Flexible cable with structurally enhanced conductors

An electrical cable having a metallic outermost sheath, the electrical cable comprising:

• a grounding conductor and a conductor assembly including an insulated conductor, the grounding conductor positioned adjacent to and in contact with at least a portion of the insulated conductor, the grounding conductor and the conductor assembly disposed within the metallic outermost sheath;
• wherein the insulated conductor includes an outermost surrounding layer comprising a strength enhancer, the strength enhancer including 0.25-0.85% of erucamide and a stearyl erucamide, the outermost surrounding layer being in direct contact with the metallic outermost sheath substantially along the length of the conductor and the metallic outermost sheath;
• wherein the outermost surrounding layer comprising the strength enhancer is formed to maintain the crush and impact resistance as required by UL 1569 second edition, revision of Sep. 10, 1998;
• and
• the electrical cable does not comprise a further protective covering between the insulated conductor and the metallic outermost sheath.

An electrical cable comprising:

• a metallic outer sheath conductively contacting a bare grounding conductor disposed within the metallic outer sheath;
• an insulated conductor consisting of an outer layer comprising a lubricant, the outer layer of the insulated conductor remaining in direct contact with the metallic outer sheath, and substantially along the length of the insulated conductor and the metallic outer sheath,
• the lubricant comprising 0.25-0.85% of erucamide and a stearyl erucamide;
• wherein:
• the electrical cable does not have an additional protective covering between the outer layer and the metallic outer sheath;
• and
• the electrical cable meets the crush and impact resistance requirements of UL 1569 second edition, revision of Sep. 10, 1998.

An apparatus for protecting an electrical cable assembly including one or more insulated conductors, each insulated conductor consisting of a single outer surrounding layer, the apparatus comprising:

• an outermost metallic sheath surrounding the electrical cable assembly;
• the one or more insulated conductors, in which each single outer surrounding layer is in direct contact with the outermost metallic sheath substantially along the length of the electrical cable assembly and the outermost metallic sheath;
• a grounding conductor contacting at least a portion of the one or more insulated conductors;
• and a strength enhancer formed of a high molecular weight silicone oil having a concentration by weight of at least 9% or a lubricant material including 0.25-0.85% of erucamide and a stearyl erucamide, the strength enhancer applied such that the outermost metallic sheath and the electrical cable assembly meet the crush and impact resistance requirements in UL 1569 second edition, revision of Sep. 10, 1998 without any additional layer between the insulated conductors and the outermost metallic sheath.

An electrical cable having a metallic outer sheath, the electrical cable comprising:

• a conductor assembly, including a bare grounding conductor and an electrically insulated conductor contacting the bare grounding conductor, the electrically insulated conductor being a Type THHN consisting of a surrounding layer, the surrounding layer consisting of an outer portion of a nylon material around an inner portion of a polyvinylchloride material, and
• the outer portion having strength enhancer comprising a lubricant in an amount to maintain a crush and impact resistance of the conductor assembly when surrounded by the metallic outer sheath meeting the requirements of UL 1569 second edition, revision of Sep. 10, 1998 without requiring an additional protective covering between the surrounding layer and the metallic outer sheath;
• and
• the surrounding layer comprising the strength enhancer being in direct contact with the metallic outer sheath, and substantially along the length of the conductor and the metallic outer sheath.