostly European companies managed to have slowed their decline and are appearing to hold their own against other regions by focusing on niche markets.”

Since 2013, 26 Chinese companies have dropped off the Top 100, Integer reports. Middle East producers, it reports, are also keeping a steady pace as Coficab grew its automotive cable revenues outside of the Middle East, and Elsewedey was doing increasingly well in the construction sector. Elsewhere, Indian producers have yet to take off despite their growing potential and maturing markets.

The above information is excerpted from the report, which is published in Excel format and contains a wealth of data over a six-year period (2010-2015), the release said. The company notes that revenues are reported in U.S. dollars, and includes insulated power cable and enamelled/magnet wire and strip figures, but it excludes revenues from copper and aluminum rod, bare overhead cables (ACSR/AAC) and wiring harness revenues.

Per Integer Research, the report “is an ideal tool for understanding the highly competitive wire and cable market, allowing you to compare company performance over time, including divisional revenues, sales by product type and country splits.”

For more information on the report, including free extracts, charts and an alpha list of featured companies from previous issues, contact Will Plunkett, Integer Research, at william.plunkett@integer-research.com. See p. 83.

CHINA

SOUTH AFRICA

short time. India is a huge country, a place with a multitudeand of quality reli- demands of modern digital devices, gions/cultures, and fromload variability, and increasingly complex and long interconnections. an industrial point of Thus, power transmission towers will view it’s not possible to be subjected to numerous changes in generalize into a single regards with design, control mechanism, evaluation. What is cerand safety and security features in the tain is that India is a land China is and will remain the most important BRICS nearoffuture, that has thousands op- driving increased demand member country, despite slowing growth. Brazil is lookfor tower maintenance and upgradation portunities, as does—to ing more like India, mired in corruption scandals, while services. a lesser extent and all the India at this point under a new regime holds the most Asia Pacific will account for the largdifferences considered promise. Again, whether the reforms promised by the share in the global market —South Africa.est Companew government in India lead to rapid growth remains Bellinafor power transmission towers and cables in terms nies in South African are to be seen. Russia will continue to have problems and it of both and revenue focusing on quality andvolume innovation and our generation, Group is laywill take several years to recover from Western-imposed with for nearly 44% and 49%, respectively, ing the groundwork a big market development there. sanctions. Not much has been heard from South Africa, in the global market by 2023.

Brazil, the world’s sixth largest economy—even though though it is now officially a member. it is very far fromTransparency Italy and presents some customs clearI think that the BRICS are going to continue to be relevant.

Market Research projance and trade policies marketforincreasingly While the pace of GDP growth may slow for a few years ects thatissues—is the global amarket power important for our strategic framework. due to political and socio-economic factors or sanctions, transmission towers and cables will One other thought: BRICS acronym was originally etc., remain temporary roadblocks at best.

Asmarket 40% should see tread the along a healthy growth path over Thethese global power transmission towers and cables annual used to define countries characterized by a developing of growth the world’s population resides in these countries, it isMarket Research. the next few years. Expected to exhibit a toppping 7%. Chart courtesy of Transparency economic situation, growth in GDP, large popinevitable that at some point in the future they will produce CAGRa strong of 7.15% over the perioda between ulation, a vast territory and abundant natural resources. and consume the majority of the world’s output.

Rahul 2015 and 2023, the market will rise from to the increased demand for technologically advanced 2015, weofcan’t talk billion of theminany as “developing Sachdev, Wire & Plastic Machinery. aInvaluation US$7.62 2014more to US$13.90 bilpower transmission towers.

Existing products in grid countries” but as superpowers that, together with the G7 lion by 2023. infrastructure in these regions, including circuit breakers, countries, theonworldwide Fabio BelliRussia facedreactors, economic political distresses in 2014 For more dominate information the report, market. contact the company fixed shunt andand conventional transformers, will na,www.transparencymarketresearch.com.

TKT Group. butnotnow the situation may be backsuch to normal in apower very at be able to deal with situations as higher “the growth of any country is possible only if the number of employed persons grows” is satisfied, India will be the next territory that we must serve intensively with our equipment and technology. Of course, the basic infrastructures are presently not sufficient and not adequate to permit the harmonious growth of this giant. Carmelo Maria Brocato, Continuus-Properzi.

18 | WIRE JOURNAL INTERNATIONAL

MAY 2015 | 37

FEATURE

INDUSTRY NEWS

DIA

INDUSTRY PROFILE Engineered for his career by his nature PROFILE

WARREN, OHIO

Paul Pawlikowski

COMPANY Delphi FOCUS The Electrical/Electronic Architecture Division of Delphi Automotive focuses on developing technology that enables automobile manufacturers to reduce the mass of wire and cable used in vehicles, with products such as halogen-free thin-wall and ultra-thin wall cable. Delphi was the first North American manufacturer of primary aluminum cable.

OF NOTE Paul Pawlikowksi was a member of an eight-member team awarded one of Delphi’s 2015 Boss Kettering Awards. His team was recognized for developing the product and processes to go into production with primary aluminum cable, sizes 0.75 to 2.5 mm2.

That success helped the company win additional business with one automotive manufacturer and enabled the company to offer aluminum cable applications to other customers.

Pawlikowski was also inducted into Delphi’s Innovation Hall of Fame this year, honored for two patents and five trade secrets.

Global Cable Manufacturing Engineering Manager Delphi

WJI: You’ve been with Delphi for 46 years: did you have any idea when you started that it would become your life-long career home?

Pawlikowski: In 1970, my only goal was to get into a school with a good engineering program. I started at Delphi (then Packard Electric Division of General Motors) as a cooperative education student at General Motors Institute (now Kettering University). And no, I wasn’t thinking four decades out.

WJI: How did it feel to be inducted into Delphi’s Innovation Hall of Fame and to win two Boss Kettering Awards for innovation?

Pawlikowski: The Boss K awards, patents and trade secrets were all team efforts. I am very proud of each team and what we accomplished. The Hall of the Fame was a matter of working with very talented and dedicated people.

WJI: What is the R&D experience for you?

Is it a grind or an intellectual puzzle?

Pawlikowski: I’ve always wanted to be an engineer. I started out as a tool engineer, then had a few process engineering positions before moving to cable process engineering.

Only 29 of my 46 years at Delphi have been in cable. I like being a manager of process engineers. It may not look romantic or exciting, but once it gets in your blood, the ability to solve problems that seem insurmountable is very rewarding. It also helps you solve problems at home. My wife and neighbors think I can fix anything.

WJI: There was a time when your company’s future was in doubt: what was that period like? What turned things around?

Pawlikowski: There was the bankruptcy in 1999. We were close to insolvency. Private

20 | WIRE JOURNAL INTERNATIONAL

investors saw promise in some of our product lines. We went through a major restructuring and survived the 2008 Great Recession. These events provided opportunities to operate at more competitive levels.

WJI: How did being a WAI member fit in?

Pawlikowski: I have countless fond memories of my work in the WAI. I was able to give something back to the industry, but I always felt like I got far more than I put in. I was especially fortunate to serve as president. I was able to bring my wife and children, who were young at the time, to most WAI events. They got to know the staff and many members so well that when I see them, most ask how my wife and children are doing long before they ask about me. My family and I are blessed with great memories thanks to the Association.

WJI: You plan to retire at year’s end: looking back, what was the best part?

Pawlikowski: I was involved in a lot of major changes at our cable plant in Ohio: the conversion from single wire drawing to multi-draw, the replacement of nearly all our bunchers, the start-up of our electron beam irradiation unit, development and production of aluminum cable, and the production of several specialty cable products.

The plant looks nothing like it did when I started. Each step came with some problems, but looking back, they provided a great sense of accomplishment and pride in our process engineering team. I got to work day-in and day-out with engineers who are among the best in the industry at their specialties, and for a guy like me, that’s about as it good as it gets.

PATENTS

Patent REPORT Technical advances are a necessity for any industry, and to that end, companies invest considerable resources in R&D. This monthly section will list the abstracts of recently approved U.S. patents. Most are direct to wire and cable while a few may be more indirect/downstream.

System and method for discovering and verifying a hybrid fiber-coaxial topology in a cable network environment U.S. Patent No.: 9,419,862 Patent date: August 16, 2016 Filed: Feb. 26, 2015 Assignee: Cisco Technology, Inc, U.S. Inventors: Rajiv Asati, Alon Bernstein, John Chapman A method in an example embodiment can include polling a first cable modem in a cable network and receiving a first response message from the first cable modem identifying a downstream frequency detected by the first cable modem. The method further includes determining the downstream frequency is split between at least two fiber nodes and determining a cable modem termination system (CMTS) service group topology, where the topology includes the at least two fiber nodes. In specific embodiments, determining that the downstream frequency is split is based on at least the first response message from the first cable modem and a second response message from a second cable modem. In more specific embodiments, the method includes constructing a hybrid fiber-coaxial (HFC) topology map of the cable network based on at least the first and second response messages, where the HFC topology map indicates the CMTS service group topology.

Sealing-member-equipped shielded cable U.S. Patent No.: 9,419,426 Patent date: August 16, 2016 Filed: Feb. 17, 2014 Assignee: Sanyo Denki Co., Ltd., Japan Inventors: Yoshihiro Shoji, Kazuhiro Makiuchi A sealing-member-equipped shielded cable includes a shielded cable that includes shielded wires and a sealing member that is molded from a resin and that includes an electrically conductive member in at least a portion thereof. The sealing member is integrally formed on one end portion of the shielded cable, and the shielded wires are electrically connected to the electrically conductive member of the sealing member.

Self-supporting stripline RF transmission cable U.S. Patent No.: 9,419,321 Patent date: August 16, 2016 Filed: Aug. 9, 2012 Assignee: CommScope Technologies LLC, U.S. Inventors: Ronald Vaccaro, Jeffrey Paynter, Frank Harwath, Alan Moe, Kendrick Van Swearingen, Scott Adams A stripline RF transmission cable has a flat inner conductor surrounded by a dielectric layer that is surrounded by an outer conductor. A jacket with an attachment feature surrounds the outer conductor. The attachment feature may be a fin aligned parallel or normal to the inner conductor. The attachment feature may be continuous or periodic along a longitudinal extent of the cable. The attachment feature may include male and female portions dimensioned to couple with one another, enabling adjacent cables to be attached to one another.

Oxide superconductor wire and superconducting coil U.S. Patent No.: 9,418,776 Patent date: August 16, 2016 Filed: Feb. 7, 2014 Assignee: Fujikura Ltd., Japan Inventor: Masanori Daibo An oxide superconductor wire includes: a superconductor laminate that comprises a substrate which is formed

22 | WIRE JOURNAL INTERNATIONAL

Patent Q & A A patent examiner’s take

Jordan Golomb, a former patent examiner, patent holder and now patent agent, recently discussed the field in a interview by Stephen Key at inc.com. Below are edited excerpts.

Why did you become a patent examiner?

Separator tape for twisted pair in LAN cable U.S. Patent No.: 9,418,775 Patent date: August 16, 2016 Filed: April 10, 2014 Assignee: CommScope, Inc., Japan Inventors: Robert Wessels, David Wiebelhaus, Trent Hayes, Wayne Hopkinson A cable includes a jacket surrounding first and second insulated conductors and a first dielectric tape, wherein the first insulated conductor is twisted with the second insulated conductor with the first dielectric tape residing therebetween to form a first twisted pair. The cable’s jacket may also surround additional twisted pairs, which are similarly formed. In alternative or supplemental embodiments of the invention, the first dielectric tape has a hollow core possessing a gas or material with a lower dielectric constant and/or at least a first side of said first dielectric tape facing to said first insulated conductor includes a plurality of ridges and valleys.

Optoelectrical composite cable U.S. Patent No.: 9,417,416 Patent date: August 16, 2016 Filed: March 13, 2014 Assignee: Hitachi Metals, Ltd., Japan Inventors: Hiroki Yasuda, Kouki Hirano, Hiroshi Sakaguchi An optoelectrical composite cable includes an optical fiber; a resin inner cylinder that accommodates the optical fiber; a plurality of electrical lines arranged outside the inner cylinder so as to cover a surrounding of the inner cylinder, and a tubular outer cylinder that collectively covers the plurality of electrical lines. The plurality of electrical lines include pairs of electrical lines, and the electrical lines constitute at least one of the pairs of electrical lines have a larger outer diameter than the other electrical lines and are arranged at opposing positions, with the inner cylinder being interposed therebetween.

I’ve been interested in inventing all my life. When I became a patent examiner, I was surprised to find out that’s unique. I studied engineering in college and then worked for Chrysler as a design engineer. I thought the best way to learn about inventing was from the inside out. Being a patent examiner Golomb is really tough. They get a lot of crap. Now that I’ve worked on the outside, some of them, frankly, deserve it.

What’s required?

I went to the patent training academy, essentially college for patent examiners, for about six months. There were lectures and classroom assignments. You start examining applications very quickly, but you’re watched very closely.

Generally, examiners learn the technology on the job. At the same time, you’re also learning the ins and outs of patent law.

Are all claims rejected the first time around?

Yes, I almost always (did that). ... We were almost never permitted to allow anything the first time around. Basically, it’s up to the patent office to establish the best case for why it’s not patentable. The applicant has to (explain) why the office is wrong, and the examiners assess the contrary evidence to make a decision.

Any advice?

Don’t rely on an attorney to educate you.

That’s a very expensive way to learn. Be really careful you don’t withhold important details.

When I was an examiner, I received responses from inventors stating, “But mine does this!”

They then revealed something that was not included in their application. However, don’t overwhelm your attorney or agent with extraneous information. That will cost you. You can offer comprehensive, quality details using only two pages.

SEPTEMBER 2016 | 23

PATENTS

in a tape shape and an intermediate layer, an oxide superconductor layer, and a metal stabilizing layer which are laminated on the substrate; and an insulating coating layer that covers an outside surface of the superconductor laminate, Also, either the entire outside surface or the entire inside surface of the insulating coating layer is coated with a coating layer formed of a fluororesin.

PATENTS

Method of making a down-hole cable having a fluoropolymer filler layer U.S. Patent No.: 9,412,502 Patent date: August 9, 2016 Filed: Dec. 23, 2013 Assignee: Rockbestos Surprenant Cable, U.S. Inventor: Scott Magner A system and method for a down-hole cable is provided. The down-hole cable includes an insulated conductor portion. A filler layer abuts and encapsulates the insulated conductor portion, wherein the filler layer is substantially formed with a foamable fluoropolymer. At least one additive is mixed with the foamable fluoropolymer filler layer.

An armor shell is applied to the exterior of the foamable fluoropolymer filler layer with the at least one additive. A bond is formed between the foamable fluoropolymer filler layer with the at least one additive and an internal surface of the armor shell.

Self-supporting stripline RF transmission cable U.S. Patent No.: 9,412,497 Patent date: August 9, 2016 Filed: Jan. 18, 2013 Assignee: Sumitomo Electric Industries, Ltd., Japan Inventors: Satoshi Hashimoto, Yuji Ochi, Takaya Kohori, Takami Sagisaka, Yuhei Mayama An object of the invention is to provide a cable capable of matching exposed dimensions of conductors with a predetermined dimension to perform good processing at the time of distal end processing. In a cable (10) in which a pair of insulated wires (1) each of which is formed by covering a conductor (4) with an insulator (5) is mutually stranded and a periphery of these stranded insulated wires (1) is covered with a sheath (6) made of an inner sheath (2) and an outer sheath (3), the conductor (4) is formed by assembling a plurality of stranded wires (4a) each of which is formed by wholly stranding a plurality of wires (4b), and by further wholly stranding the stranded wires (4a).

Wire and cable having integrally formed jacket and partitioned wall members and process and apparatus for making the same U.S. Patent No.: 9,412,495 Patent date: August 9, 2016 Filed: Oct. 7, 2011 Assignee: Encore Wire Corporation, U.S. Inventors: Mark Bennett, William Bigbee, Steve Griffin An electrical cable having an integrally formed jacket and partitioned wall members and process and apparatus for making the same, wherein the electrical cable comprises a non-metallic jacket that encapsulates an insulated conductor and a bare grounding conductor, wherein the (section cont’d. on p. 100)

24 | WIRE JOURNAL INTERNATIONAL

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ASIAN FOCUS

ASIAN FOCUS Organizers: Wire & Cable Guangzhou event in July closed with great acclaim Wire & Cable Guangzhou 2016 received very good reviews from both exhibitors and visitors at the event, which also featured an educational first: the Wire and Cable Asia Forum.

The event, which drew nearly 19,000 people, featured both exhibits as well as an educational forum.

A press release said that the event, which was held June 6-8 at the China Import and Export Fair Complex in China, was attended by 18,869 visitors from 25 countries and regions, including 3,700 buyers from overseas.

The organizers included the China Southern Power Grid Media Co., Guangzhou BoYou Exhibition Service Co., and Guangzhou Guangya Messe Frankfurt Co. The release said that the 2016 edition spanned a total exhibition space of 22,000 sqm and presented an extensive display of South China’s latest products and inno-

vations in wires and cables, manufacturing machinery as well as related materials and accessories. Some of the leading brands that were in attendance this year included Jiangsu Tongguang, Guangdong Huada, Jinglan Cable, Shandong Pacific, Shenzhen Bendakang, Shenzhen Shencable, Yunnan Zhengxiao, Dongguan Gemyoung, Guangzhou Cable Works and Guangzhou Honghui.

Jinglan Cable Co. came wanting to expand its presence in South China. One representative said that the visits they had were overwhelming. “In fact, on just the first day, we met potential clients from Saudi Arabia as well as those from within China from cities such as Guangzhou and Guiyang. We even received orders from trade associations from Nigeria.”

Guangzhou Honghui Electrician & Machinery Co., another exhibitor at the fair, applauded the effectiveness of the show. Staffer Fang Zhi said that he was impressed by the fair’s “meticulous organization” as well as the results. “We have fetched a number of solid leads from India, Iran, Japan and the U.S.,” he said. “Another company from Japan has already placed an order for a few machines from us and we are thrilled by the outcome of our participation.”

The exhibition was divided into the Equipment Zone, and the Wire, Cable and Materials Zone. They “highlighted industry innovations coming out of South China, and met the diverse demands of buyers from around the world,” the release said. Some of the buying delegations that were present included the Guangdong Province Electric Power Engineering Enterprise Association, the Anhui Province Power Engineering Association, China Wire & Cable Technology Information Union, Guizhou Power Grid, Henan Electric Power Construction Enterprises Association, Liaoning Province Power Engineering Association, Zhengwei Technology

Attendess at the Wire and Cable Asia Forum. Photo Messe Frankfurt/Wire & Cable Guangzhou.

26 | WIRE JOURNAL INTERNATIONAL

ASIAN FOCUS

(Shenzhen), and Zhuhai Power Trade Association.

Ali Al-Sakkaf, from the Al-Musbah Trading Group in Saudi Arabia, arrived at the fair to source cables for the company’s shopping mall and hotel construction projects. “In a matter of minutes, we were able to connect with wire and cable suppliers that manufacture a range of industrial- and construction-grade cables.”

Bhavesh Modi, CMD of Jaggery Wire & Cables PVT, Ltd., in India, praised the quality of the exhibitors and the displayed products and solutions. “I am looking for wire machinery and materials from China for our wire and copper cable manufacturing plant.

After only a few meetings, we are planning to make a purchase from a machinery supplier I met here today.”

The main focus was on the trade fair, but the first-ever staging of the Wire and Cable Asia Forum was also well received, the release said. The seminars saw attendance by more than 700 people in the industry, the release said. Topics ranged from government policies to the manufacturing of high-voltage cables and power grid projects to standards for electric vehicles.

Dr. Li QiuShu, from the China Southern Power Grid’s Electric Power Research Institute, gave a presentation on the charging infrastructures for electric vehicles. He discussed construction plans for charging stations following the country’s announcement of

Exhibitors came from 25 countries. Photo Messe Frankfurt/Wire & Cable Guangzhou. the 13th Five-Year Plan. “I was very happy that attendees were interested in learning more about our company’s role within the current market. The crowd here showed exceptional professionalism and possessed solid background knowledge of the industry.”

The next staging of Wire & Cable Guangzhou will be held June 9–11, 2017. For more information, go to www.wire-cable-china.com or email wire@china. messefrankfurt.com.

SEPTEMBER 2016 | 27

PEOPLE

PEOPLE AW Machinery LLC (AWM) has named Rodolfo “Rudy” Fernandez as its director of sales. He has more than 22 years of experience in the wire and cable industry, most recently serving as engineering manager for the DixieWire Division of PKC Group/AEES/Alcoa, where he was responsible for engineering, product development, R&D, process engineering, maintenance, capital Fernandez projects, quality and customer relations. At DixieWire, he supported four manufacturing locations in Mexico, Honduras and the U.S. in the automotive wire and cable industry. Based in Fairfield, New Jersey, USA, AW Machinery LLC manufactures equipment used in the wire, cable and fiber optic industries.

Graham Engineering Corp. has promoted Steve Maxson, who previously had led the company’s medical segment, to director of business development, extrusion-American Kuhne. In this expanded role, he and his team are responsible for the continuity and growth of sales and business development of the company’s American Kuhne brand. He has more than Maxson 15 years of experience in extrusion technology. He attended Rensselaer Polytechnic Institute and Wentworth Institute of Technology. Based in York, Pennsylvania, USA, and a division of Graham Engineering Corp., American Kuhne supplies engineered solutions for plastics, rubber, and silicone extrusion.

Tree Island Steel Ltd. (Tree Island) has promoted Remy Stachowiak to COO, reporting to company President and CEO Dale R. MacLean. Stachowiak will assume responsibility for the operations as well as the marketing and customer services functions. He will be responsible for the alignment and prioritizing of market and customer delivery, and ensuring operational Stachowiak excellence across the company.

He was described as “a seasoned and trusted leader who consistently delivers results... uniquely qualified to drive strategic prioritization and accountability...with a laser-focus on building customer centric organizations and operational excellence.” He has more than 28 years of leadership experience. He joined Tree Island in 2013 as vice president, sales and marketing. Prior to that, he served as COO and president of STT Stanco, a division of Semcan Inc. He also 28 | WIRE JOURNAL INTERNATIONAL

worked at Siemens, both in Canada and internationally, leading business development throughout the Americas, Europe, the Middle East, and Africa. He spent his first seven years with Stelco Inc., where he was a research investigator and R&D Group Leader. He holds degrees in mechanical engineering from McMaster University, and the University of British Columbia. Based in Richmond, British Columbia, Tree Island Steel has five plants in Canada and the U.S. that produce wire products for a diverse range of sectors.

Mark Patrizzia has joined Cincinnati Thermal Spray, Inc., as a sales engineer at its CTSEast facility in New Jersey, where he will cover the northeast as well as his network of contacts in North America. He has more than 35 year of industry experience in wire and cable as well as plastics. He most recently was a senior sales engineer for Parkway-Kew Corporation. Prior Patrizzia to that, he was a national sales manager and sales and marketing manager for Silvatrim Corporation, Uniplex Profiles, Inc., and Dande Plastics.

Based in Cincinnati, Ohio, USA, Cincinnati Thermal Spray, which provides a range of surface technology, has expanded its product range to include the wire and cable industry.

Lincoln Electric Holdings, Inc., reported two key promotions.

Michael Whitehead was named senior vice president, strategy and business development. He will be responsible for global strategic planning and mergers and acquisitions. He joined the company in 2005 as chief counsel, intellectual property, and most recently served as president of Lincoln Whitehead Electric Canada. He holds a B.S. degree in electrical engineering from The Ohio State University and a degree from the University of New Hampshire School of Law. Adel A. Mir was named president of Lincoln Electric Canada, overseeing the country’s day-to-day operations, as well as the financial and competitive success of the business. He joined Lincoln Electric Canada in 2007 and has held various operational roles within the organization and was most recently director, operations for Lincoln Canada. He holds a B.S. degree in mechanical engineering Mir

pany also announced that Gregory J. Lampert, Executive Vice President & Chief Executive Officer of the Americas, will leave the company to pursue other opportunities, pending a suitable transition period. In the interim, those duties will be assumed by company President and CEO Michael T. McDonnell. Based in Highland Heights, Kentucky, USA, General Cable is a global manufacturer of wire and cable for the energy, industrial, and communications markets.

PEOPLE

from Ryerson University and is a certified Black Belt in Six Sigma. He was described as being instrumental in Lincoln Canada attaining ISO 50001 energy management certification. Based in Cleveland, Ohio, USA, Lincoln Electric is a global supplier of welding and welding-related technology.

Michael Geiger has joined FENN as sales manager. He has more than 28 years of sales experience, with a wealth of applications expertise and knowledge A NEW KIND OF PACKAGING… within the metals FROM DeWAL industry. He most recently was an account manager at AK Steel and prior to that was Geiger a sales engineer at Ulbrich Stainless Steels and Special Metals as a sales engineer, where he was promoted to sales manager. He has also been a business owner and entrepreneur.

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General Cable Corporation has named Juan Mogollon as Senior Vice President of Latin America, responsible for the execution of the company’s strategic road-map within the Latin American region. He most Mogollon recently served as president of growth markets at Tyco International. Prior to joining Tyco, he held global leadership positions at United Technologies Corporation and General Electric.

He holds a M.S. degree in mechanical engineering from the University of California at Berkley and a B.S. degree in nuclear engineering from the University of Arizona. The com-

tension control. This gives our customers reduced downtime and increased productivity. ® not traversely buttension unidirectionally columns.

Solid Pack isdowntime a stableand put-up, control. Thisingives our customers reduced increased productivity.

This tensionincontrol becomes a critical component when using today’sat lowthe density films in resulting a spool becoming narrower without softening Because This tension control becomes a critical component whensides. using today’s low density films in high performance coaxial cables, even where unsintered a slight amount of stretching cause problems tension does not fluctuate, PTFE resistswill stretching. high performance coaxial cables, where a slight amount of stretching will cause problems DeWAL Packaging ® 5 with signal loss.

Solid Pack is for with PTFE filmloss. from ⁄32”traverse to 3⁄4”, and in 1⁄32 ” increments.

DeWAL PTFE DeWAL offers standard andsignal custom flat pad, pyramid style packages. filmPad canPackaging be as thin as 0.001”.

Flat Traverse and pyramid Flat packaging allow for longer runs per package on narrow widths.

Pad Packaging Customstate-of-the-art packages are manufactured DeWAL’s Narragansett, facilities in DeWAL’s equipment allows us at to create custom packages with RI, precision Appropriate for allalso DeWAL slit12”. film and laminatedcan products. widths up to 12” and diameters up to Packages be with or without Appropriate for alland DeWAL slit film and tension control. This gives our packages customersfrom reduced increased productivity.

Custom 3/8" downtime (9.525mm) 8" (203.2mm) widelaminated products. sideboards. Film lengths can be as Custom much as 20,000tofrom ft. packages 3/8" (9.525mm) to 8" (203.2mm) wide with diameters, width,using up totoday’s 14" (355.6mm).

This tension control becomes a criticaldepending componentonwhen low density films in with diameters, depending on traverse width, up toand 14" pyra(355.6mm).

Besides new Solid Packs, DeWAL offers traditional flat pad, high performance coaxial cables, where a slight amount of stretching will cause problems

mid packages in standard and custom configurations.

with signal loss.

For all your options, call DeWAL today.

Traverse Packaging Flat Pad Packaging Traverse Packaging

For skived, unsintered and low density PTFE film in widths from For(19.05mm) skived, unsintered and low density PTFE film in widths from 5/32" (4.123mm) 3/4" in 1/32" (0.794mm) increments.

Appropriate for alltoDeWAL slit film and laminated products.

5/32" (4.123mm) to 3/4" (19.05mm) in 1/32" (0.794mm) increments.

Film can be as thin as 0.0005" (0.013mm).

Custom packages from 3/8" (9.525mm) (203.2mm) wide be as thintoas8"and 0.0005" Custom packages up Film to 6" can (152.4mm) up to(0.013mm).

6" (152.4mm) with diameters, depending on width, upwide to 14" (355.6mm).

Custom packages up to 6" (152.4mm) wide and up to 6" (152.4mm) in diameter, with or without sideboards. in diameter, with or without sideboards.

Traverse Packaging

Flat Pad Packaging Pyramid Packaging Quality of Product...First Traverse Packaging Pyramid For skivedPackaging PTFE from 0.0005" (0.013mm) to 0.010" (0.26mm)

Pyramid Packaging

Pyramid Packaging

For5/32" skived(3.060mm) PTFE fromto0.0005" (0.013mm) to 0.010" (0.26mm) thick, and inunsintered widths from 3/4" (19.05mm) For skived, and low PTFE film in widths from to 3/4" (19.05mm) Ray Trainor Drive thick, anddensity in15 widths from 5/32" (3.060mm) in 1/32" (0.794mm) increments.

5/32" (4.123mm) to 3/4" (19.05mm) in 1/32" (0.794mm) increments.

Narragansett, RI 02882 in 1/32" (0.794mm) increments.

Narrow traverse or pyramid wound.

Film canfilm be isasusually thin asNarrow 0.0005" (0.013mm). www.dewal.com | usa1@dewal.com film is usually traverse or pyramid wound.

Custom to wide and up to Custom packages packages up up Custom to 6" 6" (152.4mm) (152.4mm) wide and up to 6" 6" (152.4mm) (152.4mm) packages up to 6" (152.4mm) wide and up to 6" (152.4mm) 800-366-8356 in sideboards. in diameter, diameter, with with or or without without sideboards. in diameter, with or without sideboards.

(International: 001-401-789-9736) Solid Pack® For skived PTFE from 0.0005" (0.013mm) to 0.010" (0.26mm) thick, and in widths from 5/32" (3.060mm) toSEPTEMBER 3/4" (19.05mm) 2016 | 29 in 1/32" (0.794mm) increments.

Narrow film is usually traverse or pyramid wound.

FIBER WATCH

FIBER WATCH Latest optical fiber capacity record set in Poland over existing infrastructure Orange Poland and Nokia announced that they have achieved a new capacity-distance record with 1.5 Tbps superchannel transmitted over 870 km between Warsaw and Wroclaw.

A press release said that the companies have sent the “world’s first optical transmission of 250 Gbps per

wavelength” over 870 km through Orange Poland’s existing network infrastructure. The milestone was set when a six-carrier 1.5 Tbps superchannel occupying a bandwidth of 300 GHz was sent over a standard single-mode fiber.

“This ground-breaking milestone will be the basis for faster networks and a better user experience for our customers,” said Christian Gacon, vice president in charge of Orange’s transport networks. “Bandwidth demands are continuing to skyrocket, but we also need to keep our infrastructure costs in check. Reaching these new heights ...we can meet bandwidth demand while maintaining the lowest cost per bit.”

The release said that the capacity and distance records were set on existing Orange Poland network infrastructure using commercially available transport infrastructure from Nokia. The companies say the results are a 25% increase in per-wavelength capacity over 200 Gbps, a 70% distance improvement compared to comparable field trials and a 250% increase in bandwidth over 100 Gbps networks using the same amount of spectrum.

Huestis Industrial Cable Jacket Strippers Model CJS 1000

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30 | WIRE JOURNAL INTERNATIONAL

How much new video? By 2020, you wouldn’t believe it For those who like statistics, Cisco’s latest annual visual networking index puts context into another universe.

By 2020, enough video will cross global IP networks in a single month that it would take more than five million years to watch it. By 2020, every second, Cisco predicts, will see a million minutes of video content cross the network. Globally, IP video traffic will be 82% of all IP traffic (both business and consumer) by 2020, up from 70% in 2015. Global IP video traffic will grow threefold from 2015 to 2020, a CAGR of 26%. Internet video traffic will grow fourfold from 2015 to 2020, a CAGR of 31%.

Internet video surveillance traffic nearly doubled in 2015, from 272 petabytes per month at the end of 2014 to 516 petabytes per month in 2015. Internet video surveillance traffic will increase tenfold between 2015 and 2020. Globally, 3.9% of all Internet video traffic will be due to video surveillance in 2020, up from 1.5% in 2015.

FASTENER UPDATE

FASTENER UPDATE Great Lakes Fasteners acquired All Integrated Solutions (AIS) has acquired Great Lakes Fasteners Corp., a Michigan-based distributor of fasteners and industrial components.

A press release said that Great Lakes Fasteners also provides vendor-managed inventory programs to original equipment manufacturers. The company offers a wide variety of products, from standards to blue print specials, as well as design and technical services for total custom fastener products. Great Lakes Fasteners has supplied fasteners and industrial supplies since 1937, and has been ISO 9001 & ISO 14001 certified since 1993.

Faulty fastener installation said to stall owners of Porsche 918 super sports car Porsche has recalled 918 Spyders sold in the United States for a potential seatbelt problem that stems from how the fasteners were installed for its sports car’s seatbelts.

Able to top 200 mph and with a price tag over $800,000, the Porsche 918 was recalled for a fastener-related issue.

Per multiple media stories, the auto maker reported that the parts manual transposed the location of the screws that hold the seatbelt mount and belt reel mount. “The problem isn’t as simple as unscrewing the fasteners and putting them in the right place because the screws are one-timeuse only, and they also aren’t identical parts.”

While the automaker is recalling all units of the 918 to inspect them, the firm indicates that vehicles with previous work on the seatbelts are more likely to have the problem. Technicians will replace the screws on the ones that do. The company will also fix the error in the parts catalog.

The reports said that Porsche 918 owners have had to deal with a few recalls on their hyper-cars since its introduction. In September 2014, Porsche repaired five of them in the U.S. because the rear axle control arms could break. The company needed to fix the vehicles again in December 2014 for defective chassis parts. There was also an issue in May 2015 where a piece of carbon fiber could damage the wiring harness.

SEPTEMBER 2016 | 31

WAI NEWS WAI NEWS

O CTOBER 18-20, 2016 | M ONTERREY , N.L. M EXICO | C ROWNE P LAZA H OTEL

INTERNATIONAL TECHNIC AL CONFERENCE

M O N T E R R E Y

Photos courtesy of the Monterrey Department of Tourism.

T

UPDATE: Kia tour set, more tech sessions and tabletops ITC attendees will be able to take part in an Oct. 20 tour of automaker Kia’s new $1 billion factory site in Pesqueria, near Monterrey, in the state of Nuevo Leon.

The morning tour, limited to the first 75 registrants, will see attendees experience the highly automated manufacturing plant that is located on a 500 hectare (53.8 million sq ft) site that also is home to numerous supplier companies’ facilities.

The Kia plant will serve as the company’s production and exportation base for North and South America, with 80% of production destined for export to 80 different countries, including the U.S., ITC attendees will get to tour the new Kia plant, which produces models the company said. The first model to be such as the Forte, shown above. produced at the plant will be 100,000 units of the Kia Forte.

The tour will include stamping, welding, painting, The plant, which began car production in May, is expectassembly and QA processes. Attendees will have to wear ed to manufacture about 300,000 vehicles/year, giving it closed shoes, long-sleeve shirts and slacks, with no high the capacity to produce a car every 56 seconds, said Kia heels allowed.

Mexico President Seong Bae-Kim.

TUESDAY, OCTOBER 18, 2016 2:30 pm - 2:55 pm FEATURED SPEAKER: Roberto de la Vega, Asociación Nacional de Transformadores de Acero AC (ANTAAC) Afternoon Session 3:30 pm - 3:55 pm “ALUMINUM MULTIWIRE DRAWING AND ANNEALING— KEY SUCCESS FACTORS AND CHALLENGES” Robert Wild, Niehoff Endex North America For fifteen years Niehoff has been developing and optimizing the processes and machinery for aluminum mulitwire drawing and inline annealing. In the automotive industry aluminum is gaining more and more importance.

32 | WIRE JOURNAL INTERNATIONAL

This presentation is tailored to manufacturers who are interested in migrating from copper to aluminum. The intent is to make them aware of the latest process and material considerations and prepare them for the challenges of this material.

WEDNESDAY, OCTOBER 19, 2016 Morning Session 11:30 am - 11:55 am “MANAGING OPERATIONAL CHANGE – CLEANING TECHNOLOGY CASE STUDY” Ernesto Osorno and Jaime Martinez, Chemetall US Inc. This session highlights Management of Change (MOC) Procedures, in the context of Cleaning Technologies, to

WAI NEWS

UPDATE: ITC tabletops Since the last issue, 15 additonal companies have reserved a tabletop position. Recent signups included: AESE SA, ANTAAC, AW Machinery, Cincinnati Thermal Spray (CTS—East), Fil-Tec Inc., Fort Wayne Wire Die, Lubrimetal SpA, MFL Group, NDC Technologies/BetaLaserMike, Pan Chemicals SpA, RichardsApex, SAMP/USA, Sikora International, Vision Engineering and Zumbach Electronics Corp.

They join those previously announced: AA Enterprise, Carris Reels, Esteves Group, Gem Gravure Company, INTEREQUIP, Micro Products Co., MGS Group, Niehoff Endex North America, Paramount Die Co., Quimica Iberoamericana, Rainbow Rubber & Plastics, Roteq Machinery, Sjogren Industries and WAI/WJI. As of press time approximately a dozen tabletops were still available.

To reserve one, contact sales@wirenet.org. assure that the following considerations are addressed before any change is implemented: 1)The technical basis for the proposed change, 2) Impact of the change on safety and health, 3) Modifications to operating procedures, 4) Necessary period for the change (temporary changes), 5) Authorization requirements for the proposed change, 6) Training of any operations, maintenance, and personnel whose job tasks are affected by the change prior to implementation of the change, 7) Modifications to process safety information and performance requirements.

The purpose of this procedure is to define the practices and other procedures that ensure all process changes are accomplished in an effective, controlled, and managed fashion after careful review and approval from the management team.

Afternoon Session 2:30 pm - 2:55 pm “FORMULATION, ANALYSIS, AND MEASUREMENT OF FINES” Horace Pops, Horace Pops Consulting Inc. This paper presents an analysis of the origin, microstructures, and make-up of fines in nonferrous products during rod production and wiredrawing. It includes a morphological genus for these contaminants leading to descriptions of eight different formation mechanisms—surface oxides, abrasive and third body wear, adhesive wear, slivers, surface deformation, delamination, and chemical compounds.

It also includes a new method to quantitatively determine the fines-potential of rod samples.

3:00 pm - 3:25 pm “HIGH-CAPACITY, HIGH-PERFORMANCE COMPOSITE CORE CONDUCTORS” Dave Bryant, CTC Global Inc. In an effort to mitigate congestion on the electric power grid while enabling the deployment of more renewable generation, the High-Capacity, Low-Sag (HCLS) Aluminum Conductor

34 | WIRE JOURNAL INTERNATIONAL

At the 2008 ITC, many attendees who sat in the technical presentations appreciated the opportunity to visit industry suppliers.

Composite Core (ACCC®) bare overhead conductor was developed. The ACCC conductor uses a high-strength, light-weight carbon fiber core that enables greater spans between fewer and/or shorter structures to reduce upfront capital costs and environmental impact. The technology, deployment and benefits are described in this paper.

3:30 pm - 3:55 pm “EFFECTIVE MEASURES TO STRENGTHEN QUALITY CONTROL AND QUALITY SUPERVISION OF CABLE PRODUCTS” Victor Muniz, NDC Technologies This presentation discusses the merits of employing multiple in-process measurement technologies such as wire preheating, scanning laser diameter, capacitance, eccentricity, fault detection, wire preheating, laser length and speed, and processors for the quality inspection and process control of communication cable.

A discussion on the importance of feedback from the final test QA lab and its relationship with product manufacturing is also provided, along with an overview of tools to link process data with cable design rules and process improvements.

4:00 pm - 4:25 pm “NOVEL HALOGEN-FREE FLAME-RETARDANT CROSSLINKED SYSTEMS FOR LOW-VOLTAGE BUILDING AND SOLAR CABLES” William Fajardo, Borealis Compounds Inc., and Linus Karlsson, Borealis AB Demand for crosslinked non-halogen flame-retardant (FR) compounds has been steadily growing over the past several years. A push for reduced fire hazard and low smoke has been gaining versus traditional halogen FR systems.

Development of a new technology platform in combination with a unique halogen-free FR system has led to two new materials meeting the performance requirements of UL44 and TUV 2Pfg 1169/EN 50618 for building wire and solar cables.

INTERNATIONAL TECHNICAL CONFERENCE

N T E R R E Y

Photos courtesy of the Monterrey Department of Tourism.

CONFERENCE REGISTRATION FORM 18-20 O CTOBER 2010 | M ONTERREY , N.L. M EXICO | C ROWNE P LAZA s Last Name

First Name

Middle

Job Title Guest Name (if attending) Company Address City

State

Postal Code

Country

Phone (Include Country Code)

Fax (Include Early Registration Fee Before September 27 USD$ Only

First Full Registration Includes: Technical Program, luncheons, reception, and breaks

Additional Full Registration First Full Registration Plus WAI Membership

Includes: Technical Program, luncheons, reception, and breaks Plus one-year WAI Membership

Regular Registration Fee After September 27 USD$ Only

q $250

q $280

q $210

q $240

q $300

q $330

REGISTRATION FEE IS PAID BY: q Check enclosed in US dollars payable to The Wire Association International, Inc. q Visa q MasterCard q American Express Fax registrations must use credit cards for payments of ALL meeting fees.

Fax No.: (001) 203-453-8384

Name on Card (Please Print)

Card Number

Single Day Registration Includes: Monday OR Tuesday Technical Program, luncheons, reception, and breaks Check one: q Monday q Tuesday

Plant Tour – Delphi Packard Wednesday 20 October

Space is limited - preference will be given to full registrants

Tabletop & Full Registration Includes: One full registration (see above), table, table drape, two chairs, and table tent sign

q $135

q $150

q $40

N/A

q $700

q $700

Expiration Date (mm/dd/yy)

Signature Cancellation Policy: Refund requests must be received in writing by October 6, 2010 to receive a full refund. No refunds after October 6, 2010.

Total USD $

MAIL Inc.

FORM TO:

The Wire Association International,

1570 Boston Post Road | P.O. Box 578 Guilford, CT 06437-0578 USA

FAX FORM TO: VISIT THE WAI ference

(001) 203-453-8384 SITE:

www.wirenet.org for con-

updates as they become available.

HOTEL RESERVATIONS: www.tinyurl.com/ITCONFERENCE2010 Conference organized by:

The Wire Association International, Inc.

Asociación Nacional de Transformadores de Acero A.C.

WAI issues Call for Papers for Interwire 2017 & Ferrous Symposium WAI NEWS

The Wire Association International has issued a Call for Papers to be presented at Interwire 2017 and the accompanying Global Ferrous Rod & Wire Symposium.

WAI’s Conference Programming Committee is seeking abstracts for proposals of papers to be presented at WAI’s 87th Annual Convention and Interwire, to be held May 8-11, 2017, at the Georgia World Congress Center in Atlanta, Georgia, USA.

This session was one of four presentations at Interwire 2015 on dust control.

Technical papers will be accepted in ferrous, nonferrous, electrical, and general categories.

Held every two years, Interwire’s conference program focuses on presentation of technical papers addressing a broad range of technology and research.

Prospective authors are asked to submit a 75word abstract of their work to be considered for inclusion in the conference program. All submissions will be reviewed by the Conference Programming Committee.

WAI is also seeking submissions for the ferrous symposium, a discrete program running concurrently with Interwire and focused on the ferrous segment. Session topics are expected to include 1. rod mill equipment for quality rod, 2. rod mill processes and procedures for quality rod, 3. coil quality for the wire mill, 4. wire rod inspection and testing, and 5. sustainability and eco-solutions.

The deadline for abstract submission is Monday, November 7, 2016. Authors will be notified whether their proposals were accepted by December 5.

Once accepted, authors will be asked to submit their manuscripts by February 6, 2017, for inclusion in the published Conference Proceedings.

For more information, visit www.wirenet.org or contact WAI’s Director of Education Marc Murray at mmurray@wirenet.org.

AUGUST 2016 | 37

WAI NEWS

From the WAI Ferrous Wire Handbook With 36 chapters over 1,168 pages, the Ferrous Wire Handbook, published in 2008, remains the Association’s most-ever comprehensive literature project, written by three dozen wire industry experts and edited by former WAI President Robert M. Shemenski, an industry consultant and president of RMS Consulting, Inc. The book is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering and operations sectors of the industry.

The chapters present straightforward explanations of different process, supported by charts and photos. The content covers a full spectrum of sectors, with individual chapters—from wire rod production and deformation in cold drawing to patenting and straightening and cutting wire—that explain the process in practical terms. A company that just wants one or two chapters need not pay for the entire book ($235/$195 for WAI members).

A PDF of a single chapter, from 4 through 36, can be ordered for $25, $20 for WAI members. Each order will include an additional free PDF with the first three chapters (A short history of the Ferrous Wire Industry, Evolution of Modern Steel Manufacture, and Modern Steel Manufacturing), which serve as an industry introduction and overview.

To get the first three chapters for free, go to www.mywai.org.

There you can see and order the other individual chapters. Future issues will present chapters summations here.

ON SALE NOW!

CHAPTER 6: Controlled Cooling of Wire Rod SUMMARY: This chapter, 24 pages, discusses the subjects in the below subheads. It includes 22 figures, charts and and pictures, an intro and a bibliography.

Chapter subheads: • eight “basic” sections • The Modern Stelmor Process • Metallurgical Aspects of Standard Stelmor Process • Mechanical Properties and Applications of Standard Stelmor Rod • Slow Cold Stelmor System • Retarded Cooling Stelmor •Oher Continuous Cooling Methods • Summary

REELS AND DRUMS Metal reels for wire and cable.

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38 | WIRE JOURNAL INTERNATIONAL

CHAPTER CORNER

CHAPTER CORNER Poland Chapter again is key organizer of technical conference on March 2-4 WAI’s Poland Chapter and the Czestochowa University of Technology (CUT) are among the organizers of a biennial technical event, the 7th International Conference on Drawing, to be held March 2-4, 2017, at the Antałówka Hotel in Zakopane, Poland.

The event theme, “Modern technologies and modelling of drawing and manufacturing processes of metal products,” will be reflected in technical presentations presented on steel wire and wire products, nonferrous wire and wire products, electrical wire, and special products.

The first day is registration and a reception, the second day has the technical sessions, with tableletops, followed

Speaking at the 2015 event were Polish Steel Association officials Stefan Dzienniak, president of the board, and Kazimierz Kowalski, deputy director. that evening by regional folk entertainment.The last day will include morning sessions and poster papers, followed by lunch and the conference closing. The event will also see the awarding of the Schneider Memorial Award to Wojciech Misiołek, a highly regarded U.S. professor, with Polish roots, who is director of the Metal Forming Institute in Leigh University.

The conference is being headed by Prof. Sylwia Wiewiórowska, Institute of Plastic Working and Safety Engineering, a member of the faculty of Production Engineering and Materials Technology at Czestochowa University of Technology (CUT) in Poland. Joining Wiewiórowska on the organizing committee are: Secretary: Dr. Ewa Staniewska; and members Dr. Robert Kruzel, Dr. Bartosz Koczurkiewicz. Manager Beata Nonas and Manager Piotr Romański.

“This will be a very impressive program,” said Jan Pilarczyk, who has retired as a CUT professor but has been a key organizer in past events, and is helping out again with this one. The long-time president of WAI’s Poland Chapter said that the technical program is coming along well, and encouraged companies to reserve a tabletop display for 420 euros to support the event. “It is amazing to have such a scope of academic expertise involved,” he said

The awards ceremony at the 2015 conference. noting that members of the Scientific Committee come from eight well-respected educational institutions.

They include: Prof. Zbigniew Muskalski, CUT; Prof.

Andrzej Gontarz, Lublin University of Technology; Prof.

Adam Grajcar, Silesian University of Technology; Prof.

Marcin Knapiński, CUT; Prof. Tadeusz Knych, AGH University of Science and Technology; Prof. Roman Kuziak, Institute for Ferrous Metallurgy; Prof. Janusz Łuksza, AGH; Prof. Jarosław Mizera, Warsaw University of Technology; Prof. Jan Pilarczyk, CUT; Dr. Łukasz Rauch, AGH; Prof. Maciej Stajniak, Poznan School of Logistics; Prof. Jolanta Staszewska, Opole University of Technology; and Wiewiórowska.

Abstracts for the event are due Sept. 20, with full text required by Oct. 15. Authors chosen for presentations will be accepted by Nov. 15. Presented papers will be published in a special issue of Hutnik-Wiadomości Hutnicze and Gospodarka Materiałowa & Logistyka.

Registration, 595 euros, includes VAT tax, accommodations at the host hotel, a copy of the proceedings, and a social program. For more details, contact Prof.

Wiewiórowska at wiewior@wip.pcz.pl or go to the event website at www.konferencja.wip.pcz.pl.

Trifecta of WAI chapter golf events to be held in September and October The New England Chapter will hold its 22nd Annual Golf tournament on Tuesday, Sept. 13, at the Golf Club of Avon. Contact WAI’s Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

The Southeast Chapter will hold its 15th Annual Golf Tournament, on Thursday, Sept. 29, at the Rock Barn Golf and Spa, Conover, North Carolina. Contact Art Deming, tel. 252-955-9451, art.deming@nexans.com.

The Ohio Valley Chapter will hold its 13th Annual Golf Tournament on Oct. 6 at the Grantwood Golf Course in Solon, Ohio. Contact: Mark MacKimm, tel. 610-685-2800 or by e-mail at markmackimm@gmail.com, or Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.

SEPTEMBER 2016 | 41

INDUSTRY EVENT

PREVIEW IWCS returns to Providence to stage its 65th annual event The IWCS International Cable & Connectivity Symposium returns to its “home” location at the Rhode Island Convention Center in Providence, Rhode Island, with a full technical program, professional development courses, presentations by industry experts, a keynote speaker, supplier exhibition, and more, to be presented Sunday, Oct. 2, through Wednesday, Oct. 5.

IWCS CEO David B. Kiddoo said that the return to Providence further bolsters the annual event. He encouraged attendees to visit www.iwcs.org to see the latest updates. For more observations from Kiddoo on these and other related topics—including the potential for a new IWCS event outside of the U.S.—see the Q&A that starts on page 45.

This year’s event leads off on Sunday, Oct. 2, with seven Professional Development Courses that are provided both in the morning and afternoon, allowing students to take two courses. These include the three “core” courses of Copper 101, Fiber 101 and Materials 101. Students can receive an Achievement Recognition Diploma after completing the core courses and several electives.

The Supplier Exhibition will take place on Monday afternoon and throughout the day on Tuesday. Observed one exhibitor, Inhol/Melos, “We see IWCS as a very good venue for our lines of compounds, especially this year because we have some specific things we’d like to talk about like, such as the fast road to UL and CSA approved highly flame-retarded, low-smoke cable constructions. We will also focus on our economical hot creep testing oven that is gaining more appreciation in the U.S. Some of that information can be seen in our Product entry on p. 90.”

Activity at the Maillefer Extrusion stand.

42 | WIRE JOURNAL INTERNATIONAL

The popular New Product Introduction presentations, provided by exhibitors, will be from 2:30 pm to 5:30 pm on Monday. The Poster Paper Session, with over 30 entries, will be displayed in the exhibition area from 4 pm to 6 pm on Tuesday. The authors will be there to discuss their topics with attendees.

The main attraction at IWCS 2016 continues to be the sessions that include the plenary keynote speaker as well as the executive and technical presentations. This year’s schedule includes more than 130 presentations in 18 sessions over three days.

The presentations start with Monday’s Executive Session, covering topics of interest for general management within companies throughout the supply chain. This year’s topics include overviews of the fiber and copper markets, along with the general economic outlook. Also, presentations will cover insightful perspectives on connectivity technology trends, critical infrastructure, hyperscale data centers and sustainability for the cable and connectivity industry. Concurrently on Monday will be Session 2, Special Applications.

Following those two sessions on Monday will be the Plenary Luncheon, featuring keynote speaker Scarlett King of Bosch Software Innovations. From her position as Director of IoT Solutions for Smart Connected Cities, Communities and Energy, she will highlight interesting IoT applications and new community projects, along with innovations that will place a significant load on the network (such as “connected cars”). She will discuss the business model connection to requirements for hyper-

Dr. Stephan Puissant, BCIAG, taught one of the Professional Development courses in 2015.

U.S.-based Carris Reels, Inc., has purchased the remaining interest in J. Hamelin Industries, a Canadian reel company that it has worked closely with since it bought half of business in 2008.

A press release said that addition of J. Hamelin, which has been serving wire and cable customers throughout Canada and northeast U.S. for 77 years, is a major plus for both companies. “We welcome J. Hamelin to the Carris family, and look forward to future growth and operating at a ‘best of industry’ Attendees talk to a Poster Paper author. (level),” said Carris Reels CEO David Ferraro. manufacturing reels, J.Dean Hamelin operAtIntheaddition ShanghaitoHOSN booth at Interwire, Zhang, l, ates extensive recycling and Edison repair Qin, network chief an of North American sales, and chief throughof South out Canada, with facilities in Quebec, Ontario, Alberta American sales, point to machines sold to the Americas. and Saskatchewan offering wood and steel reel repair/ recycling, said the release, noting the following. J. With its specific personnel servicing the U.S. and Hamelin also has U.S. assembly facilities in Marion, other markets in the American continent, HOSN is Indiana, and Enfield, Connecticut. In 2010, the compacommitted to supplying high-efficiency drawing and ny launched a significant investment and now operates stranding equipment to the wire and cable industry in a highly efficient and automated nailed wood reel plant the Americas. in St. Jerome. In addition to automated production At Interwire, HOSN displayed photos of its JLK lines, unique material handling practices have been series rigid stranding machine with bottom loading or employed, yielding a state-of-the-art facility. side loading system. This unique machine is suitable Ferraro said that J. Hamelin CEO Harold Stotland for producing large-length, compact/round Al/Cu Gem Gravure’s Markengaged Kristoff makes a New bare Product will remain actively in the organization, both wire, ACSR and aluminum alloy wire.

The machine is presentation. asIntroduction a stakeholder in Carris Reels and as vice president of driven by individual motors for the rotating cage and the manufacturing for three Carris nailed wood manufacstranding pitch cantobe adjusted freely.

Another network featured scale data accommodate the pending turing sitescenters (St. Jerome, Quebec; Enfield, Connecticut; product was an aluminum breakdown machine used for IP growth demand. and Madera, California. He noted that Stotland, who drawing aluminum alloy, and all kinds of shaped wires will see 3 through and the Posterfor the hasTuesday been active onsessions the Carris Board9of Directors from 9.5from mm 4down mm. Many also Session, pm totocontinue 61.8-5.0 pm. Wednesday willcustomers see sessions past six years, “will in that governing role.” showed strong interests in HOSN’s drum twister which 10“Harold throughand 16. The topics are “boxed” inour the talented next column, his teams complement is used cabling low, medium and high power with thefor Conference at our a Glance shown on p.voltage 44. and employee-owners, as collective experience will cables and for applying armoring and screening wires.

IWCS sponsors include, Partner Level: Cable assure we are meeting our customers’ needs for custom www.hosnglobe.com.

Components Group, The Chemours Company, packaging and solutions,” Ferraro said.

“This acquisiCommScope, Inc., Corning Cable Systems, DSM, the tion strengthens our competitive position by expandLapp Group, Mexichem Specialty Compounds, Oden

54 | WIRE JOURNAL INTERNATIONAL

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FEATURE

Carris Reels buys remaining interest in Canada’s J. Hamelin Industries

IWCS Highlight Schedule

Ultimate Automation, (for full schedule see next page) Ltd. U.K. At Interwire, Ultimate Automation displayed the latest MONDAY, OCTOBER version of the company’s3ULTIMAT UMW-100, 2D Session 1: Executive Session machine, which incorpowire forming and welding Session 2: Special rates faster drivesApplications and control systems.

The UMW can be combined with the UCW-100 Plenary Luncheon model to create an integrated forming and welding Supplier Exhibition (New Product Introductions) cell for the production of shelving products.

The Evening Reception frames are produced on the UMW-100 and then TUESDAY, OCTOBER 4 transferred into the UCW-100, where the frame supSession 3: Global FTTX & Installation port/brace wire is fed direct from coil, and welded into the4:frame.

Further options include stations Session Fiber/Cable Manufacturing and press Reliability forHamelin’s post-forming andStotland, secondary bend heads for formJ. Harold l, with Carris CEO Session 5: Copper Cables – Measurements & Reels Modeling ing loops and eyes.for Cable & Connectivity Components Dave Ferraro.

Session 6: Materials Session Fiber & Cable Measurements ing our7:geographic footprint across North America.

Session 8: Copper Cables – Performance & Design Hamelin has a track record of delivering value enhanced packaging programs through innovation in Session 9: Fiber Optic Connectors for Harsh Environments process, and reel tracking systems. We have Supplier automation Exhibition (Poster Paper Session) an exciting future as we leverage our shared experience WEDNESDAY, OCTOBER 5TH growth. As part of and knowledge to drive profitable Session 10: Next Generation Special Fibers the negotiation, Harold will have an equity position in Session 11: Powering over Communications Cable Carris, further aligning our future objectives.”

Session 12: Commercial Applications of Cable Stotland described the deal as win-win forMaterials both parties. “We opportunity to better align our comSession 13: saw FiberanOptic Connectors panies 14: to achieve sharedFiber growth objectives,” he said.

Session High Density Optic Cables “Together we are&stronger and can leverage new opporSession 15: Codes Standards tunities.”

Session 16: Manufacturing & Processing Technologies Carris Reels, based in Proctor, Vermont, manufacUltimate Automation Sales Director Martin Smith by a tures plywood, nailed wood, wood/metal, plastic, and UMW-100 model stamped metal reels andPrysmian spools, with 550 employees Technologies, Inc., OFS, Cables and Systems, in 12 locations in Canada, Mexico, and the U.S. Teijin Aramid and Underwriters Laboratories, Inc.; Ultimat manufactures the UMW 2D wire forming & Platinum DowUTW Electrical & Telecommunications, welding Level: machines, Automatic Ring Machines Solvay Specialty Polymers, Teknor Apex General Cable lands largest portion and UCW T-Welders.

The company hasCompany, a machine to Web Industries, WCISA and Wire &the Cable Technology suit everyone’s requirement from manufacture of of 3-yearGold Canadian cable contract International; Level: Hitachi Cable America, POP displays, lampshades, supermarket shelving Inc., and Canada’s hasUV; named General The LubrizolHydro-Québec Corp., and Miltec Donor Level:Cable Leoni as automotive components, etc. www.ultimat.com. its main cable supplier for Wonderful the next three years, awardCable, Inc., SICCET Srl and Hi-Tech. ing a contract an estimated million.

Foritmore details,valued contact at IWCS Operations$108 Manager Pat Hudak, tel. 717-993-9500, at phudak@iwcs.org.

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WJI: What’s your outlook for IWCS for 2016?

Kiddoo: After a strong conference in 2015, we anticipate our Cable & Connectivity Symposium to be even more robust back in Providence. Pre-registration has been excellent and sales of Supplier Exhibition space has been very successful with representation from all over the globe. Our IWCS 2016 Symposium Committee generated a record number of abstracts this year, which continues to provide innovative and broad technologies that are vital to our industry. It is this content in over 18 sessions that has been enhancing the appeal of IWCS. WJI: IWCS announced an “enhanced connectivity objective”: how will that be reflected at this year’s event?

Kiddoo: The Symposium Committee has strengthened our connectivity content and industry presence, providing interaction with technical and supply

chain professionals on the connectorisation of cabling infrastructure. We have several additional sessions to present new technologies and to promote discussion of ideas and innovations to advance connectivity solutions. In addition, our executive session and plenary keynote speakers will bring interesting perspectives on interconnect systems that require both cable and connector innovations.

WJI: Aside from connectivity, how do you view the other technical elements?

Kiddoo: The technical sessions of the program provide a balanced focus on copper cables, optical fiber cables, connector technologies and materials. There are two full sessions on international codes and standards and environmental sustainability regulations, and there will be five papers on the recently adopted 2017 National Electrical Code® requirements for Powering over LAN cables.

IWCS CEO/Director David B. Kiddoo.

Our inks are held to exacting standards. We test the effects of temperature, product surface condition, and ink longevity to ensure that our inks remain stable and endure the test of time.

At Gem, a family owned & operated company since 1952, we study all characteristics of the ink from drop formation and flight behaviors to adhesion on the product.

Visit us at the IWCS Suppliers Exhibition, Oct. 3 & 4, in booth 114 at the Rhode Island Convention Center, Providence, RI.

112 SCHOOL STREET • WEST HANOVER, MA 02339 • 781.878.0456

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IWCS CEO/Director: this event will continue to evolve

INDUSTRY EVENT

WJI: How has attendance at your Professional Development Courses done in recent years? Do those courses continue to be updated/expanded?

Kiddoo: Attendance in the Professional Development Courses

and materials, as well as courses in the latest technology issues facing the industry. This year, a new course has been added: “Introduction to the codes and standards making process,� which covers the various regional standards

A group shot of instructors in the 2015 Professional Development courses. have been growing as young engineering professionals are using this IWCS curriculum to be trained by seasoned global industry experts. Updated offerings include basic concepts in core courses related to copper, fiber

development activities and third party certification procedures.

WJI: How has the IWCS webinar series that started last year gone?

Kiddoo: The series has been tre-

mendously popular over the past year. Offered on the third Friday of every month, Attendees are able to see topical presentations and ask questions directly to the presenter. Each of these webinars are recorded and archived on the IWCS website. While many of the subjects over the past 12 months were first presented at our IWCS 2015 Conference in Atlanta, we are now receiving requests to provide this webinar forum to companies wishing to present novel technology developments. IWCS will continue to offer these technical webinars as a complementary service to our industry patrons.

WJI: Last year saw IWCS deploy a social media campaign: will the 2016 show further those efforts?

Kiddoo: We had a great deal of success on social media, as a result of our initiatives during the IWCS 2015 Conference in Atlanta.

Throughout each month since, our following on Facebook, LinkedIn

Visit us at IWCS Booth #205

46 | WIRE JOURNAL INTERNATIONAL

INDUSTRY EVENT

and Twitter has been increasing steadily and impressively. With the added publicity each and every month for our IWCS Webinar Series events, many of our patrons are now using social media to keep track of IWCS activities throughout the year.

We will again have a strong pres-

beyond its annual show in the U.S. Is that still a possibility?

Kiddoo: IWCS has been working in cooperation with other industry organizations to explore the potential of providing an IWCS “regional” Cable & Connectivity Technical Symposium in China. The number

conference for more “regional” interests and will not replace the global networking and learning experience uniquely provided at our annual event. We will be announcing further details on the inaugural China Symposium during IWCS 2016.

WJI: Anything else you’d like to note?

Kiddoo: An important part of the IWCS mission is to provide scholarships to deserving engineering students and technicians. We continue to provide annual student scholarships and endowment programs to the University of Massachusetts Lowell and University of North Carolina Charlotte. Last year, we also introduced an annual program—in partnership with Cable Components Group Attendees could talk to exhibitors representing more than a hundred companies. and the Wire and Cable Industry Suppliers Association ence by our social media team at this of high level technology contribu(WCISA)—to provide scholaryear’s IWCS 2016 in Providence. tions coming from China through ships to Renssalaer Polytechnic We anticipate that many of the comour IWCS “Call for Papers” process Institute. WCISA and IWCS panies that are providing speakers or have increased significantly each will again host a Monday Night are part of our Supplier Exhibition year. As part of our discussions with Reception at IWCS 2016 to will further expand their outreach by these companies, we are finding honor our industry’s young prore-tweeting, liking or following our out that quite a few Chinese IWCS fessionals, new visitors to IWCS promotion of their IWCS presence patrons are unable to travel to the and students who are showing and participation! annual conference in the U.S. for a interest in joining our cable and variety of reasons, but wish to be a connectivity industry upon gradWJI: There has been some talk part of our IWCS Conference expeuation. about IWCS establishing a presence rience. IWCS will stage this Chinese

48 | WIRE JOURNAL INTERNATIONAL

Visit us at IWCS BOOTH #213

INDUSTRY EVENT

PREVIEW

Representatives from multiple industry organizations that supported Wire & Cable India at the 2014 event.

Industry focus turns to India Wire & Cable India, the No. 1 trade fair for the wire and cable industry in India, will take place at the Bombay Exhibition Center in Mumbai from October 5–7, 2016. Held concurrently will be Tube India International, Metallurgy India as well as India Essen Welding & Cutting 2016.

Wire & Cable India, Tube India International and Metallurgy India will be organized by Messe Düsseldorf and its Indian subsidiary, Messe Düsseldorf India, with the support of the Confederation of Indian Industry while India Essen Welding & Cutting is jointly organized by Messe Düsseldorf India and Messe Essen.

The organizers expect some 400 exhibitors from 25 countries to take part in these four events. Strong exhibitor registrations from Indian and international companies have already been received at this early stage. There will again be country group participations from Austria, China, France and Italy.

On display will be machinery and plants for wire production and processing, forming technology, spring-making technology, cable and stranded wire machines, tools and auxiliaries for process engineering, measuring and control technology as well as a variety of wires, rolled wire, bare wire, bars, sheet metal, special wires and cables.

Dave Forber, c, talks to attendees at the Wire & Plastic Machinery booth in 2014.

Activity on the show floor for the wire and cable event.

50 | WIRE JOURNAL INTERNATIONAL

HV and EHV cables, we have a prominent presence on the Indian market. We have successfully met the challenging requirements of Indian customers and welcome the opportunity to speak with them.”

Another exhibitor, Hamond Dayal, managing directorinternational, Micro Products Company, observed that his company’s high performance butt welders are used by some of the leading Indian wire and cable manufacturing companies. “As the wire and cable manufacturing sector grows in India, this market offers us great opportunities, especially for our high end top-of-the-line welders. We have been at the last three shows and seen a very positive market trend. We expect more booth traffic and welder inquiries. Face-to-face meetings with potential customers gives them the assurance that we are there, our feet Dayal firmly on the ground, ready to offer after-sales service with commissioning, parts, etc., all of which matters greatly to them. We will also use this venue to meet with our reps from India and surrounding regions, and strategize for the future. We expect to have a very successful show.”

For further information about Wire & Cable India, contact Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com; www.mdna.com.

An alpha list of exhibitors from outside India provided by the organizers starts on the next page.

INDIA’S WIRE AND CABLE INDUSTRY IS ‘QUITE COMPETITIVE’ Huned Contractor, editor of WAI’s WIRE BULLETIN publication in India, contacted Thomas Schlitt, Managing Director, Messe Düsseldorf India, about the event. Below are excerpts from that interview HC: What will be the highlights of this year’s WCI 2016?

Schlitt: Wire & Cable India 2016 will showcase machines and plants for wire production and processing, forming technology, spring-making technology, cable and stranded wire machines, tools and auxiliaries for process engineering, measuring and control technology, all types of wires, rolled wire, bare wire, bars, sheet metal as well as special wires

and cables. We are expecting around 300+ companies across 25 countries and some 15,000 trade visitors.

HC: As the Asian economy has been sluggish of late, how will the show help exhibitors and visitors?

Schlitt: The wire and cable industry in India is quite competitive in its production costs compared to other developed and developing countries. This cost competitiveness needs to be maintained by adoption of new and clean technologies that lower specific energy consumption and generate much lesser pollutants. We need to automate processes and focus on product quality and packaging to produce wires that are

internationally acceptable. Exhibitors will be able to showcase their latest technologies to minimise the cost and increase productivity and quality.

HC: What is your overview of the Asian wire and cable industry?

Schlitt: The Asia Pacific region makes up for a majority share of the world’s wire and cable materials market, accounting for significantly more than half of global demand.

The presence of several manufacturing-based economies in this region of the world has resulted in the region’s dominance. North America and Europe follow the demand generated from the Asia Pacific region.

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Tube India International 2016 will also be held as well as Metallurgy India 2016, which will feature the entire portfolio of the metallurgical industry with electrical and automation technology systems.

The events are supported by IWCEA (International Wire and Cable Exhibitors Association), IWMA (International Wire & Machinery Association), ACIMAF (Italian Wire Machinery Manufacturers Association), WCISA (Wire and Cable Industry Suppliers Association) U.S. and ITA (International Tube Association). The Indian associations SWMAI (Steel Wire Manufacturers Association of India) and AIWMA (All India Weldedmesh Manufacturer`s Association) are also providing support.

The organizers note that demand for wire, cable and tubes in India continues to be high. Despite the global steel crisis and excess production capacities in China the Indian economy posts strong growth for these areas.

One exhibitor, Thomas Lerch, sales manager, cable machinery division, TROESTER, a supplier of VCV and CCV lines, said that his company looks forward to meeting existing customers at the event to continue long-term partnerships built on trust. He also hopes to make new contacts to present the company’s latest developments in CV line and compounding technology. “This Lerch event is a priority exhibition in this region as it provides an international platform to participate in the potential growth of India and its neighboring countries.

As a leading manufacturer of high performance machinery for

INDUSTRY EVENT

HC: How does this compare with the global scenario?

Schlitt: Despite the global steel crisis and excess production capacities in China, the Indian economy posts strong growth for these areas. Germany is India’s biggest trading partner in the EU. The tradSchlitt ing volume between Germany and India has tripled over the past ten years. The demand for plant and machinery is moderate; the Indian automotive industry, however, reports positive sales figures.

HC: Over the years, how has this event got better in terms of facilities, promotions, etc.?

Schlitt: Our show has grown by approximately 9% from the last couple of editions. For this edition we are getting a large number of machinery manufacturers to display their products. A massive visitor promotion campaign is underway and we are expecting record turnout of industry professionals this year.

HC: We understand the show will have a technical element Has that program been confirmed?

Schlitt: For the first time, a technical conference will be held Oct. 7, the last show date, primarily focusing on the mercury-less polymers used for various applications in the wire and cable industry. The theme will be Polymers in Cable and Wire.

HC: What are the main target groups?

Schlitt: WCI 2016 will address all relevant target groups, including: wire, cable and spring manufacturing, manufacturing of connecting/fastening elements; manufacturing of other wire goods; glass fiber cable industry; iron/ steel and nonferrous metal industry; automobile industry; construction industry; chemicals industry; electrical industry/electronics; manufacturer of machines and plants for producing wire and cable; measuring, controlling and regulating technology; aerospace supply industry; telecom industry; computer manufacturing, etc.

HC: What is your future vision for WCI? Schlitt: We plan to add some new unexplored segments, such as fasteners, springs, polymers and gear boxes.

Alpha list of exhibitors Below is an alpha listing for exhibitors outside India provided by the organizers. For more details, including booth numbers, go to www.wire-india.com and see the show program at the event.

Elektronik GmbH

• ACIMAF - Italian Wire Machinery Manufacturers Association

• Besel Basim San Ve Tic AS

• Advantage Austria

• Bongard Trading GmbH

• Aeroel SrL • AESA SA (AESA Cortaillod) • Alessandro Stella Srl • Andritz AG • Anhui Giant Machinery Equipment Co. • Anhui Herrman Impex Co Ltd

• Bettonville Ltd • Buss AG • BWE Ltd • Ceeco Bartell Products • CGN Dasheng Electron Accelerator Technology Co • China Ciangshuo Machinery Co Ltd

Development Ltd • Conoptica AS • Continuus-Properzi SpA • CSG Wiremachinery Solutions GmbH • Dae Sung Ind. Machine Co • Daido Kogyo Co, Ltd

• Ann-Chain Enterprise Co

• China TJK Machinery Beijing Co Ltd

• Dango & Dienenthal Hollerbach GmbH

• Asteq Srl

• Com Colombia SAS

• Belec Spektrometrie Opto-

• Comsuc Technology

• Dango & Dienenthal Maschinenbau GmbH

52 | WIRE JOURNAL INTERNATIONAL

• Dango & Dienenthal Umformtechnik GmbH • Danyang Litong Cable Technology Co, Ltd • DEM SpA • Deyang Jiechuang Wire & Cable Machinery Co, Ltd • Domeks Makine Ltd Sti • Dongguan City Qingfeng Electrical Machinery Co • Dongguan Gemwell Electrical Machinery Co

HigH Performance X-eTfe Extrusion LinE Rosendahl‘s processing equipment for aerospace and automotive cable production with X-ETFE in single or dual layer insulation design.

Meet us there!

www.rosendahlnextrom.com

INDUSTRY EVENT

• Dongguan Senjia Machinery • DVS Deutscher Verband für Schweißen und verwandte Verfahren e V • EB Tech Co, Ltd

• Guizhou Aerospace Nanhai Science & Technology Co

• EBNER GmbH

• Hefei Smarter Technology Group Corp

• Eder Engineering GmbH

• HDO Plast • Hefei Innovative Electrical & Machinery Science Co

• EJP Maschinen GmbH • Eleteck Wire & Cable Co • Eurodraw Wire Equipment

• Hefei Tongding OpticalElectronics Technology

• evobeam GmbH • Fainplast Srl • Farbwerke Herkula SA/AG • FENN LLC • FIB belgium SA

• Henrich Maschinenfabrik GmbH

• Henan Yinwang Trade Co

• HMP Heinrich Müller • ICE - Italian Trade Comission • IDEAL-Werk

• Flymca & Flyro

• iiM AG

• Focus GmbH • Fuhr GmbH & Co KG

• InnoVites

• G.Y.M. Co, Ltd • Gauder SA

• Intras Limited

• Glory Mica Co Ltd • Golden Technologies Wire & Cable Equipment Co

• Inosym Ltd • IWMA - International Wire & Machinery Association • Jiangsu China Star New Materials Technology Co

54 | WIRE JOURNAL INTERNATIONAL

• Jiangsu Greenshine Wire & Cable Co • Jiangsu Handing Machinery • Jiangsu Winlong Cable Machinery Co Ltd • Jiangsu Xinda Science & Technology Co Ltd • Jiangyin Hitech Industry Co • Jinglin Packaging Technology • Kablosan Sar Medya Altan Kilinc • Kyoeisha Chemical Co • LAP Laser Applications Asia Pacific Pte Ltd • M + E Macchine + Engineering Srl. • Madem Gulf Industries • MAG • Maillefer Extrusion Oy • MALI GmbH • Mario Frigerio SpA • Maschinenbau Scholz GmbH & Co KG

• Messe Düsseldorf North America • Medek & Schörner GmbH • Messe Duesseldorf China Ltd • Messe Duesseldorf North America • Mexichem Specialty Compounds Limited • Micro Products Company • Nanjing Zhongchao • Nantong We Up International Trading Co • Newtech SrL • Ningbo Kaite Machinery • Nuova Tecno Tau Srl • Omeya Technology Co • Orbis Will GmbH & Co KG • Otomec SrL • Promostar SrL • Proteco Srl • Proton Products International

• Supreme Superabrasives • Wardwell Braiding Co • Suzhou Forever Import & • WCISA - Wire and Export Corp, Ltd Cable Industry • Wellion wire & Cable Machin• Suzhou Listrong Mechanical ery Co Ltd & Electrical Co • Wintime Machinery • Taizhou Jinlianli Electrical Co Ltd Machinery Co., Ltd. • Wire & Plastic • TKT GROUP SpA Machinery Corp • Trafco Srl • Wuxi Baochuan Machinery • Tongling Xingang Plastic Manufacture Co Ltd Products Co, Ltd • Xuzhou Henghui Braiding • Trafco Srl Machine Co Ltd • Triumph Cable Co Ltd • Yangzhou Havet Machinery • Troester GmbH Co Ltd & Co KG • YUANG HSIAN Metal • Upcast Oy Industrial Corp • VÖDKM/AWCMA • Zaonee Group Co Ltd Verband • Zenkoh Co Ltd • Voge Composites, LL • Zhejiang Baichuan Conductor • WAFIOS AG Technology Co • Wai Tak Lung Machinery CabWire offered a combination of education market• Zhejiang Rongtai and Electric •ing Walson Woodburn Wire opportunities in aDie congenialMaterial setting.Co Ltd Pvt Ltd • Zumbach Electronic AG

56 | WIRE JOURNAL INTERNATIONAL

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EVENT WRAPUP

INDUSTRY EVENT

• Shanghai Yessjet Precise • Queins Machines GmbH Machinery Co • Redex SA • Shanghai Yupin • RichardsApex Communication Technology • RK Umformtechnik GmbH Co., Ltd • Ronak Industry • Shantou Senyang Wire & • Rosendahl Nextrom GmbH Cable Materials Co. Ltd • Royle Extrusion Systems • Shaoxing Kaicheng Mica Pvt Ltd Material Co., Ltd • RSD Technik GmbH • Shenzhen Maxsharer Import • S.Y.M. Co Ltd and Export • Sampsistemi Srl • Shenzhen Xinchang Long New Material Technology • Sar Medya Altan Kilinc • SIKORA AG • SAS Engineering A total of 22 presentations were made in two tracks. & Planning Srl • Simco Spring the company’s success.

Machinery Co • Seltek Srl Probst reported that electrical systems for vehicles • Sinosteel Zhenzhou Research • Shanghai Asahi Polymer have evolved to support new features demanded by Institute of Steel wire Material Co Ltd customers.

Today, the wiring system for the average Products Co Ltd • Shanghai Dehong New vehicle includes SKET1,500 GmbH single cables Materials Co Ltd 3,000 meters, •with and 3,000 contacts. Those products, he • SMEETSsaid, nv/SArepresent a • Shanghai Hosn Machiney labor-intensive assembly business, and as result, they now Technology Co Ltd • Southwire Company, LLC have 70,000 employees in 82 plants worldwide.

• Shanghai KECHEN Wire & • Spirka The ferrous track was a collection ofSchnellfelchter outstanding, comCable Machinery Co Ltd Stolberger KMB GmbH

Wire connects us all!

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Wire-Drawing Technology worldwide in performance Experience and know-how, developed for decades, certify HENRICH Maschinenfabrik among leading suppliers of international cable- and wire industry. More than 3.000 Wire-Drawing units are well established worldwide. HENRICH product range covers entire drawinglines and single-action machines for conductor cable, installation- and special cable, telecommunication cable, trolleyand enamelled wire. The production range is completed by cooling- and cleaning devices for drawing- and cooling solution, drawing tools and pay-off devices.

The complete program is available at www.henrich.net HENRICH designs, manufactures, supplies and installs custom-made and on demand.

Go, count on us!

THE 7th ALL CHINAINTERNATIONAL WIRE & CABLE INDUSTRY TRADE FAIR

26.-29.09.2016 Shanghai New International Expo Centre

Visit us at Booth W1F61 · Hall W1

6th International Exhibition

5 – 7 October 2016

Bombay Convention and Exhibition Centre, Mumbai, India

Visit us at Booth G45 · Hall 01

Henrich Maschinenfabrik GmbH · Rehbergring 17 · 35745 Herborn · Germany · Phone: +49 (0) 2772 506-0 · E-Mail: henrich-gmbh@henrich.net · www.drawing-ahead.com

FEATURE

’

Most wire and cable manufacturing is for commodity production, but increasingly, more companies are offering specialty products. This feature presents comments from some of those producers, Integer Research, and more.

WJI: How does your company choose a specialty cable to develop? Does that often stem from one or two possible reasons?

In many cases, our specialty/custom cables are built when some of our customer’s requirements—such as mechanical properties or country approvals—are not satisfied by our standard product range. Once an inquiry is submitted, our design department tries to find a solution that best meets, or exceeds, the customer’s expectations.

In other cases, we are able to take one of our mainline products and customize its construction, such as adding shielding, changing insulation materials, or jacket compounds, in order to meet a customer’s unique applications. For example, Liebherr, one of the world’s largest manufacturers of construction and industrial machinery, determined that customizing the HELUWIND WK 103w EMV, traditionally used in a wind turbine’s cable loop, would be their best option for their LH 150 EC High Rise, an electric material-handling machine. Kevin Siegel, marketing manager, HELUKABEL USA. Since our business is largely in the aerospace and defense sector, weight savings is always an area of interest and we are constantly looking for ways to improve the A&D products. That focus can be seen in cables we made that were part of a SBIR (Small Business Innovation

Michael Weiss, president, WHITMOR/Wirenetics.

58 | WIRE JOURNAL INTERNATIONAL

Research) based on nanomaterial shielded wires, with the intent of using a lightweight material for EMI shielding to gain weight savings on the overall cables. Michael Weiss, president, WHITMOR/Wirenetics.

In 2015, about four million Variable Frequency Drive (VFD) units were sold in North America, indicating an enormous potential for specifically designed VFD cables.

These cables are mostly required for the interconnection between the motor and drive. Lapp Group has always been a leader in the development of innovative VFD cable solutions, and we’re the first company to introduce this type of design to the marketplace. Lucas Kehl, product manager, Lapp Group.

Comtran develops specialty products that are a natural fit with our strengths as a company: engineering competency, manufacturing capability and product differentiators in the industry. Does the product provide a value for both the customer and the company? Does it help the company achieve a competitive advantage? Our VITALink® Circuit Integrity products not only correspond well with our sales objectives and product portfolio within the Marmon Cables companies, but also serve the higher purpose of life safety while providing the contractor a superior solution to meeting building codes for critical circuits. Danielle Braley, sales engineer, Comtran.

WJI: Would a specialty product always stem from a specific customer request, or could you develop a product if you believe that the market would welcome it?

Specialty/custom cable creations are developed from both scenarios actually. Not all custom cables are developed from formal requests for one specific customer/application. They may also come from informal discussions with customers about where technology is headed and future expectations of components. These conversations are crucial because it allows us to develop cables alongside new technological advancements, instead of reacting to market changes. This is what allows us to stay ahead of technological trends. An example of this process would be our TOPSERV Hybrid servomotor cables that combine

Quabbin Wire: we’re proud to say that we’re ‘splineless’

U.S.-based Quabbin Wire & Cable reports that it has made a remarkable specialty cable advance: a splineless Cat. 6a cable. Below, Jim Rivernider, vice president of engineering, discusses what the company has achieved.

allowed) to develop a design that would eliminate the spline without compromising the performance. Recent work on Cat. 8 cable brought these efforts WJI: What advantages does a to the forefront. Our “splineless” cable provide end users? due diligence was done Rivernider: Splines are used in by filing a provisional WJI: How sure were you that there category cables to reduce cross talk, patent and then showing would be enough customer interest in and that’s particularly important in and introducing our design this product to justify the investment? shielded cable, but splines are also idea to key cumbersome. The players in the biggest problem industry to get is that assemblers their perspecneed to cut them tive and level out during patch of interest. cord assembly, and This helped us that can be tricky. get a current Because the spline feel for how the is placed in the product would center of the cable, be received into removing it takes the market, as precision cutting. well as to address By removing the obstacles that may spline and a second come as a result of component, the a new and innovatape, our new cable tive product, such is easier to maneuas compatible plugs ver and work with.

Quabbin Wire & Cable Process Engineer Jason Sterndale, l, and Vice and connectors.

It’s also lighter.

President of Engineering Jim Rivernider display the company’ s patent, We’ve made it #9,355,759 B2, for its splineless Cat. 6a cable.

WJI: How big a very compatible market is there for for connectors this product?

Rivernider: Having a design with through efforts and collaboration Rivernider: The size of the a spline has never been the ideal with connector manufacturers so market is basically as big as the construction for reasons mentioned that the cable is ready to be deshielded patch cable market, above. However, the splines are ployed. This isn’t always the which includes applications in data needed to achieve the desired crosscase; there have been instances centers that span the globe. We are talk performance in shielded Cat. 6 where there are substantial wait still learning of other applications times for plugs or connectors to and 6a cable. We had been working that this product is perfect for too. be developed. on and off for 10+ years (when time

WJI: Quabbin Wire & Cable reports that its new Cat. 6a cable has achieved an industry first: what exactly is it?

Rivernider: We set out to design a Cat. 6a cable that does not have a separator or spline, and I’m proud to say that we have done that.

WJI: What was the key to achieving a “splineless” cable?

Rivernider: Without going into the details, the key was the shield arrangement. We had an idea for a design change that would allow us to not need the spline. Also, by eliminating the spline, we were also able to eliminate another component, and that’s a polyester tape.

At right, Quabbin Wire’s splineless cable.

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WJI: Your company has sought a patent for this: what’s the status, and how has the process gone?

Rivernider: We previously filed for two patents, one of which was not a success story but resulted in being a learning experience for what to do with future patents. One important takeaway was that we knew we needed a patent attorney, and that it would be best to have one with experience in wire and cable. Even still, our patent was rejected twice.

WJI: Why the two rejections?

Rivernider: The first time was that our claims were deemed too broad, which is not uncommon in this process. Since the issuance of our patent we have filed a continuance with the objective of broadening our claims further as we have found additional applications for the construction and believe securing our protection in these areas is warranted and justifiable.

power and signal elements to connect servo drives and ® motors that use the SICK HIPERFACE DSL protocol, and others that followed shortly thereafter. Kevin Siegel, HELUKABEL USA. As an innovative company, we want to be on the forefront of product development whether it is to meet an existing need or create a new one. A concept can be inspired by anyone, anything or anywhere. What is key within the Comtran organization, and throughout the Marmon Group as a whole, is that innovation is encouraged and supported at all levels and that time and resources are allocated to nurture these efforts.

Our two-hour, fire-rated circuit Integrity cables were developed because there was a need in the marketplace to ensure the public’s safety in the event of a fire and old Danielle Braley, sales engineer, methods were expenComtran. sive, labor intensive and cumbersome. With the availability of new compounds and the recognized need, the VITALink® concept was born and became the first polymeric cables available in the marketplace. Danielle Braley, sales engineer, Comtran.

WHITMOR/Wirenetics is divided into two business units: WHITMOR is 100% a custom wire and cable manufacturer while Wirenetics is a distributor for other manufac-

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WJI: Was there one or two key people who drove this project?

Can you estimate how many staff hours went into the R&D and the patent process?

Rivernider: Yes, while we very much work as a team, there were two of us at Quabbin that invested extra time and effort. I’m very proud to have led the design of the cable, and Jason Sterndale deserves credit for the unique tooling. In total, we estimate that 300+ hours have been spent on the design, development and patent process to date.

turers’ products. On the WHITMOR side of the business every day consists of manufacturing custom cables that are driven by our customers. By working closely with our customers we are developing solutions that in most cases are specific to their requirement(s). Some instances may require an NDA (non disclosure agreement) that we sign with a customer. This will keep the development unique (as well as protected for both parties). In other cases there are products developed from an overall need from the general community. Michael Weiss, WHITMOR/ Wirenetics.

Definitely both! For example, our ÖLFLEX® VFD 2XL series is perfect for customers who need an XLPE insulation. In addition, we added features that make the product unique in the market. It now has both a UL TC-ER 600V and 2000V rating so customers who have a demand for a cable with both can now streamline their inventory and select only the Lapp solution. Also, we’ve equipped this cable with a TPE-based jacket that makes for a better choice for customers who don’t want PVC-jacketed VFD cables. The ÖLFLEX® VFD 2XL is a reduced-diameter cable that provides different voltage ratings per UL TC-ER. Smaller diameters mean more room and less weight in the cable tray, while the dual voltage rating reduces inventory SKUs. These unique attributes make routing faster and easier, help expedite installation and provide cost savings. Lucas Kehl, Lapp Group.

FEATURE

Specialty Cable Corporation: it’s all special If ever there was a company one would expect to be a natural for this feature, it would be Specialty Cable Corporation (SCC) in Wallingford, Connecticut, so its responses were singled out. Below, SCC Vice President of Sales Jim Streifel discusses his company’s ‘special’ focus.

Streifel: Not all of our constructions makes for a dynamic workplace WJI: How does your company are specific to a company or individual that’s never boring. choose a specialty cable to develop, use. Many have been developed over Many of our cables start out from such as the described one you have the years as industries have evolved. a concept or an actual need from a chosen to highlight?

A great example of this is the aerocustomer with a very specific applicaStreifel: You asked us to focus on space industry, which has continued to tion that was not being met from any a single specialty cable, but as you redesign and refine the aircrafts. The cables commercially available. Going might guess from our company name cables have needed to become lighter back to the above nuclear power plant basically e-v-e-r-y-t-h-i-n-g we make and able to handle higher temperatures cable, our customer needed that for its is a specialty cable, so our experito operate in increasingly hostile enrobot that would perform maintenance ence is different from most other vironments. Those companies. We conditions forced manufacture us to refine and a variety of redesign our cable cables to service constructions. many markets.

Our foundation WJI: For such has been flight a product, do you critical wire start R&D with a and cable for high degree of conthe military fidence of the final and commerresult? cial aerospace Streifel: When markets, but we first engineer we also service and select our the medical, constructions for heat-tracing, our prototypes, we industrial, do start out that commercial Specialty Cable Corporation Vice President of Sales and Marketing Jim Streifel. way, but experience and high-end has shown that little audio markets. actually goes as planned. Adjustments on the reactors while they were in Many customers purchase special inevitably have to be made during the operation. As you can imagine, it is not proprietary constructions from us that process, from concept to final proan easy job shutting down and restarthave been developed by both parties duction runs, something needs to be ing such a site. The plan was to have to address an unique situation for adjusted. Yes, that can be frustrating, this robot stay inside the reactor for which only a specially designed cable but it’s also exciting learning how our several years performing the necessary would work. designs actually perform in the real maintenance, eliminating the shutI could point out a few that we find world, and what we need to do to down need. Our customer gave us the especially interesting, such as the make them even better. cable requirements and details about polyimide cable we build for robots the harsh environment it would need to used in a nuclear power plant that, WJI: Do you set specific time goals? operate in. Once we understood all the once they go in, will never be seen Streifel: We assemble a product requirements, we went to work designagain. Or, there’s the high-end audio development team for every new ing a cable that was up to the task. cables that use cryogenetic copper design to work on the project. This conductors to eliminate noises caused usually consists of individuals from WJI: Would a specialty product by the earth’s north and south poles. engineering, production, quality and always stem from a specific customAdditionally, we produce cables sales. An initial timeline is set for er request, or could you develop a that are used in our most advanced all stages of development. These product if you believe that the market military weaponry. Seldom is our timelines will vary depending on the would welcome it? production ever off the shelf. That

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WJI: Do you seek to have specialty products represent a certain percentage of your revenues?

Streifel: New products and new designs are key to our business strategy as well as our future. New

WJI: Do you patent your products?

Streifel: Many of our processes are proprietary and our new constructions are customer specific.

The cables are typically low volume and will not be mass produced, so the cost associated with securing a patent is usually not justified. There are a handful of other companies that may have the technical and processing abilities to design and manufacture the cables, but because of the time it takes to development and the low volume, most of our competitors choose to pass. Our ability to move the process quickly and efficiently enables us to cost effectively design and manufacture the cables.

designs force us to continually keep pace with the ever-changing industry needs. Our policy is to build on our past successes, with an emphasizes on continual improvement. This

keeps us sharp and experts in our industry.

WJI: What aspect did the editor not ask about that would have been of interest?

Streifel: I cannot overstate how important quality is. Along with new products and designs you must have a quality product. I know, that sounds like a given, but our customers today expect nothing less than an exceptionally high-quality product. Of course, they also want it delivered on time and at a fair price, but quality trumps everything, and that focus drives us. SCC meets or exceeds the industry’s most stringent of standards. We have numerous QPLs, UL and CSA ratings. Our quality systems are recognized by AS9100 and ISO 9001. What we do is too important for us to approach our work without being prepared to be the “special” company that we know we are.

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difficulty of the cable requirements, design, material, manufacturing and testing criteria. We usually meet every two weeks to discuss the status of the project or more if the project requires more immediate attention.

FEATURE

WJI: For such a product, do you start R&D with a high degree of confidence of the final result?

99% of our R&D is started with confidence and based on our 57 years of experience that the final result will be successful. Often we are approached with an idea from someone that does not understand the complexity of designing and making the product.

By them not knowing the equipment that is used to manufacture wire and cable and/or market conditions, material restrictions, etc., we sometimes have to inform the customer of obstacles we need to overcome.

In most cases it comes down to financial limitations.

This is where we work our hardest to accommodate the requirement and at the same time, work with or around the limitations. On occasion we come across an application that is simply too difficult. In those rare cases the ideas will never leave the drawing board as even with today’s modern equipment, the idea just cannot be manufactured. Michael Weiss, WHITMOR/Wirenetics.

Yes, once a concept is justified for further development, I am very confident that our team is personally and emotionally committed to the success of the product. In addition to our talented engineers, we are also privileged as a member of the Marmon Group to rely on resources within sister companies to help prob-

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lem-solve should a challenge arise. With the VITALink CI product, we just completed a hugely successful round of testing to UL 2196, which some would classify as one of the toughest two-hour fire rating tests for cables in the world. We collaborated on this project with team members from Marmon Technology & Innovation Center, Rockbestos Surprenant, and Cable USA. I am extremely proud of our team that has developed an exceptional product to serve the industry. Danielle Braley, Comtran.

There is great confidence amongst our specialty/custom cable department in Windsbach. Our cable R&D engineers have years of experience and come from different backgrounds that include chemistry, electrical

engineering, and mechanics. Their knowledge of different synthetic materials, and understanding how, and with what, those materials can be combined, gives us endless capabilities to construct unique cable constructions. Kevin Siegel, HELUKABEL USA.

FEATURE

Aerospace: an especially challenging specialty cable market U.K.-based Integer Research has just come out with a study on specialty cables. It notes that their work continues to be the only in-depth source of information on key vertical markets within this sector. Below is an overview of just one of the six industries covered in the report: aerospace cable. wiring harness is manufactured. As a with the largest players being: Boeing The specialty cable market as a result, the majority of demand is in air(U.S.), Airbus (France), Lockheed whole may well be the least undercraft manufacturing hubs in the U.S., Martin (U.S.), United Technolostood and analyzed high-market China and France, and in locations gies (U.S.), General Electric (U.S.), segment as it is highly dependent where there are wiring harness producNorthrop Grumman (U.S.), Raytheon on standards and specifications that ers, such as in Morocco and Mexico.

(U.S.), Safran (France), Finmeccanica change over time. Each end-use marAs a result, some of the primary (Italy) and Rolls-Royce (U.K.). ket segment is distinct, and therefore purchasers of aerospace cable are those Integer has estimated cable demand requires a different approach. who produce The aerospace wiring harness market is esfor aircraft pecially chalThe top 10 aerospace cable producers represented and airframe lenging as it has 70% of the market in 2015 producers, such unique drivers as Labinal (Sathat are not so US$ million fran), Boeing, easily quantified.

EADS (which The market is Rest of the World owns Airbus), geographically USA Sukoi and the diverse, with Aviation InU.S. activity dustry Corposignificantly ration of China different from (AVIC). the European and Aerospace Asian markets, cables have the latter two some of the of which have most rigorous country-by-countest specificatry distinctions. tions and stanThe rise in dards and so is aircraft demand SEI Marmon Mitsubishi WL Gore Southwire Huber & Aerospace Other TE Global Nexans Prysmian focused among in the last decade Suhner Wire & companies Connectivity Cable production Cable fewer compahas been rapid, nies than in as growth in the The majority of aerospace specialty cable is produced in the U.S. other industrial size of midsectors, with the dle-class globally top 10 companies representing 70% for aircraft by identifying aerospace has increased alongside cheaper fares of the total market in 2015. As the and more globalized business. Demand production by region and determining U.S. is a key site for civil and military the intensity of use of cable: looking is concentrated among a relatively aircraft production, a third of aeroat electrical install, cable value and the small number of producers of comspace wire and cable production is percentage of spend that is for cable itmercial and military aircraft, engines based there and only three of the self (excluding labor and accessories). and avionics companies and space top 10 producers do not have a plant The current demand for aerospace and satellite systems’ manufacturers, in the U.S. cable has reached more than US$400 with primary purchasers of aerospace cable including those who produce million globally.

The key distinction for the point of wiring harness for aircraft and airframe For more report details, please consumption of cable is split between producers. contact the editor, Louisa Winnik, at two key areas, where the main body of The largest aerospace companies are louisa.winnik@integer-research.com. the aircraft is produced and where the primarily U.S. or Western European, Also, see p. 101.

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WJI: Do you set specific time goals, i.e., by three months agree on basic solution; eight months have three different versions to test/assess; 14 months have cable ready for tests, etc.?

This can be divided into two sections: 1. When a customer brings new design for a current requirement, we will normally complete the process within one to three weeks.

2. When a new design with unproven materials comes to us, the process will then take two weeks to three months, depending on the complexity. In our world, we have to be able to respond quickly to our customers’ requirements and our custom cable team is very good about bringing the

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solution to completion with minimal delays. Michael Weiss, WHITMOR/Wirenetics.

We have in-house test centers to guarantee quality and reliability to our customers with the shortest possible lead times.

Here in the United States, the laboratory is a member of the UL Client Data program, meaning that we can shorten the time for select UL approvals by completing tests for which Lapp has been self-certified. A typical innovation process at Lapp includes concept, development and prototyping, followed by industrialization Lucas Kehl, product manager, and validation beLapp Group. fore a new product is

Innovation meets Tradition

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Lapp has R&D departments in various regions across the globe. Our engineers work hard to make sure we’re always among the top innovative cable manufacturers.

Here at Lapp, it’s not just the R&D department who drives development projects—we thrive on a cross functional team consisting of product management, supply chain, quality control, manufacturing and others. Our company follows an internal innovation and commercialization process for all our projects that’s consistent worldwide. Lucas Kehl, Lapp Group.

FEATURE

launched. While we’re typically able to estimate how long the process will last, it’s sometimes hard to be exact because we’re dealing with high level innovative product development. Lucas Kehl, Lapp Group.

You absolutely need a product development strategy that includes a primary objective with milestones and deadlines in-between to keep progress moving.

And even when you’ve obtained the primary goal, it’s important to build upon that accomplishment – there’s always room for product expansion, product enhancements, cost improvements, etc. From a salesperson’s

perspective, that timeline can’t be quick enough, however great products take careful planning, persistence and execution. Still, speed to market is important and Comtran’s design through delivery process is well-organized and rapid. Being a mid-size cable company offers the advantage of a focused team with streamlined processes, communication and approvals. Comtran’s 20 year veteran Design Engineer Bruce Lamoureux sums it up best, “I’ve been in the business a long time, and I’ve launched more products in two years than I did in

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eight years at a bigger company,” he says. “There’s just not as much red tape.” Just within the last six months, the Circuit Integrity cable line grew from three constructions to nine, with additional improvements in certifications and conduit fill; making it the only approved product in Canada and achieving the best conduit fill in the industry. Danielle Braley, sales engineer, Comtran.

We are conscious of our customer’s timelines to bring new products to market where our cables will be used, and try to develop our specialty/custom cables accordingly. Most special cable requests from customers can be solved with the appropriate structural design and the proper use of existing plastics.

Due to a high diversity of materials, especially in the plastics sector, and the technical expertise of our engineers in Windsbach, a solution can be conceived within one to four weeks, depending on the application. In some cases, a customer visit is made to look at the particular application on-site. In these cases, the cable must only be designed and manufactured over a period of about three to four months, then pass a testing phase of about one to three months.

The length of the test period again depends on the application. For example, meaningful results from a torsion test can be obtained after about a month, while a track cable test requires a minimum of three months and can last as long as a year or more. In

Kevin Siegel, marketing manager, HELUKABEL.USA. market. If a material is located, sample tests must take place, which can take up to three months to determine its effectiveness. In special cases, this timeline can be extended based on the delivery times for sample materials.

The production and the tests again require the timeframe described above.

There are also special cases in which the customer requires a country approval, such as UL, VDE, or CCC, which can further extend the development timeline by up to nine to 12 months.

Kevin Siegel, HELUKABEL USA. WJI: Do you patent your products? Do you do a patent search to see if anything similar is offered, and if so, can that end the process or result in a change in direction?

For innovations with a high level of importance, we carefully evaluate the costs affiliated with obtaining a patent. This decision is not only based on commercial parameters but also encompasses factors that revolve around the effects the invention has on the image of the company. We decided to patent the rope that includes the electrical conductor for the SkySails kite, which provides wind propulsion for cargo ships, in conjunction with the rope manufacturer. Before starting the patenting process, we thoroughly search the internet for existing patents that might interfere with our innovation.

However, this is rarely the occasion. Should that be the case, we make sure that our innovation doesn’t interfere with the existing patent.

In more complicated cases we also get a patent lawyer involved. Kevin Siegel, HELUKABEL USA.

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this case, depending on if the customer has immediate deadlines, we use extrapolated data from the vast amount of test data we have gathered over the years to forecast the ending test result.

There are also cases in which a new raw material (special plastic, fabric or yarn) is required. This requires research to explore what options are available in the

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A Comtran VITALink® cable.

We generally do not seek a patent, but instead will trademark many of our products. Michael Weiss, WHITMOR/Wirenetics.

WJI: Do you seek to have specialty products represent a certain percentage of your revenues?

Since 2010, Comtran has rebalanced its product portfolio embracing the 80/20 strategy for sales and manufacturing. In order to use our resources wisely and operate our business as efficiently as possible, our goal is to have 80% of our profits come from 20% of our products. Although the organization stays true to its roots in maintaining a core base of commercial cable products, we are continually expanding into more profitable specialty cable markets and leveraging our expertise to get a leg-up on competition as demonstrated in recent specialty product cable introductions, including our DEFENSE-LINK™ Shipboard cables and VITALink® 2 Hour Fire Resistive cables. Comtran continues to lead the way in specialty cable products. Danielle Braley, Comtran.

In that we have no catalog to sell from for the manufacturing division, everything is a specialty product. The only cables we stock are those that are contractually ordered and scheduled. What we sell to one customer, in most

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We do not hold any existing patents, though some of our employees do. The benefit of a patent is protection of a unique idea, however a company must also consider if intellectual property will be exposed and how a patent can be defended if it’s infringed upon. There is always someone out there willing to build the better mouse trap with an improvement on an existing idea, therefore we do not let an existing patent prevent us from moving forward. Per our director of engineering, Rama Nippani, “For any new product, we mold our designs to not encroach an existing patent. We are obviously pursuing new designs every day which shows in our new and innovative ® products like the VITALink , DE™ FENSE-LINK shipboard cables, and Hub-LINK™ transit cables.”

Danielle Braley, Comtran.

FEATURE cases, cannot be sold to any other customer. Our manufacturing of specialty products is not driven by metrics, but it is an area that we are very aware of and always looking for opportunities. This was a founding principal of the company and remains in place today. We want to ensure that these products are of value and not just hitting a metric check mark. Michael Weiss, WHITMOR/Wirenetics.

As a company, we recognize that innovation is critical for maintaining a leading marketing position. Therefore, we do have targets regarding new products as a percentage of revenue. Lucas Kehl, Lapp Group.

WJI: What aspect did the editor not ask that would have been of interest?

Any cable installation in a building or structure may be

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subject to inspection by the local Authority Having Jurisdiction (AHJ). It’s important to remember that interpretation of NEC code requirements and the subsequent adopting of new regulations differs by state, city or county.

Lapp products are tested in accordance with applicable agency standards in our state-of-the-art laboratory that’s a member of the UL Client Test Data Program (CTDP).

When testing products, we employ the same methods, procedures and equipment used by UL. Additionally, we have an internal 5V (validation) process that confirms product integrity and lets us uphold our industry-leading reputation for high quality. Lucas Kehl, Lapp Group.

Over our many years in business, we have been sought out to provide answers for unusual applications. These requests have come from a number of industries such as (but not limited to) oceanographic, entertainment (television, motion picture studios, audio equipment manufacturers), automotive restoration, home and industrial lighting, medical, geophysical, seismological.

To this day we stand firm on the two principal cornerstones we were founded on service and quality. We feel our quality system is second to none and we stand behind every product we sell. Michael Weiss, WHITMOR/ Wirenetics.

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INNOVATIONS

INNOVATIONS Evolving (and investing) to meet changing cable producer needs As the wire and cable industry evolves, so must the companies that supply it. For Cable Components Group (CCG), a U.S. supplier of extruded profiles that was closely following trends, it has responded by undertaking a $3 million investment to become a vertically integrated compound supplier. Below, CCG President Charlie Glew discusses the impetus that led to this direction.

Local Area Network (LAN) cables are being formulated WJI: CCG started out in 1998 to manufacture extruded with higher performance incorporated in foamable pellets. profiles for the copper wire and cable, and the fiber optic These new pelletized materials optimize chemical foam cable market: what happened that led to your decision to rates and fire retardancy characteristics. also become a compounder?

Glew: CCG started up to manufacture extruded proWJI: How many new lines will you have, and are files with a focus on Ethernet cabling which was rapidly you able to fit them in your plant or does it have to be evolving to enhance data speeds over twisted pair cables. expanded to make this possible?

Extruded profiles were needed to improve the electrical Glew: CCG has had high temperature twin-screw comperformance of the newest Cat. 6 designs. CCG produced pounding lines at its a range of designs to facility in Pawcatuck, include crosswebs, CT and manufactured tubes and tapes.

FluoroFoam® in a Materials selection joint collaboration was also crucial to with LEHVOSS North meet the higher and America. A new high higher data speeds as temperature twinwell as enhancement screw line is being in fire retardancy and installed dedicated to low smoke characterthe manufacture of istics. CCG’s patented FluoroFoam®. This FluoroFoam® was dedication will ensure introduced, the first the highest quality chemically foamable chemically foamable perfluoropolymer, FEP or MFA and mitii.e., FEP, MFA or gate any cross contamPFA, which met all ination and also supof the aforementioned port CCG’s extrusion material selection Cable Components Group President Charles Glew by one of the of crosswebs, tubes, criteria. It also fit the and tapes, as well as ultimate goal of light- company’s two new Buss Kneaders. customer demand for weighting materials. chemically foamable pellets for insulation or jackets.

Environmentally, less material for flame and smoke generaThe aforementioned two Buss Kneader Lines, along with tion or less combustibles; and better electrical properties for this high-temperature, twin-screw line, will be CCG’s improved dielectric constant for data cables. initial full scale compounding capability.

A new materials laboratory has been set up and a LAB WJI: When do you hope to start supplying compounds, twin screw is also being added. This line will be used to and what is your strategy? qualify materials and allow CCG to manufacture 250 to Glew: CCG will be compounding materials on the two 500 lb lots for customer evaluation. new Buss Kneader lines this September. These two lines have the unique capability of compounding materials at WJI: Are you confident you have the expertise you need to lower temperatures enabling the chemical foaming agents do this? Have you made a key hire to head this initiative? and high fire retardancy loading to be incorporated without Glew: Unequivocally, we are ready and have some strong degradation. This $3 million capital investment gives CCG talent to support material science innovation. CCG holds the latest computerized compounding technology, and the 20 patents and half of those patents relate to CCG’s formuability to enter a range of new markets to include aerolation for a wide range of foamable pelletized materials. space, automotive and the newest materials for power over

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WJI: What will future LAN cables have to be able to do?

Glew: New power over LAN cables are now being developed to power communication cables to simultaneously transmit 1 Amp and 200 watts of power, along with the 10 gigabits of data. An array of new devices, from wireless hubs to security cameras to LED lighting, require power that cannot be supplied by fiber optic cables. This duality of function, i.e., (data and wattage) will dramatically increase demand for higher temperature, more thermally stable materials like FluoroFoam® WJI: Just how strong FEP or MFA for insudo you see the high-end lation, crosswebs and data cable market? tapes. LAN jackets today Glew: Currently, the have traditionally been strongest growth marrated to 60°C jackets, ket segment in copper but that’s not going to be cables is for high-speed thermally stable enough CCG is covering a “pyramid” of material needs for the indutry.

4-pair Local Area to withstand the added Network cables (LAN), heat generation with the Cat. 6 and 6A. In 2016, Cat. 6A has grown 55% over 2015, use of 24, 23 and even 22 AWG wire. The Underwriter and the expectation is that it will continue that exponential Laboratory Limited Power (LP) listing, with 192-cable growth rate for several years. Approximately, 500 million energized at 1 Amp in a bundle, will be the definitive feet of Cat. 6A will be sold this year, and an estimated five safety test for these cables and this solid and/or foamed billion feet of category cable, i.e., Cat. 5e, 6, 6e and 6A, combination of 200°C rated insulation, crossweb, and will be sold and installed in North American commercial jacket will be needed to meet this rigorous 2017 National buildings this year.

Electric Code safety standard for Power over LAN. Innovations is an occasional section where companies can discuss new technology, going beyond “the specs” to cover aspects such as the real-world need for innovative technology. Companies that would like to be considered for future submissions can send an e-mail to editor@wirenet.org.

SEPTEMBER 2016 | 75

INNOVATIONS

There has been a singular focus towards chemically foaming materials with a vision toward “lightweighting plastics.”

CCG has hired six new people to staff the new compounding area, and two new laboratory technicians. Heading up the team is Kevin Slusarz, M.S., chemical engineering. We are pleased to say our two newest employees are June graduates, Lyle Topa, a mechanical engineer from URI, and David Connor, a chemical engineer from RPI.

TECHNICAL PAPERS

TECHNICAL ECHNIC PAPER Cellular polymers in cable extrusion: technology fundamentals and some case studies Customers continue to seek further advances in foaming technology, but it has become increasingly challenging to attain meaningful gains, even as more pressure comes from seeking replacements for materials that may be restricted.

By Horst Scheid

Consumer and business demand for high bandwidth communication increases the market for high frequency cables in computer networks, CATV and GSM systems.

The optimization of electrical and mechanical characteristics of cable insulation by usage of foam techniques requires a perfect understanding of material effects and their influence on the production process. This paper introduces some physical basics related to cable manufacturing. Polymer and gas selection is discussed and important technical demands are shown. For cable applications, the main focus is usually not lightweighting foam but creating a foam structure that fits to wire insulation requirements such as closed cell structure, mechanical stability for bending the cable without geometric distortion, electrical parameters like energy loss and high fre-

Table 1. Typical CBAs and some of their properties 76 | WIRE JOURNAL INTERNATIONAL

quency applications. It also presents some examples of recent/actual research by the author's company.

Foaming in cable manufacturing Material selection. Blowing agents are organic or inorganic additives used in the manufacture of foams. The use of blowing agents in the rubber and plastics industries was hugely affected by global agreements—such as the 1987 Montreal Protocol and the Kyoto Protocol—which imposed severe environmental restrictions. There are a number of environmental problems associated with blowing agents, from global warming, ozone-depleting potential and atmospheric lifetime and volatile organic compounds to the long-term breakdown of products, halogen-free nature and acidification potential. In addition, blowing agents must satisfy the requirements of the marketplace including cost, flammability, compatibility with insulation materials, and safe and economic manufacturing processes.

Chemical blowing agents (CBAs). These substances are added to the polymer—either as a granulated masterbatch or as a powder to mix with the polymer before the extrusion process begins—or it is already contained into the polymer. The amount of the admixed CBAs determines the degree of foaming, but the melt temperature also does because the strength of the decomposition process is a function of temperature. Organic as well as anorganic CBAs are used, including well known types such as azodicarbonic acid diamide (ADC) and sodiumbicarbonate in combination with citric acid. Typical amounts of added substances

WJI: Who does this presentation address?

Scheid: This article is meant to be informative to engineers in the cable industry who are interested in getting a better understanding of the foaming process.

WJI: Why are you as a machine manufacturer involed in research in polymer formulations?

Scheid: I found that communication between cable manufacturers and polymers supplier is somewhat difficult: cable manufacturers are not very interested in polymer chemistry, whereas polymer suppliers often do not have a good understanding of the cable specifications and the related processing. As a machine supplier, we are inbetween both parties, and as we are not just selling machines but the complete process, we are deeply involved into processing as well as polymer formulations.

Acting as a link, we try to contribute to optimization for both sides.

WJI: Do you expect that future advances can be more than just incremental?

Scheid: As foam techniques are well established in the cable manufacturing, I’m not expecting to see big steps, as there were some 10 or 20 years ago, but even small improvements are important due to increasing demands. For example, higher cable service temperatures can necessitate a changeover to polymers with higher processing temperatures, which in turn requires different nucleation systems as mentioned within this paper.

WJI: Do you see the need for any further research in this area?

Scheid: Definitely yes. As described in the case studies, there are still required compliances that can-

are between 1% and 5% of the total weight and those mixtures are reaching foaming degrees of up to 60 %1.

CBA decomposition may be either endothermic (often producing mostly CO2 while needing energy to react) or exothermic (often producing mostly N2 while releasing chemical reaction energy), which can be measured by DSC methods.

In any case, they decompose thermally while giving off some chemical by-products that can affect other additives like flame retardants, stabilizers or colorants. By-products may also act as nucleation particles but can be a problem for electrical characteristics when the polymer is used as an insulation layer in radio frequency cable manufacturing.

The melt temperature and the residence time in the barrel should be chosen so that decomposition rate is well defined and no post-foaming effects occur. The decomposition time is a function of particle size because chemical reaction happens first on the particle surface. Table 1 shows some typical CBAs with the related decomposition temperature range and gas yield. As marked by underlining in the table, some released gases are unwanted because of their chemical reactivity (SO2) or their bad influence on the electrical cable characteristics (H2O).

Physical blowing agents (PBAs). The alternative to CBAs is the physical foaming process, where liquids or gases are injected into the extruder and dissolve in the plastic material under influence of heat and pressure.

not be fully achieved at this time. For instance, a replacement of the widely used ADC nucleation due to the REACH directive is Scheid actually very important. We are in close contact with several material suppliers and have already conducted tests with alternative nucleation systems, but research like this continues, and has to continue doing so. We are constantly on the track of innovations to address future challenges, which makes what we do exciting.

Questions for the author?

Contact him at scheid@siebe.de.

Some important properties of gases used for physical foaming, listed in Table 2, compare (H)CFCs, organic and anorganic types. Inert gases have the best properties for physical blowing agents. In most cases nitrogen is used.

The significance of CFCs almost vanishes despite its high solubility because of the ozone layer depletion. Water steam as blowing agents cannot be used in cable manufacturing because of bad electrical properties, and Pentan and Butan are combustible. Carbon dioxide is not simple to handle but its higher solubility in comparison to nitrogen promotes its use, especially for higher void rates.

In most current cable applications a nucleation substance (sometimes called a ‘kicker’) is added to the polymer to start the bubble growth process. These nucleation substances can work in an active or a passive manner. Passive means that only a non-reactive powder (e.g. talcum, SiO2 or TiO2) is used. Active nucleation substances work equivalently to CBAs, so a small intrinsic foaming ratio (around 5% void) already exists without adding extra gas to the melt. As passive nucleation generates typically larger bubble sizes, this is more common for bigger cable types with large insulation wall thickness.

Other foaming techniques exist, such as expanding the material by adding polymer spheres filled with gas. By heating the spheres they expand to a predefined size without chemical decomposition7. The additive does not mix SEPTEMBER 2016 | 77

TECHNICAL PAPERS

What’s noteworthy in this paper

TECHNICAL PAPERS

TECHNICAL PAPER with the polymer matrix, so the process has to be selected according to polymer and product demands.

Physical foaming based on thermodynamic instability (‘self-nucleation’) is possible. The advantage of this is that no nucleation substance is needed. As such processes are rarely used for cable insulation, no more details are described here.

Polymer selection

Fig. 1. Processing window for foams of amorphous and polycrystalline polymer.

IWMA CabWire World Conference 2015

In principle, most polymers can be foamed. The selection criteria are the electrical properties and the rheological characteristics. Considering the molecular structure, foaming of polycrystallinic or partially crystallinic materials is more difficult than amorphous materials like polystyrene (PS).

See Fig. 1. For polycrystallinic polymers, the process temperature range is smaller. That means the production of fine cell-structured foams requires a more exact process control.

The relative permittivity εr is a very important electrical parameter in the cable industry. Solid polymer values are in the range of about 2.1 (PS) to 6.0 (PVDF). Because communication cable engineering requires smaller εr values, cables are manufactured using a bamboo technique or produced with polymer foam. By this means, cables can be produced with relative permittivities down to 1.3 (see Eq. 1 for foamed polymer), depending on the void ratio (see Fig. 2). Other important electrical parameters like the electrical loss factor tan δ, molecular polarity or the linear attenuation cannot be described in detail within this context but must be taken into consideration when selecting a cable November 2015 – Duesseldorf insulation polymer.

Some important properties of gases used for physical foaming are listed in Table 2 to give a comparison between (H)CFCs, organic and anorganic types. Inert gases have the best properties for physical blowing agents. In most cases nitrogen is used. The significance of CFCs almost vanishes permittivity of the polymer foam despite its high solubility because of the ozone layer depletion. Water εr steam as blowing agents can’t F = relative εrP = relative of the solid polymer Fig.used 2. Change of manufacturing relative permittivity, be in cable because density of bad and electrical properties, Pentan permittivity and Butan are Smf =ina comparison foam modeltofactor propagationCarbon speed,dioxide depending on thetolinear combustible. is not simple handlefoaming but its higher solubility nitrogen sg = the void ratio as volume/volumefoam promotes its use especially for higher void rates. degree (for HD-PE).

Gas

Tc

Pc

bp

Permeation in PE

Formula

[°C] [MPa]

Argon (Ar)

-122

4.91

-186

220-1100

197

3.37

28.0

n.a.

31

7.38

-78.4

-147

3.39

198

[°C, 1013mbar] [10-12 mol/msPa]

Solubility

usability

[x*N2] 2

+

≈1000

-

2900-3800

≈ 10

+

-195.8

30-225

(:=) 1

++

4.37

23.8

n.a.

n.a.

--

96

4.93

-40.8

50-60

30

--

Water (H2O)

374

22.0

100.0

n.a.

n.a.

--

Helium (He)

-268

0.23

-269.0

1300-2000

0.25

o

i-Pentane (CH3)2CHCH2CH3 Carbon Dioxide (CO2) Nitrogen (N2) CFC 11, CFCl3 (Trichlor-fluormethane) HCFC 22, CHF2Cl (Chlordifluormethane)

Table 2. Gases for physical foaming with some relevant properties (n.a. : data not

Table 2. Gases for physical foaming with some relevant properties. available)

Eq. 1

An additional criterion for polymer selection is the admixed nucleation substances that might interact with the polymer. If an active nucleation substance is used for direct gassing, the amount can be around 10 times smaller than by mixtures for chemical foaming. Passive kickers are used much more for high-temperature applications. In both cases, about 0.2-0.5% in weight is sufficient for a startup setup. If the base polymer matrix does not contain nucleation substances, a kicker as powder or granules can be added to the polymer before

In most current cable applications a nucleation substance (sometimes called ‘kicker’) is added to the polymer, in JOURNAL order to start the bubble growth process. These nucleation substances can work in an 78 | WIRE INTERNATIONAL active or a passive manner. Passive means, that only a non reactive powder (e.g. Talcum, SiO2 or TiO2) is used. Active nucleation substances work equivalently to CBAs, so a small intrinsic foaming

TECHNICAL PAPERS

the melt process begins (e.g. by a dosing station on top of the extuder hopper). For high frequency applications it is important to know that most additives are polar and reduce the electrical quality of the final insulation, so the dosing amount should be kept as small as possible.

Gas solution, diffusion and nucleation in continuous extrusion The following facts are only described briefly, more details can be found in other literature2.

When using a direct gassing process, gas is injected under high pressure into the barrel; the injection position is typically at 18-20D, using a 30-33D screw.

Under typical extrusion conditions (T>120°C, p>10MPa), nearly all inert gases are overcritical (sometimes called ‘supercritical’). Water, CFCs and organic gases can switch from undercritical to overcritical while changing the process temperature or pressure. This phase transition should be avoided because the flow measurement at the critical point using parameters like cp or density is not well defined.

Independent of injecting gas or releasing it by a CBA, solubility can be described with Henry’s law, where:

Eq. 2 CA = blowing agent mass concentration Pl = partial pressure S0 = gas solubility coefficient at 0 K ∆H = molar solubility enthalpy of the gas R = gas constant (from gas law pV= nRT) The aboves shows that pressure should be high and the temperature low in the melt to increase solubility of the blowing agent. For cable applications, it is necessary to have a minimum barrel pressure at the end of the screw of around 100 to 150 bar; a higher pressure level (200-250 bar) gives more spare in process stability and is recommended when using self nucleation techniques.

After the gas and the polymer are put together, the next basic step is homogenizing the gas solution inside the barrel. The efficiency of the mixing process is related to the geometry of the screw and the mixing elements, but it is important not to think in terms of pure mechanical mixing.

The process is not based on a 2-phase (emulsion) system, but on a single-phase (solution) system with a solubility gradient. Too long mixing elements or static mixers with high shear rates can deteriorate even a homogeneous solution. Therefore, Siebe designed different screw types with integrated mixing elements to get the fast required dissolution and the constant homogeneity needed.

For the diffusion process of the blowing agent in the melt, not only physical gas properties (e.g. solubility, diffusion rate) are important, but also extrusion parameters like melt temperature and barrel residence time. The latter can be a problem with small extruders at high output rate

Fig. 3. Foam cone between die and cooling trough of a typical RF cable. in the continuous processing. Diffusion can be described with Fick’s law, where:

Eq. 3 t = time D0 = binary diffusion coefficient of gas in polymer at 0 K x = diffusion distance ED = molar activation energy of the diffusion Once the foaming agent is fully dissolved into the melt, temperature and viscosity must be optimized to have the best conditions for cell formation. If temperature is too high and/or viscosity is too low, the cell membranes will go under a minimum thickness and the bubbles will collapse. With too low temperature and/or too high viscosity, bubbles cannot expand because of a high surface energy.

Nucleation As the inner pressure of the dissolved gas (partial pressure) gets higher than the outer pressure (static melt pressure), the formation of cells can start. This happens near the end of the cross head or where it comes out of the crosshead die for extrusion or in injection molding machines by shrinkage or opening the mold, resulting in a pressure drop. Normally, cell growth needs nucleation spots (e.g. solid particles or micro-cracks), where gas molecules accumulate. The pressure drop causes an over-saturation of gas in the melt that in physical terms is a thermodynamic instability. As an unstable physical system tries to stabilize all the time, a certain amount of gas separates from the polymer. The gas molecules collect at the mentioned nucleation spots, building so called ‘microbubbles’. Existing microbubbles than expand by gas diffusion into the bubble until they reach an equilibrium between pressure inside the cell and steam pressure. At very high pressure drop rates, nucleation is the main stabilizing process. At reduced pressure drop rates, more and more gas separates from the melt just by diffusing to existing cells. At the atmospheric saturation point nucleation

SEPTEMBER 2016 | 79

TECHNICAL PAPERS

TECHNICAL PAPER that can be reached by using blends of HD-PE/LD PE/nucleation and nitrogen is around 75%. In the 1990s, Siebe introduced CO2 for physical foaming for such cables. The resulting void of 78-80% was considered to be a maximum for this kind of construction for years.

Recently, Siebe collaborated with a major Korean cable manufacturer to elaborate the absolute void limit with stable production and improved electrical characteristics.

After making a base material benchmarking with HD and Fig. 4. Cross section of a high void RF cable insulation.

LD polyethylene from different suppliers, some nucleation materials were tested. The final choice was an ADC in a special low concentrated masterbatch; the amount was and diffusion stop. The larger and faster a pressure drop reduced to around 0.1% in weight, which means 1 granule is, the larger the number of cells because diffusion time masterbatch per 1000 granules PE. To get the necessary (or diffusion length) is reduced. In a simplified model of homogeneity of this mixture, the screw was optimized perfect spherical bubbles, free surface energy ∆F has to be for good melt mixing in the first section and a good gas equal to volume creation energy, where: dispersion after the injection point of CO2. Sophisticated melt cooling towards the cross head was necessary to achieve good melt strength for bubble growth and the Eq. 4 flow channels were optimized to prevent stagnation of melt and the related decomposing of gas and melt. Even σ = melt surface tension the entry of the cable into the cooling trough had to be A,V,r = surface area, volume and radius of the cell modified due to the buoyancy of the foam, tending to p = inner pressure of cell create excentricity and/or ovality of the insulation layer.

Finally, a stable void of 84% was reached with a 7/8 in.

If bubbles with very different radii contact each other, cable (9 mm inner conductor, 23 mm insulation diamethe membrane between can burst and the gas of the small ter) and a void of nearly 86% is possible with a 1-5/8 in. cell enters the bigger one as the inner pressure of small cable (14 mm inner conductor, 43 mm insulation diamebubbles is higher than that in the large cells. This means, ter). Fig. 4 shows a part of the insulation cross section. that in high void applications, a too long time between The inner conductor has been removed and the cutting the initial foam growth and lowering temperature below plane was colorized in black for better contrast. Even mechanical stability lets the foam structure tend to create the increase of around a 5% void compared to previous larger cells, and the foam collapses. As a consequence, values seems to be a small improvement; this means gas is lost at the foam surface and void ratio reduces and from the polymer side, with a 85% void there is a quarter the inner foam structure becomes poor. Therefore, the enless cell membrane material than with a 80% void cable. try to the cooling water should be chosen at the point of Blowing agent for FEP foam. While FEP has excellent maximum void content. electrical and thermal characteristics, some characteristics—such as the dissipation factor, dielectric constant Case studies (capacitance and attenuation) and the fire retardant High void RF insulation. Due to the good elecproperties—can be further improved by foaming of the trical properties and its relatively low price, PE is material. By foaming, a material reduction in weight widely used for RF cable insulation. A typical void and insulation thickness is also possible. The requirement here is to ascertain optimum processing conditions for achieving high void contents (circa 50%) with formulations suitable for use in wire and cable applications. Together with Colorant Chromatics Group (a subsidiary company of Polyone) Siebe worked on processing new formulations of blowing agents.

As shown in Table 1, most CBAs are not suitable for the high processing temperatures of FEP of around 400°C. With typical decomposing temperatures between 150 and 200°C, an undefined amount Fig. 5. Lab extruder with modular screw for testing of polymers and additives.

80 | WIRE JOURNAL INTERNATIONAL

SEPTEMBER 2016 | 81

TECHNICAL PAPERS

of gas would be lost through the unmolten polymer to the feeding section of the extruder leading to a totally unstable void percentage. Established foam techniques for FEP base on physical foaming with N2 and boron nitride as a passive nucleating agent. This requires additional physical foam equipment, but the aim was to find a solution for existing FEP extruders. (Another foaming sometimes referred as ‘free foaming’ produces gases at excessive temperatures and high shear rates by thermal decomposition of polymers to create a foam structure. Because of its toxic and hazardous by-products, this method cannot be recommended3).

In a first attempt, a high temperature CBA developed and manufactured by Colorant Fig. 6. Plot of FEP foam density vs. let-down of ‘option 1’ and the final Chromatics was tested on a Siebe lab CBA. machine with a modular screw. See Fig. 5.

Siebe made trials to replace microsphere foaming with a Unfortunately, the decomposing of the setup for physical foaming with nitrogen and the TPU-HFCBA (see option 1 in Fig. 6) worked only with a shear FR. The advantage compared to CBAs is that the already intensive screw design (which is adverse to the senincorporated ATH acts as passive nucleating agent so no sitive polymer material) and the void ratio was quite more additives were needed. With a standard extruder setlow compared to the let-down ratio and the cell size up suitable for PBA, a foam of around 50% void with an was quite large (400 µm and more). Based on these average cell size around 300 µm was processed. See Fig. initial trials it was possible to develop further the for7. The maximum void here is limited by the high flame mulation and processing technology to meet the requireretardant filling ratio. When using a HFFR with 50% ments previously stated. The final formulation worked hydroxide only half of the matrix is useful to build cell then as expected from the DSC analytics: the active membranes with sufficient melt strength and foaming up material releases the gas and the passive component to 50% void would correspond to around 75% with an uninduces the bubble growth by its surface roughness4. filled polymer.

Like that, a chemical foam void ratio of up to 50% 3 Due to the bubbles containing now N2, the flame spread(densities below 1.3 g/cm ) was reached with a ‘siming is still low despite the increased polymer surface, as ple’ 3-zone standard FEP screw. Cell sizes of 200-300 nitrogen acts as a flame retardant as well. This research is µm fit well to cable applications with small insulation still in progress to optimize the final setup, for example uswall thickness. The formulation is now available for age of nanoclays8 and/or CO2 that may improve void and further development activities and commercialisation5. cell structure due to the better gas solubility. See Table 2.

Flame retardant (HFFR) material foaming. Flame retardant materials contain a significant amount of around Conclusion 50% non-halogen containing compounds (like aluminumAs shown in the case studies, there is still a lot of progress or magnesium hydroxides, ATH/MDH, see for example6). being made in foaming techniques. Unfortunately, unlike When exposed to heat, these metal hydroxides decompose in the past, little improvements in the final results require to form water molecules in an endothermic reaction. This results in reduced flame spread and smoke generation.

The idea of foaming was to reduce combustible material with almost the same geometry combined with reduced polymer cost. After the customer tried several CBAs with TPU and SEB-based HFFR without success, the selection was a foaming process with Expancel microspheres7.

Even though microspheres are fine for a lot of applications here it was the wrong approach, as those microspheres consist of a polymer shell encapsulating a hydrocarbon gas. With a void of 50%, half of the final volume would be filled with a burnable gas so the effect of ATH or MDH is at least compensated. Aggravating is the huge Fig. 7. TPU-HFFR physical foam with N2 as PBA. surface of the bubbles that facilitate flame spreading.

TECHNICAL PAPERS

TECHNICAL PAPER more and more technical effort combined with higher investment cost. Anyway, market demands for better quality or new applications are one development challenge.

Another ‘driving’ aspect are regulations: after ADC was listed on the ‘European Union’s Substances of Very High Concern’ candidate list under the REACH directive in 2012, the replacement of this very common foaming/ nucleating agent has become a challenging work for the near future.

References 1. R.L. Helberg, Chemisches Verschäumen, Kunststoffe 6, 1985.

2. S. Reiner, Scheid, "From the Physics of Foaming to the Production of High Frequency Cables," 2001 IWCS conference proceedings.

3. Society of the Plastics Industry, ‘Safety and Health Hazards Associated with Foaming Fluoropolymers using Thermal Degradation Processes, http://www.datacable.org/ issues/free-foam.htm, July 2001.

4. S. Reiner, "Thermoplastic foam extrusion with physical blowing agents," 2002 IWCS conference proceedings.

5. Moloney, "New high temperature chemical foaming agent (CFA) solutions for fluoropolymers," 2015 AMI Polymer Foam conference proceedings.

6. Nabaltec, Apyral 40CD datasheet, (2014).

7. Akzonobel, "Short Introduction to Expancel Microspheres," 2013 datasheet.

8. Beyer, "News on nanocomposites as flame retardants for the cable industry," 2008 AMI Cables conference proceedings.

82 | WIRE JOURNAL INTERNATIONAL

Horst Scheid is the R&D manager at Siebe Engineering, Germany. In 1968, he worked in the injection molding machinery research group of Arburg, then in 1990 he joined the COSY beam accelerator group in Juelich Nuclear Research Centre, where he stayed for four years. He Scheid received his doctoral degree in nuclear physics from the University of Bonn. In 1996, he joined Siebe Engineering, where he has focused on foam extrusion, new extrusion processing techniques, and enhanced inline quality control. This paper was presented at the 7th biennial CabWire World Conference, DÜsseldorf, Germany, November 2015.

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PRODUCTS & MEDIA

PRODUCTS & MEDIA TECHNOLOGY Crosshead series features superior flow characteristics via MAGS adjustment

Family of universal TPEs are designed to handle the harshest environments

U.S.-based Guill Tool & Engineering Co., Inc., has introduced the company’s EW 500 Series rubber/silicone crosshead with Mechanically Assisted Gum Space (MAGS) adjustment.

A press release said that the new extrusion head is designed specifically for the flow characteristics and unique processing challenges of elastomeric compounds.

One key feature is the Guill-engineered mechanically assisted gum space (MAGS) adjustment system.

This new method of gum space adjustment allows the operator to make an effortless adjustment from a single point using a common socket wrench. It eliminated struggles with multiple nuts and bolts to adjust gum space, which leads to faster adjustments. The visual indicator on the core tube allows the operator to see how far the gum space has been moved, making those adjustments much more accurate and repeatable.

The hardware-free and patented cam lock design means that no time is wasted unbolting and resecuring fasteners for disassembly and reassembly, the release said. Only half of a rotation of the cam nut is required to loosen and automatically extract the deflector from the head body, which is another time saver. Also, with no undercuts on the deflector, there are no material hang-ups when extracting the deflector, allowing for faster and easier cleaning and changeover.

The new 500 Series also features the company’s latest Center-Stage concentricity adjustment system, which significantly reduces pressure on the tooling, and allows easier and more precise concentricity adjustments without loosening the face bolts. Easy-Out inserts for the adjusting bolts also allow simple replacement of locked or damaged adjusting bolts, which further saves on repair and downtime. The crosshead has a cast aluminum liquid-fed cooling sleeve that allows the user to switch out the cooling jacket in the event of a line obstruction, again reducing downtime compared to traditional integrated cooling systems.

The 500 Series crosshead with MAGS gum space adjustment is a drop-in replacement on most existing NRM lines, but can also be adapted to fit any extruder design or line layout. For a video of it in action, go to https://youtu.be/jeNovmMtcBs. Contact: Guill Tool & Engineering Co., Inc., tel. 401-828-7600, sales@guill.com, www.guill.com.

U.S.-based S&E Specialty Polymers has launched a new family of Universal TPEs under the company’s TufFlex™, TufFill™ and TufPrene™ brands. These TPEs are specifically designed to survive the harshest environments for wire and cable industry applications, with formulations that exceed the performance characteristics of traditional materials.

90 | WIRE JOURNAL INTERNATIONAL

A press release said that the new compounds are a hybrid between TPE-TPO-CPE alloys, combining and highlighting the best property of each component. The compounds do not just match the properties of engineering elastomers, but actually exceed them as well as adding some unique attributes, all with an attractive cost structure.

The release cited the characteristics of two of the grades. TufFlex™ 2272-6500FR is flexible (75A), has a wide range of operating temperatures (-60C to 105C), has good oil resistance (I and II), has high FR resistance (LOI 35%+); good high heat deformation properties, and is UV and fungi resistant. TufFlex™ 12-003-75A, is also flexible (75A), with a wide range of operating temperatures (-70C to 125C), and superior physical properties, such as 4900 psi tensile strength at break.

The company also reported that TufFill™ 15-058, a new TPE compound, has been approved for use by a leading U.S. city’s Transit Authority. The non-halogen material is used in subways and underground tunnels for a wire and cable jacketing application. TufFill™ 15-058, non-halogenated, was specifically designed for transportation, industrial and utility markets. It offers excellent processability (low shear rate, no die-drool) and has good chemical resistance.

Contact: S&E Specialty Polymers, tel. 978-537-8261, info@sespoly.com, www.sespoly.com.

PRODUCTS & MEDIA

HFFR bedding compound described as the first extrudable flame retardant Inhols/Melos reports that after years of research and partnering with a cable manufacturer, the company has succeeded in developing bedding compounds, FM 0474/5,

for the U.S. market that will enable manufacturers to get essential approvals.

A press release said that due to the company’s persistence and belief in its product, it was able to develop a highly flame-retarded, non-halogen compound that can help to pass demanding cable burning tests. Further, it can do so

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SEPTEMBER 2016 | 91

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at an economical cost. The development stemmed from an effort that started two years ago with a medium-sized cable factory in the U.S. that was willing to work with Inhol/ Melos because it had not been able to achieve UL and CSA approvals by using conventional constructions. The manufacturer, it said, was impressed with the ease of processing and even more so with the cable burning tests. “They got approved and even got LS (low smoke) recognition, all from using our FM 0474/5 bedding compound.”

The release said that the product was found to continuously pass all requirements, which led to more interest, from copper cable manufacturers, but also from the fiber optic cable producers, which likewise have found success with the highly flame-retarded bedding compounds.

“Consider (this to be) the first extrudable flame-retardant on the globe!” the release said.

Contact: Ron Goethals, Inhol/Melos, tel.

31-356033234, ron.goethals@inhol.com.

Flame-retardant sleeving can be used to meet many industry specifications U.S.-based Techflex reports that its F6 Woven Wrap Flame Retardant sleeving provides protection in the toughest environments while still allowing for time saving application and easy access for maintenance.

A press release said that F6, a flame retardant with UL & VW-1 ratings, has a melting temperature of 482°F. The product’s “memory” causes the sleeve to self-close, and to also snap back when opened. The combination of flame retardance, ease of installation and complete coverage makes F6 Woven FR an ideal solution for many commercial and aerospace applications. F6 meets the following testing specifications: Smoke Density Test ASTM E-662; Surface Flammability Test ASTM E-162; and Smoke Toxicity Test SMP 800-C. The product comes in seven nominal sizes, from 3/16 in. to 1.5 in., all with a wall thickness of .027 in.

Since 1965, Techflex has been engineering and manufacturing a wide range of braided sleeving products for a variety of industries from biomedical and aerospace to wire, hose and cable bundling protection solutions for high performance automotive enthusiasts.

Contact: Techflex, tel. 973-300-9242, www.techflex.com.

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Welding machines can operate even better with 2nd generation controls Germany’s August Strecker GmbH & Co. KG, announced the further development of its Full-Parameter-Control (FPC), the company’s technology for welding machines such as its FPC EVO2 bzw and FPC EVO2 Zero Gap models.

A press release said that the first generation was noteworthy for easy and safe storing of customer specific or material specific welding recipes; menu-guidance, easy-to-understand in an incredible number of different languages; improved quality by fix programs with automatic selection (no manual setting of pressures, capacities, times); complete functionality identical to well-proven Strecker V20weld/anneal control; primary voltage compensation for unstable mains supply systems; secondary voltage calibration to harmonize operation of several welding machines in the same factory; and monitoring of relevant welding parameters for quality recognition and documentation.

The second-generation of controls, the release said, offers constant current control (KSR/50Hz over 60Hz) to reduce the influences on the weld quality due to temperature, contact, material or cutting quality. Especially important for welding large quantities, it offers zero-gap innovative adjustment of the clamping tools to each other, so there is no need for regular review or setting of the air gap to optimize the deburring result, all of which provides for a longer lifetime of the jaw inserts.

The FPC Evo2 step-by-step model will be fitted with an additional hydraulic function for optimized motion control/positioning. Even after many welds or temperature fluctuations in the work environment, positioning points are reached more safely, with no need for readjustment.

The various welding machine types equipped with FPC will be changed to this latest version this year. It is also possible to retrofit/upgrade options for already delivered units that are MS/SS/MS in FPC execution (no 3-phase model).

Contact: August Strecker GmbH & Co. KG, tel. 496431-96100, www.streckerusa.com.

Wire galvanizing lines can save on energy use and maintenance costs Germany’s KÖRNER, represented in the U.S. by Straus-Artys Corporation, reports that it has introduced wire galvanizing furnaces that meet all requirements and are characterized by very low energy consumption and maintenance costs.

A press release said that based on new energy-saving burner technology, KÖRNER can heat up their robust and durable wire galvanizing furnaces with ceramic baths without immersed burners, which are susceptible

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PRODUCTS & MEDIA

Wire stripper can handle the larger sizes

to breaking. In recent months, a wire galvanizing furnace employing this technology was delivered that operates with a throughput capacity of about 6.3 metric tons/hour.

A technology leader in building hot-dip galvanizing furnaces, KÖRNER has been offering such technology for more than 85 years. The company has extensive experience with immersed burners, induction heating and heating with a heating cover. In this instance, the company combines the immersed burner’s low levels of energy consumption with the maintenance-free heating cover heating. It also builds galvanizing furnaces with steel kettles, high velocity heating, double-walled steel tanks and, for high requirements, flat flame burners.

Contact: KÖRNER, www.wirekoerner.com; Straus-Artys Corporation, info@straus-artys.com, www. straus-artys.com.

The Eraser Company reports that its E200 heavy-duty wire stripper is designed to process the most demanding wire and cable products.

A press release from the U.S.-based company said that the E200 has a robust construction that allows it to strip large magnet, enamel and film insulated wires. The model will strip most types of film insulation, including varnish, enamel, polyester, and other resins from round, square and rectangular wires, as well as some types of Litz wire. The E200 has counter-rotating wheels which give an aggressive stripping action on tough insulations.

The model can process wire sizes from 1-20 awg (7.34 0.81 mm) or square wire up to ¼ in. x ¼ in. (6.35 mm x 6.35 mm). For rectangular wire the maximum wheel opening is ¼ in. (6.35 mm) and the maximum material width is 2.0 in.

(50.8 mm). The model can handle a strip length with mini stop from ½ in. to 2 ¾ in. (12.7 to 69 mm); a strip length with regular stop from 1.0 in. to 3 ½ in. (25.4 to 89 mm).

Contact: The Eraser Company, tel. 315-454-3237, sales@eraser.com, www.eraser.com.

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At wire Düsseldorf, Maillef provides operator of cables for healthcare applications—whichThe haveSurface been Inspector single armor, athe single MC with Luminary HCF cable does extruder, model MXI 150, th approved for use in patient care areas—thatup-to-the-second it reports is digital image feedback of the current the job of two cables when connecting to LED and fluwith a low melt temperature. ideal for both LED and fluorescent dimming. jacket, bar or waterorescent soluble tape quality on any producfixtures, dimmers, switches, occupancy sensors A press tion line. This continuous stream of real time informaand other controls. Their use can save up to 30% of release said tion–especially the labor failureand images–allows the operator installation costs compared to traditional wirthat the newest to isolate causes of ing jacket imperfections andreducing water solmethods, while also procurement time and cable, UL type uble tape folds. This result allows material waste. you to identify the MC-PCS, causes ofissurface defects and prevents com-dual grounding path The MC Luminarycustomer HCF cable’s anplaints addition to or rejects. features a combined armor and full-sized aluminum theUsing company’s the Surface ground/bonding Inspector, you can capture images of a full-sized green conductor, along with popular line ofcable, save your printed the images disk and print them This provides insulated coppertogrounding conductor.

MC out Luminary to include™in your reporting both internally thequality necessary redundancy to ensure the highest level Metal-Clad and to your customers.

The Surface Inspector’s display of safety in patient care areas equipped with numerous Cables, which also makes it easy for engineering devices. and production metal-encased The new MFL Groupsuper . .lighting . . . . . . . control . . . . . . . wire . . . . 529 Mossberg combine visors toelecexamine the defect. design responds to the rapidly increasing use of solid MGS Manufacturing Inc . . . . . . . . . . 103 Mossberg tricDefect lighting and can locations alsoLED be recorded, this willlighting allow fixtures in healthcare state and fluorescent Micro Products Co . . . . . . . . . . . . . .

132 Nextrom ( control circuits for further analysis applications. of the defects later on. The Surface ™ under a single interlocked armor. With a dual groundInspector will catch defects onLuminary the wires Mid-South before Cable they reach Wire . . . be . . .surface-mount . . . . . . . . . . . 110 Nextrom O can The MC HCF ing path that enhances safety, MC Luminary HCF has your customers or fail the field. ed, in fished, and/or embedded in plaster.

Morgan-Koch Corp .Parallel . . . . . . .bonding/ . . . . . . 127 Niehoff En been approved for use in patient care areas Contact: under NEC The unit ensures good medi Craig Girdwood, Taymer International, Inc., grounding conductor enables faster termination.

517.13. The new cable is designed specifically for use due to the homogenous melt, tel. 905-479-2614, ext.

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PRODUCTS & MEDIA

Radiating cable offers multiple pluses RFS, a global designer and manufacturer of cable and antenna systems plus active and passive RF conditioning ® modules, reports that its line of RADIAFLEX cables represent the world’s leading “leaky feeder” cable solution.

A press release said that the cables act as distributed antennas, allowing operators to scale and tailor contoured RF coverage in challenging confined spaces such as metro, rail and road tunnels and indoor environments.

Corrugated outer conductors and small bending radii provide the flexibility for easy installation.

The cables feature RFS’ patented “higher order mode suppression technique” to support current and future in-tunnel and in-building commercial and private radio services from 698 MHz to 2700 MHz, the release said.

“Select RADIAFLEX cables have no stop band from 698-2700 MHz.” It notes that RFS is the only company with the intellectual property and leading-edge technology to suppress stop bands in radiating cables.

Per the release, the RADIAFLEX cables offer low longitudinal loss and are available in low coupling-loss variants

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that are specifically designed for building and tunnel applications, the release said. RADIAFLEX supports all major services up to 6 GHz, making it ideal for multi-operator and multi-band applications in locations such as parking garages, tunnels and mines.

Every cable type is purpose built for a special application, depending on the slot configuration, the release said. One RADIAFLEX cable style is ideal for belowand above-ground mining environments. It was among the first radiating cables to obtain U.S. Mine Safety and Health Administration (MSHA) certification and has been deployed in major mines in the U.S. and South Africa.

Due to high demand, RFS is expanding manufacturing capabilities for its domestic radiating cable product offerings at its headquarters in Meriden, Connecticut, the release said.

The expanded production capacity will enable faster delivery for North American customers, reduce lead times and freight costs, and permit smaller order quantities for North American customers.

Contact: RFS, www.rfsworld.com.

Germany’s Woywod Kunststoffmaschinen GmbH & Co. has introduced a four-liter weighing hopper, the TRW 4L, for the processing quantities up to approximately 80 kg/h.

A press release said that the new compact and low-cost weighing hopper is in addition to the already existing weighing hoppers and “Loss-in-Weight” Systems. The unit, which is designed for granular, free flowing materials and regrinds and can be used in all areas of the plastic processing. It also fits perfectly in the PLASTICOLOR modular system, like all other pieces of the equipment, which makes it possible to use to upgrade already existing equipment.

The new hopper comes in three versions: one that has a small hopper for manual refilling by the operator (without refill valve); one with an inlet funnel and hopper loaded for automatic refilling (without refill valve); and one with a storage hopper and butterfly valve for automatic refilling, that allows the unit to be filled manually, or by a hopper loader or from a larger storage hopper mounted above.

The weighing hopper, in combination with the PLASTICOLOR 1500 dosing unit, can be used as a gravimetric single dosing unit or for in color-change systems. The hopper is positioned on a slanted extension to avoid collision with the main material hopper.

“Thus these two components make up a perfect unit for capacities up to 80 l/h. Also, extremely small quantities can be dosed in gravimetric operation.” The unit can also be used as a gravimetric throughput measurement system/extruder regulation (for instance for small extrusion lines or laboratory lines).

The hopper offers independency from the bulk density, quick changeover at order changes, robust construction, individual layout depending on the requirements, exact dosing of small quantities, easy operation and quick and operator friendly cleaning (weighing hopper can be removed without tools).

Contact: Woywod Kunststoffmaschinen GmbH & Co., tel. 49-89-854-800, woywod@plasticolor.de, www.plasticolor.de.

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AUGUST 2016 | 99

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Weighing hopper is compact, low-cost

Patent Update PATENTS

(Cont’d. from p. 24)

insulated conductor and the bare grounding material are separated by a wall that runs the length of the electrical cable and is integrally formed with the jacket. A die assembly unit for manufacturing an electrical cable having an integrally formed jacket and partitioned wall members. The die assembly unit comprising a die assembly nozzle and a die assembly cap. The die assembly nozzle further comprising an extrusion tip with at least one wall channel to allow for the creation of the integrally formed wall members.

Electric cable 9,412,488 August 9, 2016 Filed: Sept. 27, 2012 Yazaki Corporation, Japan Kousuke Kogo To provide an electric cable that can satisfy flame retardancy and battery fluid resistance in the CHFUS region provided in ISO 6722 and also satisfy wear resistance and low-temperature impact property by using a halogen-containing flame retardant. An electric cable in which a coat layer is formed of a resin composition that includes (A) 55 to 85 parts by mass of a polypropylene homopolymer, (B) 5 to 20 parts by mass of a polypropylene-based modified resin, (C) 5 to 20 parts by mass of a polyolefin-based copolymer, and (D) 5 to 15 parts by mass of a modified olefin-based elastomer, respectively and further includes 1 to 45 parts by mass of a metal hydroxide and 10 to 80 parts by mass of a halogen-containing flame retardant based on 100 parts by mass of the resins (A), (B), (C), and (D) in total.

U.S. Patent No.: Patent date: Assignee: Inventor:

Shielded wire arrangement for die testing U.S. Patent No.: 9,412,674 Patent date: August 9, 2016 Filed: Oct. 24, 2013 Assignee: Xilinx, Inc., U.S. Inventors: Myongseob Kim, Henley Liu, Cheang-Whang Chang, Sanjiv Stokes An integrated circuit includes a die having a conductive layer. The conductive layer includes a data wire, a first power supply wire of a first voltage potential, and a second power supply wire of a second voltage potential different from the first voltage potential. A segment of the data wire is located between, and substantially parallel to, a segment of the first power supply wire and a segment of the second power supply wire. Further, the first power supply wire is coupled to a first probe structure; and, the second power supply wire is coupled to a second probe structure.

100 | WIRE JOURNAL INTERNATIONAL

Methods of manufacturing wire, multi-layer wire pre-products and wires U.S. Patent No.: 9,406,417 Patent date: August 2, 2016 Filed: Dec. 13, 2013 Assignee: General Cable Industries, Inc., U.S. Inventor: Frederick Kelley Exemplary methods for manufacturing a wire and resultant wires are disclosed herein. The method includes extruding a receptor cross-linkable polymer that is substantially free of curing agent about a conductive core and extruding a donor polymer in association with a curing agent. The method includes disposing the donor polymer about the receptor polymer and conductive core to create a multi-layer wire pre-product. The method also includes heat curing a multi-layer wire pre-product to form a wire.

Flame-retardant resin composition for aluminum electric wire and aluminum electric wire using same U.S. Patent No.: 9,406,413 Patent date: August 2, 2016 Filed: Aug. 21, 2012 Assignee: Yazaki Corporation, Japan Inventor: Kousuke Kogo The invention relates to a flame-retardant resin composition for an aluminum electric wire, the resin composition comprising: a base resin containing (A) 75 to 95 parts by weight of a resin composition containing 45 to 65 parts by weight of an olefin-based resin having a tensile modulus of 1000 to 1500 MPa, 10 to 30 parts by weight of an olefin-based resin having a D hardness of 40 to 55, and 5 to 15 parts by weight of a maleic acid-modified resin and (B) 5 to 25 parts by weight of a flexible resin, and (C) 90 to 150 parts by weight of magnesium hydroxide blended into 100 parts by weight of the base resin.

Metallic card wire 9,404,2013 August 2, 2016 Filed: May 23, 2013 Groz-Beckert KG, Germany Yuning Zhang A metallic card wire has an elongated rib portion and teeth. The teeth have a front segment, a top segment and a back segment. The front segment has the connection of the tooth from the elongated rib portion and the front segment including a tip which is actively taking fibers in carding.

The top segment has at least one hunch after the tip in the direction of the back segment. If more than one hunch is present the first hunch is the hunch positioned closest to the tip; if only one hunch is present this hunch is the first U.S. Patent No.: Patent date: Assignee: Inventor:

Rotatable cable reel U.S. Patent No.: 9,403,659 Patent date: August 2, 2016 Filed: March 5, 2014 Assignee: Southwire Company, LLC, U.S. Inventors: Juan Gonzalez, James Tuggle, Franklin Calhoun A cable reel of the present disclosure can include two flanges and a central drum being independently rotatable from one another. The drum, which can be configured to receive a cable, can be mounted on an axle. The two flanges can be rotationally mounted on the axle at opposing distal ends of the axle. Bearings in the flanges can allow for a full rotation of the flanges about the axle.

Wire feeding systems and devices U.S. Patent No.: 9,403,234 Patent date: August 2, 2016 Filed: Oct. 18, 2012 Assignee: Illinois Tool Works Inc., U.S. Inventors: Mark Christopher, Brian Ott, Michael Vandenberg Provided herein are systems including a wire spool having a core with a core diameter and wire wound around the core and having a wire diameter. An outer diameter of the wire spool is defined by a sum of the core diameter and the wire diameter. The systems may also include a sensing system having a sensor component disposed on the wire spool and/or a wire spool hub. The sensing system is adapted to acquire data corresponding to a parameter indicative of the outer diameter of the wire spool.

Wire harness and method of manufacturing the same U.S. Patent No.: 9,403,495 Patent date: August 2, 2016 Filed: April 5, 2012 Assignee: Yazaki Corporation, Japan Inventors: Hiroki Gotou, Toshio Okazaki There are provided a wire harness and a manufacturing method thereof which can reduce number of components and which does not require an electric wire to be formed longer than necessary. A wire harness includes an electric wire and a tubular corrugated tube made of synthetic resin and arranged to receive the electric wire to protect the electric wire. The corrugated tube is bent at an appropriate section when wired on an automobile. The corrugated tube includes recessed grooves and protrusions arranged alternately along a longitudinal direction. The adjacent protrusions of the appropriate section on the inward side are attached to each other by welding. The appropriate section is bent in a non-restorable fashion in a direction in which the appropriate section is bent when wired in the automobile.

PATENTS

hunch. The back segment forms the connection of the top segment towards the elongated rib portion and the front segment of the next tooth.

Carbon steel wire with high strength and excellent ductility and fatigue resistance, process for producing the same, and method of evaluating the same U.S. Patent No.: 9,403,200 Patent date: August 2, 2016 Filed: May 6, 2010 Assignee: Bridgestone Corporation, Japan Inventors: Wataru Shimizu A carbon steel wire with unprecedentedly high strength and excellent ductility and fatigue resistance, a process for producing the same, and a method of evaluating the same are provided. Provided is a carbon steel wire having a carbon content of 0.50 to 1.10% by mass, wherein the ratio of the hardness of the surface layer portion on a cross section and the hardness of the surface layer portion on a longitudinal section is represented by a coefficient X1, and the ratio of the hardness of the center portion on the cross section and the hardness of the center portion on the longitudinal section is represented by a coefficient X2, wherein X1 and X2 satisfy the following expressions: 0.9<coefficient X1.ltoreq.1.10, and 0.9<coefficient X2.ltoreq.1.10, and wherein the carbon steel wire has a tensile strength of 4000 MPa or higher.

Coaxial electric wire and method for manufacturing the same U.S. Patent No.: 9,402,845 Patent date: August 2, 2016 Filed: Sept. 9, 2014 Assignee: Yazaki Corporation, Japan Inventor: Mitsuharu Nagahashi A coaxial electric wire with an inner conductor, an inner insulating layer covering a periphery of the inner conductor, an outer conductor covering a periphery of the inner insulating layer, and an outer insulating layer covering a periphery of the outer conductor, where the inner insulating layer is made of a first insulating tube having an elongated cylindrical shape and an insulation performance, the outer insulating layer is made of a second insulating tube having an elongated cylindrical shape and an insulation performance, the outer conductor is made of a conductive tube having an elongated cylindrical shape and conductivity, the coaxial electric wire is manufactured by inserting the inner conductor into the first insulating tube, inserting the first insulating tube into the conductive tube, and inserting the conductive tube into the second insulating tube.

SEPTEMBER 2016 | 101

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trials, and more. A Bachelor’s degree in Science or Engineering or higher is required along with 10 years of technical service experience in flexible wire and cable formulation development and compounding of PVC with an emphasis on Automotive and Plenum formulation technology. Please contact Donna Campesi at donna.campesi@axiall.com.

CAREER OPPORTUNITY TECHNICAL SERVICE ENGINEER (Flexible Wire and Cable Formulation): This position, with Axiall Corporation in Madison, MS, utilizes technical service to support compound sales efforts by investigating problems and recommending solutions.

This position will play an important role to ensure Axiall understands and meets their existing and future internal and external customers’ ever-changing needs. The position provide technical services to internal and external customers, conducts development efforts to generate new products and improve existing products, investigates/solves customer issues, helps optimize customer processes, conducts customer

SALES REP. Southwestern Wire, Inc., a leading producer of chain link fencing & steel wire products, nationwide, seeks a motivated Sales Rep. to join our current team based in Norman, OK. This individual will be responsible for maintaining current customer relationships and developing new customer relationships, to promote & sell our products via

the telephone & face to face. Overnight travel as required to tradeshows, and to visit customers within an assigned territory. Casual office environment. Pay based on experience; full benefits; Drug testing required; EOE/AA. Apply in person M-F 8-5 at Southwestern Wire, Inc., I-35 & Tecumseh Rd, Norman, OK or email resume to jobs@southwesternwire.com. Please contact us at 405-447-6900.

POSITIONS WANTED WIRE & CABLE REPRESENTATIVE AVAILABLE FOR THE AMERICAS. Do you need an experienced salesman in Mexico, Central and south America? Please contact Antonio Ayala at 1953ayala@gmail.com.PE

FOR SALE 1 - NEB 72-C #2 Braider, Long Legs, Motor 2 - NEB 48-C Harness Braiders, Motors 1 - HACOBA Model DF24 24-Carrier Braider 2 - J.B. HYDE 24-C, 48-C Braiders 1 - CEECO 60” Rotating Cabler 1 - REEL-O-MATIC 24” Caterpuller Capstan 1 - GOODMAN 18” Caterpuller Capstan 1 - ROYLE 48” Belt Wrap Capstan 1 - VITECK 36” Belt Wrap Capstan, CBW-36-D 1 - BARTELL 36” Dual Wheel Capstan 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - ALLARD 36” Closer, Model STC-36 2 - SYNCRO FX13, F13 Rod Breakdown Drawers 1 - DAVIS STANDARD 4.5” 24:1 Extruder 1 - DAVIS STANDARD 3.5” 24:1 Extruder Line 1 - ENTWISTLE 2” 24:1 Extruder 1 - DAVIS STANDARD 1.5” 24:1 Extruder 1 - BRABENDER 1.25” 24:1 HiTemp Extruder 1 - SKALTEK 2000mm Payoff, Model AX20-4K-1 2 - TULSA 96” Payoffs, Model CTPO-30, 2005 1 - SKALTEK 1600mm Payoffs, Model A16-4K Commission

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PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry Manufacturers to secure the services of executives, managers, and thousands of key individual contributors. Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593, Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, ers and pointers). Tel: 727-863-4700 or by e-mail, please send to urbassoc@ verizon.net.

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ADVERTISER ............................ PAGE

Amaral Automation Associates..........................31 Anbao Wire & Mesh Co Ltd ................................54 Black Sea Technology Inc ..................................95 Boxy SpA/Howar Equipment ..............................98 Cable Components Group ..................................21 Carris Reels Inc .................................................. C4 Clinton Instrument Co .........................................46 Commission Brokers Inc ..................................102 DRUIDS Process Technology SL .......................75 DeWal Industries Inc ...........................................29 George Evans Corp .............................................96 Fenn LLC ..............................................................13 Flymca &Flyro ......................................................91 Fuhr GmbH & Co KG ...........................................27 Gem Gravure Co Inc ............................................45 GMP Slovakia .......................................................38 Henrich GmbH .....................................................57 Honeywell ...............................................................1 Howar Equipment ................................................16 Howar Equipment/Boxy SpA ..............................98 Huestis Industrial ................................................30

Inhol BV ................................................................47 Inosym Ltd .....................................................14, 43 Interger Research ........................................83, 101 IWG High Performance Conductors Inc ............61 KEIR Manufacturing Inc ......................................96 Lamnea Bruk AB ..................................................54 Lloyd & Bouvier Inc .............................................24 Locton Limited .....................................................96 MFL Group ...........................................................19 Mexichem Specialty Compounds Inc ............... C2 Micro Products Co...............................................71 NDC Technologies ...............................................64 Niehoff GmbH & Co KG.......................................55 P & R Specialty Inc ..............................................33 Paramount Die Co .................................................4 Pressure Welding Machines Ltd ........................63 Properzi International Inc ...................................93 Proton Products International Ltd ...............18, 56 Queins Machines GmbH .....................................37 Rainbow Rubber & Plastics Inc............................2 Rosendahl Nextrom GmbH ...................................5

SEPTEMBER 2016 | 103

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

ADVER DVERTISERS’ ISERS’ INDEX ADVERTISER ............................ PAGE Rosendahl Knill Group........................................53 SAMP USA Inc......................................................17 Process Sheaves LLC .........................................48 SIKORA AG ............................................................7 Sjogren Industries Inc ................................... 68-69 Steel Cable Reel / Tektapes .................................97 Stolberger Inc dba Wardwell Braiding Machine Co ........................................65 August Strecker GmbH & Co KG .......................67 Teknor Apex Co ...................................................49 Ulbrich Stainless Steels Inc................................15 Upcast OY ............................................................25 WAFIOS Machinery Corp ................................... C3 Windak Group ......................................................73 Wire & Plastic Machinery Corp ............................9 Witels Albert USA Ltd..........................................38 Wyrepak Industries .......................................72, 94

November 2016 WJI Green Focus Wrapup: IWCS Wrapup: wire & Cable India

WIRE ASSOCIATION INT’L ADS Ferrous Wire Handbook ......................................12 Monterrey ITC ................................................ 35-36 Interwire 2017................................................. 39-40 WAI 2017 Reference Guide .................................70 WAI Membership..................................................89 Wire Journal Digital Edition..............................103

WIRE JOURNAL

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104 | WIRE JOURNAL INTERNATIONAL

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