WO2000030126A1

WO2000030126A1 - Urethane-based coating for mining cable

Info

Publication number: WO2000030126A1
Application number: PCT/US1999/026895
Authority: WO
Inventors: Timothy Edward Klappenbach; Timothy Bernard Bruewer
Original assignee: Amercable
Priority date: 1998-11-13
Filing date: 1999-11-12
Publication date: 2000-05-25
Also published as: AU1819100A

Abstract

A cable (10) adapted for harsh and abrasive environments is provided. The cable (10) has at least one conductor (12, 14, 16) within a jacket (16); and a urethane-based coating over the jacket (16). According to one aspect of the invention, the urethane-based coating is a thermoplastic material. The thermoplastic material preferably has tensile strength which breaks in the range of 20 to 50 MPa; an elongation at break in the range of 150 to 700 percent; a durometer hardness in the range of 60 Shore A to 75 Shore D; and abrasion resistance in the range of 0.01 to 0.05 cm3 volume loss measured using the method outline in ISO-4649-1985(E). An adhesive is preferably used to bond the thermoplastic material of the coating to the jacket of the cable. According to a more advantageous aspect of the invention, the urethane-based coating is a thermoset material. The thermoset material preferably includes a filler system selected from the group consisting of: carbon black, non-black inorganic filler, and any combination thereof. The thermoset material is preferably co-extruded with the jacket, so no adhesive is needed. The thermoset material preferably has: a tensile strength at break in the range of 14 to 31 MPa; an elongation at break in the range of 150 to 750 percent; a durometer hardness in the range of 40 Shore A to 95 Shore A; and abrasion resistance in the range of 0.050 to 0.10 cm3 volume loss measured using the method outlined in ISO-4649-1985(E). Processes of providing the urethane-based coating over the cable jacket are also provided.

Description

URETHANE-BASED COATING FOR MINING CABLE

TECHNICAL FIELD The invention generally relates to a urethane-based coating for improving the damage resistance of cables used in high abrasion service applications, such as mining.

BACKGROUND OF THE INVENTION A conventional power or telecommunications cable is constructed of one or more insulated conductors with a protective outer jacket. An electrical power cable is typically constructed with conductors formed of copper wire for efficiently conducting electrical power on whatever scale is desired. A telecommunications cable is typically constructed of relatively small wire conductors for conducting electrical signals or, more recently, fiber-optic strands for conducting optical signals. In applications where multiple conductor paths and/or increased flexibility of the cable is desired, a plurality of conductors are bundled together to form a conductor core. For example in a typical electrical power cable, three or more insulated electrical conductors are separately insulated and intertwined together in a helical arrangement and enclosed in a protective outer jacket. Intertwining the conductors increases the flexibility of the cable but causes the intertwined conductors to have an irregular surface and forms interstices between the individual conductors and between the conductors and an inner surface of the jacket. In a telecommunications cable, a greater number of individual conductors are often intertwined together in more complex helical arrangements, which can include, for example, multiple bundles of helically twisted cables and the bundles are in turn intertwined in a helical arrangement. In the typical electrical or telecommunications cable, the interstices between the conductors are filled to form a generally circular cross-section cable. Power and telecommunications cables are used in many environments. One of the harshest environments for cables is coal and other mining operations. In particular, the cables used in mining operations tend to be subjected to severe abrasion as the cables are positioned and as equipment, traffic, and mining materials are moved over or along the mining cable. There has been a long-felt need for a improved mining cable that is capable of performing well in this harsh environment.

SUMMARY OF THE INVENTION According to the invention, a cable adapted for harsh and abrasive environments is provided. The cable has at least one conductor within a jacket; and a urethane-based coating over the jacket. According to one aspect of the invention, the urethane-based coating is a thermoplastic matenal. The thermoplastic mateπal preferably has: a tensile strength at break in the range of 3,000 to 8.000 psi (20 to 55 mega Pascals (MPa)); an elongation at break in the range of 150 to 700 percent; a durometer hardness in the range of 60 Shore A to 75 Shore D, and abrasion resistance in the range of 0.4 to 3.2 mg measured according to the Taber Abrasion method using 1,000 g wt and 5,000 revolutions, and more preferably, an abrasion resistance in the range of 0.01 - 0.05 cm³ volume loss when tested in accordance with ISO-4649- 1985(E), a copy of which is attached hereto as appendix A and incorporated herein by reference. (This standard is substantially similar to DLN standard 53516). An adhesive is preferably used to bond the thermoplastic mateπal of the coating to the jacket of the cable. According to another aspect of the invention, the urethane-based coating is a thermoset matenal, which is preferred over the thermoplastic matenal. The thermoset mateπal preferably includes a filler system selected from the group consisting of: carbon black, a non-black inorganic filler (such as kaolin clay or hydrated silica), and any combination thereof. The thermoset mateπal is preferably co-extruded with the jacket, so no adhesive is needed. The thermoset mateπal preferably has: a tensile strength at break in the range of 2,000 to 4,500 psi (14 to 34 MPa); an elongation at break in the range of 150 to 750 percent; a durometer hardness in the range of 40 Shore A to 95 Shore A; and abrasion resistance in the range of 1.0 to 1.50 mg measured according to the Taber Abrasion method using 1,000 g wt and 5,000 revolutions, and more preferably, an abrasion resistance in the range of 0.05 to 0.10 cm³ volume loss when tested in accordance with ISO-4649- 1985(E). Processes of providing the urethane-based coating over the cable jacket are also provided. These and other aspects and advantages of the invention will become apparent to persons skilled in the art from the following drawings and detailed descπption of a presently most prefeπed embodiment of the invention. BRIEF DESCRIPTION OF THE DRAWING The accompanying drawings are incorporated into and form a part of the specification to provide illustrative examples of the present invention and to explain the pπnciples of the invention The drawings are only for purposes of illustrating preferred and alternate embodiments of how the invention can be made and used It is to be understood, of course, that the drawings are not to engineeπng scale, but are merely intended to represent and illustrate the concepts of the invention The drawings are not to be construed as limiting the invention to only the illustrated and descπbed examples Vaπous advantages and features of the present invention will be apparent from a consideration of the accompanying drawings in which FIG 1 is a perspective view with a partially broken away portion of a representative jacketed cable, including optional πp cords, which can be provided a urethane-based coating according to the present invention, FIG 2 is a cross-sectional view of the cable in FIG 1 taken along line 2-2, FIG 3 is across-sectional view of a second embodiment of cable illustrating an alternative πp cord position, FIG 4 is a cross-sectional view of a third embodiment of a representative cable according to a presently most-prefeπed embodiment of the invention, without πp cords, wherein the cable has a circular cross section, and FIG 5 is a cross-sectional view of a fourth embodiment of a cable according to another presently most-prefeπed embodiment of the invention, without πp cords, wherein the cable has a "flat" cross section

DETAILED DESCRIPTION OF A PRESENTLY MOST PREFERRED EMBODIMENT AND BEST MODE OF PRACTICING THE INVENTION

Basic Cabie Structures The cable can be of any conventional design, which includes at least one conductor in a protective jacket In mining operations, the conductor is typically an electπcally conductive mateπal for conducting electπcity, preferably copper Of course, the invention is applicable to fiber-optic cables for conducting optical signals that can also be needed in vaπous harsh environments The cable typically includes a plurality of conductors intertwined with each other in a generally helical aπangement within the jacket presenting a circular cross-section Thecable can also be made in what is sometimes refeπed to as a "flat" design, which is an oblong cross- section created by, for example, three straight and parallel conductors aπanged in a row. If desired, an insulating filling mateπal is used to expand and fill in the interstices between the intertwined conductors and the jacket. The jacket helps hold the cable together and provides some of the structural strength and integπty of the cable. The present invention will be descπbed by referπng to vaπous examples of how the invention can be made and used. Like reference characters are used throughout the several views of the drawing to indicate like coπespondmg parts

FIGS 1-3 Referπng to FIGS 1 and 2. the numeral 10 generally designates a cable assembly. In the illustrated embodiment, the cable assembly 10 includes three helically extending insulated conductors 12, 13, and 14 enclosed in an inteπor passage 15 of a tubular protective outer cable jacket 16 The insulated conductors 12, 13 and 14 include outer surfaces 17, 18 and 19 and are intertwined together in a helical aπangement forming a plurality of helically extending interstices 20, 21, 22 and 23. Interstice 20 is bounded by surfaces 17 and 18 of conductors 12 and 13 and by inner surface 24 of outer jacket 16. Interstice 21 is bounded by outer surfaces 18 and 19 of conductors 13 and 14 and by inner surface 24 of outer jacket 16. Interstice 22 is bounded by surfaces 17 and 19 of conductors 12 and 14 and by inner surface 24 of outerjacket 16. Interstice 23 is bounded by surfaces 17, 18 and 19 of conductors 12, 13 and 14 It is common to have fill mateπal 25 is positioned in the interstices 20, 21, 22, and 23 in the cable assembly 10 The fill material can be extruded mateπal, or it can be a fibrous mateπal, such as a plurality of fibrous strand bundles 26, 27, 28, and 29 These fibrous strand bundles can be formed of polymeπc mateπals such as polyacrylate or natural polymeπc mateπals of cellulosic oπgin. Strand bundles 26, 27, 28, and 29 extend the full length of the cable assembly 10 and are positioned to helically extend in the interstices 20, 21, 22, and 23, respectively. It should be appreciated, however, that other fill mateπal structure can be used, such as tape or powder mateπals. Each electπcal conductor 12, 13 and 14 includes a conductor core 30, 31 and 32 and an insulation layer 33, 34 and 35. Each conductor core 30, 31 and 32 compπses a plurality of copper wire strands 30a, 30b, 31 a, 3 lb, 32a and 32b, respectively Copper wires 30a, 30b, 3 la, 3 lb, 32a and 32b are preferably annealed copper manufactured in accordance with ASTM Specifications B-3 or B-33 Insulation layers 33, 34 and 35 are preferably made of mateπal such as layers of a silicone rubber impregnated glass tape, GEXOL®, ethylene propylene rubber (EPR), or other chemically cross-linked, thermosettingpolyolefin (In some applications other than mining, such as for shipboard cable, it can be desirable that the polyolefin be flame retardant ) It should be appreciated that the core and individual conductor insulation may vary depending on the application For instance, in a conventional power cable application, the conductor core is preferably class B, C or D soft or annealed copper (either tinned or bare copper), or class G, H, or I flexible copper (either tinned or bare copper) in accordance with ASTM Specifications B-3 and B-8 A strand shield may be provided which is formed by extruding a semiconducting layer over the conductor core, applied in tandem with and firmly bonded to an insulation layer The insulation layer is preferably ethylene propylene rubber (EPR) meeting the requirements of the Insulated Cable Engineers Association ("ICEA") standard S-75- 381, either Type 1 or Type 2 insulations (In certain other industπal applications, the Underwπters Laboratones Standard is ULS 1072 for Medium Voltage solid dielectπc cable (MV90)) Over the insulation, a semiconducting insulation screen, which meets or exceeds the requirements ICEA S-68-516, is extruded directly over the insulation to form an insulation shield In telecommunications embodiments, the conductors are either electπcal and or fiber- optic The electπcal conductors in telecommunications applications are preferably solid conductors The insulation layers for the conductors are preferably made of polypropylene or polyethylene Although πp cords are not generally used in the mining industry, as best illustrated in FIG 1 , one or more np cords 36a, 36b and 36c, made from a high strength mateπal, can be positioned to extend longitudinally along the inteπor passage 15 of jacket assembly 16. Preferably, πp cords 36a, 36b and 36c extend along and run generally parallel with a longitudinal axis 38 of the cable assembly 10 and are 120° apart positioned on opposed sides of the cable In the embodiment illustrated in FIGS 1 and 2, rip cords 36a, 36b and 36c are positioned adjacent the inner surface 24 of outer jacket 16 and exteπorly of the insulated conductors 12, 13 and 14 and fill mateπal 25 A binder tape 39 is helically wound around the extenor of the conductors 12, 13 and 14 and fill mateπal 25 and is used for holding the conductors and fill mateπal together duπng manufacture A longitudinal positioning (non-helical) of the πp cords is prefeπed, forming an acute angle with the helical path of the binder tape and fill mateπal However, the πp cords can be wound in a helical aπangement provided they are positioned exteπorly of the fill mateπal 25 In a second embodiment, illustrated in FIG 3, an easy stπpping assembly 100 can be useful m a situation where integral fill is used Assembly 100 preferably includes three longitudinally extending insulated conductors 112, 113 and 114 enclosed in an inteπor passage 115 of a tubular protective outer cable jacket 116 The insulated conductors 112, 113 and 114 include outer surfaces 117, 118 and 119 and are intertwined together in a helical aπangement forming a plurality of interstices 120, 121, 122 and 123 Interstice 120 is bounded by surfaces 117 and 118 or conductors 112 and 113 and by inner surface 124 of outer jacket 116 Interstice 121 is bounded by outer surfaces 118 and 119 of conductors 113 and 114 and by inner surface 124 of outer jacket 116 Interstice 122 is bounded by surfaces 117 and 119 of conductors 112 and 114 and by inner surface 124 of outer jacket 116 Interstice 123 is bounded by surfaces 117, 118 and 119 of conductors 112, 113 and 114 To prevent water from traveling down the interstices 120, 121, 122 and 123 in the cable assembly 100, a fill mateπal 125 can be positioned in the interstices 120, 121, 122 and 123 Each electπcal conductor 112, 113 and 114 includes a conductor core 130, 131, and 132 and an insulation layer 133, 134 and 135 Conductor cores 130, 131 and 132 each compnse a plurality of copper wire strands 130a, 130b, 131a, 131b, 132a and 132b are preferably annealed copper manufactured in accordance with ASTM B-3 or B-33 Preferably, three longitudinally extending πp cords 136a, 136b and 136c are positioned in the inteπor passage 115 of jacket 116 Rip cords 136a, 136b and 136c extend along and run generally parallel with a longitudinal axis of the cable assembly 100 In the embodiment illustrated in FIG 3, longitudinally extending πp cords 136a-c are positioned adjacent fill mateπal 125 and conductors 112, 113 and 114 Binder tape 139 is interposed between np cords 136a-c and inner surface 124 of outer jacket 116 Binder tape 139 is preferably tearable and is helically wound around conductors 112, 113 and 114 and fill mateπal 125 and πp cords 136a, 136b and 136c

FIGS 4-5 FIGS 4 and 5 illustrate presently most-prefeπed embodiments for mining cable, without πp cords, where FIG 4 illustrates a mining cable having a circular cross section, and where FIG 5 illustrates a mining cable having a "flat" cross section Referπng to FIG 4, the cable includes a relatively thin polyurethane sleeve 401, a thermoset jacket 402, a structural reinforcement 403 (such as cotton, polyester, nylon, or any other spun fiber, or fiberglass), a braid shield 404, insulation 405, separator 406 (such as mylar tape), conductor 407, ground check 408, filler 409 (such as jute, an elastomer, polypropylene), and a ground strand 410 Referπng to FIG 5, the "flat" cable includes a relatively thin polyurethane sleeve 501, a thermoset jacket 502, a ground check 503, a core binder 504, an insulated ground 505, insulation 506, a conductor shield 507, and a conductor 508

Jacket and Urethane-Based Coating According to the invention, the jacketing mateπal of a mining cable preferably is formed of a polymer mixture based on any of the following polymers Chloπnated Polyethylene (CPE), Chlorosulfonated Polyethylene (CSM), Polychloroprene (CR), or Natural Rubber (NR) According to the invention, a urethane-based coating is provided over the jacket of a cable The urethane-based coating improves the abrasion resistance of the cable Urethane polymers are polymers that contain urethane groups, which are also known as carbamate groups, in the backbone of the polymer chain In general, a linear urethane polymer chain is a thermoplastic mateπal and tends to have good impact strength, good physical properties, and excellent processabihty, but owing to its thermoplastic characteπstic, limited thermal stability A branched chain or cross-linked polyurethane is a thermoset mateπal and tend to have lower impact strength, but owing to its thermoset characteπstic, good thermal stability

Thermoplastic Urethane Coating According to a first aspect of the invention, the urethane-based coating is a thermoplastic urethane The thermoplastic urethane mateπal can be either polyether or polyester based, with polyester being the presently more prefeπed construction Suitable thermoplastic urethane coating mateπal can be obtained from commercial suppliers The thermoplastic urethane sleeve is preferably extruded as a sleeve over a pre-existing jacketed cable The wall thickness of the thermoplastic urethane sleeve over the cable core can range down to about 0 05 inches (0 13 cm), although it is difficult to extrude a thickness of less than about 0 075 inches (0 2 cm), and 0 100 - 0 125 inches (0 25 - 0 32 cm) is more prefeπed For larger cables, the urethane sleeve thickness is preferably about one-third (33%) of the jacket wall thickness 1 The thermoplastic urethane sleeve has the following physical property ranges:

2 Tensile at Break (psi) 3,000 to 8,000, with 4,700 psi nominal prefeπed

3 (20 to 55 MPa with 33 MPa nominal prefeπed);

4 Elongation at Break (%) 150 to 700 percent, with 400-600 percent prefeπed;

5 Durometer Hardness 60 Shore A to 75 Shore D, with 85 to 95 Shore A

6 prefeπed;

7 Abrasion Resistance 0.4 to 3.2 mg, more preferably 0.01 to 0.05 cm³ vol. loss.

8 The abrasion resistance can be measured according to the Taber Abrasion method using 1,000

9 g wt and 5,000 revolutions, which methodology is well known to those skilled in the art. The

I o abrasion resistance is more preferably measured as volume loss using the method outlined in ISO-

I I 4649- 1985(E), which employs a 40 meter length of travel and a constant force of 10 Newtons on

12 the sample.

13 The thermoplastic urethane is preferably extruded over the pre-existing jacketed cable

14 using the following extrusion process parameters:

15 Extruder (LTD) 15: 1 to 32.1, with 24: 1 ratio is prefeπed;

16 Compression Ratio 2.5: 1 to 3.0: 1: and

17 Compound Melt Temperature 330 to 350 °F (165 to 177 °C).

18 To prevent slippage of the thermoplastic urethane sleeve relative to the cable jacket and

19 core, it is preferable and beneficial to provide a minimal amount of chemical adhesion between

20 the cable core and the thermoplastic urethane sleeve. The desired adhesion levels are in the range

21 of 1.0 to 3.0 pounds per inch force needed to separate the thermoplastic urethane from the cable

22 jacket of the cable. The adhesion is attained by the use of vaπous commercial adhesive products,

23 with cyanoacrylates and epoxy systems being prefeπed, or urethane based adhesives. 4

25 Thermoplastic Urethane Example 6 This example process utilizes either a polyester or polyether based urethane, which is

27 extruded over an existing jacketed cable. The base cable used in this example process is a 2/0 8 2kV shielded design. It is to be understood, of course, that other types of cable can be used.

29 The thermoplastic urethane used in the example was the following ether based resin: Trade name - Elastollan 1185 A: Manufacturer - BASF; Tensile at Break - 33 Mpa nominal; Elongation at Break - 640% nominal; Hardness - 85 shore A; and Abrasion Resistance - 30 mg, preferably 0.036 cm3 vol. loss, nominal. Pπor to extrusion, the resin is heat dπed to remove any surface moisture present. A standard thermoplastic extruder with a presently most prefeπεd L/D ratio of at least 24: 1 is recommended Screw designs utilizing a compression ratio of between 2.5: 1 and 3.0: 1 are recommended The following extrusion process parameters were used in the expeπment: Extruder L/D - 24/1; Screw Design - 2.5:1 to 3.0: 1 compression ratio; and Extrudate Temp - 330 to 350 degrees F (165 to 177 °C). The wall thicknesses of the thermoplastic urethane sleeve can range down to about 0.050 inches (0.13 cm), although it is difficult to extrude a thickness of less than about 0.075 inches (0.2 cm), and 0.100 - 0.125 inches (0.25 - 0.32 cm) is more prefeπed. For larger cables, the urethane sleeve thickness is preferably about one-third (33%) of the jacket wall thickness. Pπor to coating with the thermoplastic urethane, the jacket of the cable is treated with a suitable bonding agent to provide adhesion between the thermoplastic urethane jacket and the cable. The adhesive is selected so as to activate at the temperatures attained duπng the extrusion process. According to the example, the type of adhesives used are marketed under the trade names "Chemlok 219" and "Chemlok 250", both commercially available from Lord Chemical.

Thermoset Urethane According to a second aspect of the invention, a thermoset compound based on a urethane polymer is used to coat the jacket of a cable. This option differs from the thermoplastic urethane in that the urethane coating is a thermoset mateπal. Advantages of using a thermoset urethane include higher upper temperature resistance and improved bonding of the components. An additional advantage of the thermoset option is that these mateπals can be custom designed to balance physical properties of the finished mateπal, for example, the urethane coveπng m this case is a specially compounded matenal specifically designed to balance abrasion resistance and flexibility to the finished cable The base compound can be either polyether or polyester based, with the polyester mateπal being prefeπed. In addition to the polymer, this option also employs the use of vaπous fillers, plasticizers, process aids, and vulcanization systems to attain the desired finished product. Of major importance to the performance of the finished product is the filler system and the vulcanization system of the compound. Typical filler systems for thermoset urethane systems are compπsed of carbon black and inorganic mineral fillers Typical carbon blacks used are categoπzed as S AF (super abrasion furnace) or HAF (high abrasion furnace), and typically have a particle size ranging from about 1 to about 50 nanometers in size, with from about 20 to about 30 nm being prefeπed Typical percentage loading levels are between 10 to 40 percent by weight of the total recipe, with about 20 percent by weight being prefeπed Inorganic fillers compπse kaolin (hydrated aluminum silicate), talc (magnesium silicate), or silica (hydrated silica) families, and provide the benefit of non black compounds The prefeπed filler system for non-black compound is silica based Typical silica utilized in this type of recipe range from about 120 to 160 square meters per gram surface area (reinforcement properties of silica are based on the measured surface area), with 150 - 160 range being the prefeπed mateπal. Typical percentage loading levels are slightly lower than those seen with carbon black systems, and range from 5 to 25 percent of the total recipe In certain formulations, it is sometimes beneficial to use both black and non-black mateπal to provide a balance of physical, chemical, and processing properties to the finished product - as is well known to those skilled in the art The thermoset systems can be vulcanized by the use of organic peroxides or sulfur based systems The prefeπed method of vulcanization uses organic peroxides The thermoset urethane coating has the following physical property ranges. Tensile at Break 2,000 to 4,500, with >3,500 psi prefeπed (14 MPa to 31 MPa, with > 24 MPa prefeπed), Elongation at Break 150 to 750 %, with 400 to 600 % preteπed; Durometer Hardness 40 to 95 Shore A, with 70 to 80 Shore A prefeπed; and Abrasion Resistance 1.0 to 150 mg, with <100 0 prefeπed, more preferably 0.050 to 0 10 cm³ volume loss, with <0 08 prefeπed The thermoset urethane is preferably co-extruded over the base jacket mateπal and co- vulcanized to produce the finished cable. In the case of neoprene or CSM, the compounded urethane would utilize a sulfur cure system to attain the desired level of composite properties. In the case of a CPE substrate, the urethane would employ a peroxide cure system for adhesion The product is to be manufactured on a typical lead line. For example, the first tuber extrudes the jacket substrate, i.e., neoprene, CPE, or CSM. Wall thicknesses of this extrusion would preferably account for approximately two-thirds (67%) of the finished cable diameter of the product. The second tuber extrudes a specially designed urethane compound over the substrate, preferably compnsmg approximately one-third (33%) of the jacket wall thickness The following are expected to be the prefeπed extrusion process parameters: Extruder (L D) 15: 1 to 24 1, with 15: 1 prefeπed, Compression ratio 1.5: 1 to 2 5.1, with 1.5: 1 prefeπed, and Compound Melt Temperature 140 to 270 degrees F (60 to 132 °C), preferably 165 to 185 degrees F (74 to 85°C) After application of thejackets, the cable is preferably water cooled, then immediately run through the lead extruder. The internal diameter of the lead extrusion would be set at about 96% of the cable outer diameter with a wall thickness of about 0 2 inches (0 5 cm) The finished construction is then be placed in an autoclave, and the cable cured. Typical wall thicknesses of the urethane coating can vary from at least 0.050 inches, and for larger cable about one-third (33%) the thickness of the jacket being the presently most prefeπed. Due to the cross linked nature of this polymer, thinner wall thickness of the urethane coating is desirable. Due to the process of co-extruding the thermoset urethane over the non-vulcanized jacketing mateπal, and co-cuπng the combination, adhesive systems are not necessary with the thermoset urethane coating.

Scope of Invention Not Limited to Preferred Embodiments The invention is descπbed with respect to presently prefeπed embodiments, but is not intended to be limited to the descπbed embodiments It will be readily apparent to one of ordinary skill in the art that numerous such modifications may be made to the invention without departing from the spiπt and scope of it as claimed

Rubber — Determination of abrasion resistance using a rotating cylindrical drum device

Caoutchouc — Dέtermination de la rέsistance a /'abrasion _> I'aide d'un dispositrf έ tambour tournant First edition - 1985-04-01

APPENDIX A

(10 pages)

UDC 621.4 : 620.1 : 539.538 Ref. No. ISO 4649-1985 (E)

Descriptors : rubber, vulcanized rubber, tests, wear tests, abrasion tests, test equipment INTERNATIONAL STANDARD ISO 4649-1985 (E)

1 Scope and field of application 4 Definitions

This International Standard specifies a method for the deterFor the purposes of this International Standard the followmc mination of tne resistance of rubber to aorasioπ by means of a definitions apply rotating cylinσπcal drum σevice

4 1 abrasion resistance The resistance to wear

The method involves determination of the volume loss of a rubmechanical action upon a surface ber test piece through abrasive action by rubbing over a specified grade of abrasive cloth Because factors such as the NOTE — For the purpose of this International Standard the abrasion grade of abrasive particles and adnesive used in the manufacresistance is expressed either as a relative volume loss referred to a ture of the cloth, and contamination and wear by previous calibrated abrasive cloth or as an abrasion resistance index referred to a testing, lead to variations in the absolute values of abrasion standard rubber loss, all tests must be comparative standard rubbers being included so that the results may be expressed either as a relative 4.2 relative volume loss The volume loss, in cubic volume loss referred to a calibrated abrasive cloth or an abramillimetres, of the test rubber after being subjected to abrasion sion resistance index reterred to a standard rubber by an abrasive cloth will cause the appropriate standard rubber (see clause 6.1 in annex B) to lose a mass of 200 mg under the

No close relation between the results of this abrasion test and preferred conditions of test for method A, namely a distance of service performance can be inferred 40 m, a load of 10 N and using a non-rotating test piece

NOTE — The higher tne relative volume loss the lower is the abrasion

2 References resistance

ISO 48 Vulcanized rubbers — Determination of hardness 4.3 abrasion resistance index The ratio of the volume (Hardness between 30 and 85 IRHD loss of a standard rubber to the volume loss of the test rubbe- measured under the same specified conditions and expressed

ISO/R 275, Zinc oxide for paints as a percentage

ISO 471, Rubber — Standard temperatures, humidities and times for the conditioning and testing of test pieces 5 Apparatus and materials

ISO 2393, Rubber test mixes — Preparation, mixing and 5.1 Abrasion machine vulcanization — Equipment and procedures

The test apparatus (see figure 11 consists of a laterally movable

ISO 2781, Vulcanized rubber — Determination of density test piece holder and a rotatable cylinder to which the abrasive cloth (5.2) is fixed.

ASTM D 1765 Standard classification system for carbon blacks used in rubber products The cylinder shall have a diameter of 150 ± 0,2 mm and a length of about 500 mm and shall be rotated at a frequency of 40 ± 1 mm - ', the directions of rotation being as indicated in

3 Principle figure 1

Subjection of a cylindrical rubber test piece to the action of an The test piece holder shall consist of a cylindrical opening, the abrasive cloth of specified abrasive grade at a specified contact diameter of which can be adjusted from 15.5 to 16.3 mm, and a pressure over a given area device for adjusting the length of the test piece protruding from the opening to 2 ± 0,2 mm The holder shall be mounted on a

Abrasion takes place over one of the flat end surfaces of the swivel arm which in turn is attached to a sledge which can be cylindrical test piece, the abrasive cloth being attached to the moved laterally on a -pindle. The lateral displacement of the surface of a rotating cylindrical drum against which the test holder shall be 4,20 ± 0,04 mm per revolution of the drum piece is held and across which it is traversed Suitable attachments may be provided to rotate the test piece during the test run by rotation of the test piece holder

Determination of the loss in mass of the test piece and calcupreferably, at the rate of 1 revolution per 50 revolutions of the lation of the volume loss from the oensity of the material drum _N0TE - With this lateral movement the test piece passes over any 5 4 Balance one area of the abrasive cloth four times

The balance shall be of sufficient accuracy to enable the mass

The centre axis of the holder shall have an inclination of 3° to loss of a test piece to be determined to ± 1 mg the perpendicular in the direction of rotation (see figure 1 ) and shall be placed directly above the longitudinal axis of the 5.5 Standard rubbers cylinder to within ± 1mm

Specifications for standard rubbers are given in detail in

The swivel arm and test piece holder shall be free from vibration annex B during operation, and so disposed that the test piece is pressed against the drum with a vertical force of 10 = 0,2 N obtained by adding weights to the top of the test piece holder For 6 Test piece special purposes a force of 5 ± 0 1 N may be used

6 1 Type and preparation

The abrasive cloth shall be attached to the drum using three evenly spaced strips of double-sided adhesive tape extending The test pieces shall be cylindrical in shape of diameter along the complete length of the cylinder Care shall be taken 16 ± 0 2 mm with a minimum height of 6 mm to ensure that the aorasive cloth is firmly held so as to present a

Test pieces are normally prepared using the hollow drill (5 3) unifprm abrasive surface over the whole area of the cylinder During cutting the cutting edge snould be lubricated with One of the strips shall be placed where the ends of the abrasive water to which a wetting agent has been added Punching of cloth meet Ideally the ends should meet exactly, but any gap the test pieces is not permitted left between them shall not exceed 2 mm The adhesive tape shall be about 50 mm wide and not more than 0,2 mm thick

Alternatively test pieces may be vulcanized in a mould

Placement of the test piece on to the cloth at the beginning of a If test pieces of the required thickness are not available the test run, and its removal after an abrasion run of 40 necessary thickness may be obtained by bonding a piece of the (equivalent to 84 revolutions), shall be automatic In special test rubber to a base element of hardness not less than 80 cases of very high volume loss of the test piece, an abrasion IRHD The thickness of the test rubber should be not less than distance of only 20 m (equivalent to 42 revolutions) may be 2 mm used If using an abrasion distance of 20 m, a revolution counter or automatic stopping device should be connected to

6.2 Number the drum

Three test runs shall be carried out This will normally require

To protect the abrasive cloth from damage by the test piece three test pieces but only one test piece may be necessary if holder, a oevice for switcniπg off the apparatus just before the the mass loss per run is very low lower edge of the test piece holder touches the cloth is recom mended

6 3 Time interval between vulcanization and testing

5.2 Abrasive cloth

For all test purposes the minimum time between vulcanization

Abrasive cloth made with aluminium oxide of grain size 60, at and testing shall be 16 h For non-product tests, the maximum time between vulcanization and testing shall be 4 weeks and least 400 mm wide, 473 mm long and 1 mm average thickness shall be used as the abrasive medium for evaluations intended to be comparable, the tests, as far as possible, shall be carried out after the same time interval For product tests, whenever possible, the time between vulcani.

In a test using a non-rotating test piece of the standard rubber ation and testing shall not exceed 3 months In other cases described in annex B, clause B 1 , this abrasive surface shall tests shall be made within 2 months of the date of receipt of the cause a mass loss between 180 and 220 mg for an abrasion product by the customer distance of 40 m

6 4 Conditioning

When each new sheet of cloth is first used the direction of motion shall be indicated on the sheet, as it is important that Condition all test pieces at standard laboratory temperature in the same direction be used for all subsequent test runs accordance with ISO 471 for a minimum period of 16 h im mediately before testing

Notes on a suitable paper are given in annex A

NOTE — For some rubbers which are sensitive to moisture the humid ity should also be controlled

5.3 Hollow drill (see figure 2)

The drill may be required for preparation of test pieces 7 Test temperature (see 6 1) The frequency of rotation of the drill needs to be at least 1 000 m - ' for most rubbers, and even higher for rubThe test shall be carried out at standard laboratory temperature bers with a hardness of less than 50 IRHD (see ISO 48) i (sc_eeo I ICSnO A 4T71M) During a test run there may be a considerable increase in Perform three test runs on each rubber under test Norman temperature at the abrading iπtenace which may lead to only one run per test piece is earned out but if the mass loss ι temperature rises within tne test piece For the purposes of this relatively small up to three test runs can be carried out on ttv International Standard such temperature rises are to be same test piece When repeat runs are made on the same tes disregarded, the temperature of test being that of the ambient piece, sufficient time shall be allowed between such runs fo atmosphere and of the test piece before commencing the test the temperature of the whole of the test piece to return to stan dard laboratory temperature For non-rotating test pieces car<

When repeat runs are made on the same test piece sufficient shall be taken to ensure that the test piece is always placed r time shall be allowed between such runs for the temperature of the sample holder in the same way If a series of rubbers i' the whole of the test piece to return to standard laboratory being tested all three test runs on the same rubber shall be ca^r temperature πed out consecutively

8.2 Density

8 Procedure

Determine the density ot the test material by the methoc specified in ISO 2781

8 1 General test procedure

8.3 Comparison against standard rubbers

Before each test any rubber debris left on the abrasive cloth from a previous abrasion test shall be removed with a brush A In this International Standard the test rubbers are comparec strong brush of about 55 mm diameter and about 70 mm against standard rubbers Two standard rubbers are specifiec length is recommended for this purpose In some cases a blank in annex B for use with the two methods of expressing result test with a stanoard rubber will effectively clean the abrasive (see clause 9) That specified in clause B 1 is intended for us< cloth in method A where the abrasion resistance is expressed a relative volume loss ΔK (see 9 1 ) That specified in clause B. 1

The test run may be carried out with the test piece either intended for use in method B where the abrasion resistance ι rotating or stationary (non-rotating) For method A (9 1) the expressed as an abrasion resistance index ARI (see 9.2) non-rotating test piece shall be used For method B (9.2) the rotating test piece is preferred but the non-rotating test piece The mass loss of a standard rubber shall be determined by car may also be used The test piece used shall be stated in the test rying out a minimum of three test runs both before and afte report, because the results obtained by these two procedures each test series following the procedure in 8 1 There shall be < can differ For measurements intended to be comparable, the maximum of three test rubbers in each test series same conditions shall be used For rubbers which have a tendency to smear the mass loss o the standard rubber shall be determined after each test run Ir

Weigh the test piece to the nearest 1 mg Fix the test piece in extreme cases of smearing there will be a considerable reduc the test piece holder in such a way that a length of tion in mass loss of the standard rubber measured after the tes 2 0 : 0 1 mm protrudes from tne opening This length shall be run compared to that measured before the test run This is αu controlled by means of a gauge to the Tact that in the test run the abrasive cloth is beirv- cleaned by the standard rubber as opposed to the standarr

The test piece should be pressed against the drum with a verrubber being abraded by the cloth If the reduction in mass los tical force of 10 _: 0,2 N If, for special cases the vertical force of the standard rubber is greater than 10 %, then the method i is reduced to 5 ± 0 1 N this shall be stated in the test report not valid because the severity of abrasion is lower

Move the test piece holder and sledge to the starting point 9 Expression of results place the test piece on the abrasive cloth and set the cylinder in

The results may be expressed either as a relative volume los' motion Check for vibration in the test piece holder This test (method A — see 9 1) or as an abrasion resistance in e method does not yield meaningful results if there is abnormal (method B — see 9.2) vibration in the test piece holder The test run is stopped automatically after an abrasion distance of 40 m When Calculate the mean value of the mass losses of the test rubber relatively large mass losses (usually more than 400 mg in 40 m) m, and of the standard rubber m_s from the three and sι> occur, the test run may be stopped after 20 m, and the length separate determinations respectively of exposed test piece reset to 2,0 ± 0.2 mm so that the test can be restarted and completed At no time shall the height of the Calculate the volume losses of the test rubber V, and of th' test piece be less than 5 mm If the mass loss is greater than standard rubber, V_s (for metnod B only) from the respectiv 600 mg in 40 m, the test should only be carried out for half mass losses and densities distance (i e 20 m) and this should be stated in the test report The results should be multiplied by 2 so that the mass loss can 9 1 Method A — Relative volume loss, Δ still be given for an abrasion distance of 40 m

In this method the standard rubber specified in clause B 1 ιr

Weigh the test piece to the nearest 1 mg after the test run annex B is used The non-rotating test piece shall be used fo Sometimes a small edge hanging from the test piece has to be both the test rubber and the standard rubber The measurec pulled off before weighing especially if a non-rotating test mass loss of the standard rubber using a non-rotating test pieci piece is used shall be within the range 180 to 220 mg The relative volume loss (see 4.2) is given by the formula 10 Test report

200 The test report shall include the following particulars : _Δjy = _t x a) sample details : where

1 ) full description and origin,

V is the volume loss, in cubic millimetres, of the test rubber; 2) compound details, cure time and temperature, if available, m_s is the mass loss, in milligrams, of the standard rubber (clause B.1) using a non-rotating test piece. 3) method of preparation of the test pieces from the sample, i.e. whether cut or moulded;

NOTE — The non-rotating test piece is used because of the considerable experience obtained previously with this method using the b) test method : reference to this International Standard, non-rotating test piece. c) test details ^•

9.2 Method B — Abrasion resistance index, ARI

1 ) standard laboratory temperature used,

In this method, the standard rubber specified in clause B.2 in annex B is used. The same type of test piece (rotating or non-

2) whether a non-rotating or rotating test piece was rotating) shall be used for both the test rubber and the standard used, rubber.

The abrasion resistance index (see 4.3) is given by the formula 3) type of standard rubber used,

4) any deviations from the test prpcedure, especially if

ARI = — x 100 the test run comprised only half the abrasion distance or if half the vertical force was used; where d) test result :

V_s is the volume loss, in cubic millimetres, of the standard

1) either the relative volume loss or the abrasion rubber (clause B.2); resistance index,

K_t is the volume loss, in cubic millimetres, of the test rubber. 2) standard deviation of test result,

NOTE — The rotating test piece is the preferred test Diece because the 3) density; abrasion loss is more uniform over tne wnole surface of the test piece in contact with the aorasive cloth e) date of test.

Annex A

Notes on a suitable abrasive cioth

(Forms an integral part of the Standard.)

A suitable abrasive cloth is produced commercially¹¹. It comhas shown that a minimum of a few hundred runs can be car prises corundum particles of gram size 60, i.e. passing through ned out with this type of cloth. a 60 mesh sieve, bonded to a twill cloth with a phenolic resin. As produced, the abrasive cloth causes an abrasion loss of Abrasive cloth produced and standardized in this manner

more than 300 mg when the standard rubber specified in annex be obtained from the Bundesaπstalt fϋr Mateπalprufunc B, clause B 1 , is tested using a non-rotating test piece. It is (BAM), Unter den Eichen 87, D-1000 Berlin 45, or th< necessary to perform one or wo runs with a steel test piece to Laboratoire de recherches et de contrόle du caoutchouc reduce the abrasive loss to aoout 210 to 220 mg. Experience (LRCC), 12, rue Carves, F-92120 Montrouge, France

II Details may be obtained from the Secretariat of ISO/TC 45 (BSIl or from ISO Central Secretanat ISO 4643-1985 (E)

Annex B Standard rubbers

(Forms an integral part of the Standard )

B.O Introduction Sheet out the mix on an open mil to a thickness of about 10 mm and check the batch mass

The use of a standard rubber is intended to minimize the variation in abrasion resistance found between laboratories and beNOTE — Other mixing procedures may be used provided the Quality of tween machines operating under nominally identical condi the standard rubber produced meets the requirements of B 1 5 tions

The composition and methods of manufacture of the standard rubbers described below are to be taken as a guide other for B 1 3 Vulcanization mulations may be used provided that they fulfil the requirements given in B 1 5 and B 2 4 The standard rubber Bring the mould to the vulcanization temperature and then in described in clause B 1 shall be used for the calibration of the sert an unvulcaπized piece of mix which has been pre-heated abrasive cloth (52) and for the calculation of the relative for 20 m at 70 °C An excess of approximately 10 % is recom volume Joss, AV (see 9 1) The standard rubber described in mended Vulcanize in a closed press at 150 ± 2 °C for clause B 2 shall be used for the determination of the abrasion 30 ± 1 mm using a moulding pressure of 3 5 MPa resistance index (see 9 2)

Sheets measuring approximately 180 mm x 120 mm x 8 mm

B.1 Standard rubber for the determination will provide about 65 test pieces of relative volume loss, ΔK

B.1 1 Formulation of standard rubber B 1 4 Storage

Store the standard sheets in a cool dark place and wrap them with materials which protect the sheets from attack by ozone (for example polyethylene)

B.1 5 Quality

^• See ASTM D 1765 Each batch of the standard rubber should be compared to a "reference sheet obtainable from the Bundesanstalt fur Matenalprufuπg (BAM) Uπter den Eichen 87 D-1000 Berlin 45 or the Laboratoire de recherches et de coπtrole du caoutchouc

B.1.2 Mixing procedure (LRCC) 12 rue Carves F 92120 Montrouge France using an abrasive cloth prepared in accordance with annex A

The following procedure is recommended

Masticate the natural rubber to a Mooney viscosity The quality of the standard rubber shall be examined by deter ML (1 + 4) at 100 °C, of 80 ± 5, using a mixing mill which mining the abrasion resistance of a test piece taken from a cor complies with the requirements specified in ISO 2393 Then πer of the sheet measured using a non-rotating test piece as prepare the mix in an internal mixer Cool the internal mixer to described in this International Standard and then comparing maintain the temperature at 50 ± 5 °C this mass loss with the mean mass loss of a 'reference sheet in immediate consecutive tests The differences between the mass losses shall not exceed 8 mg

Time

(mm)

**. standard rubber sheet shall be considered to be a reference

Add the rubber 0 sheet if the mass losses measured at six dif erent places (four at the corners and two in the middle) differ by not more than

Add the accelerator antioxidaπt and zinc oxide 5 10 mg and the mean value differs by not more than 5 mg fro the mean value of six single values of another reference sheet

Add the carbon black and sulfur 8

NOTE — It is permitted to carry out three test runs on the same test

Discharge 30 piece ISO 4649-1985 (E)

B.2 Standard rubber for the determination of quirements of ISO 2393; an internal mixer may be used abrasion resistance index, ARI however, instead of the mixing mill specified in ISO 2393 Sheets shall be vulcanized at 140 °C for 60 mm

B.2.1 Formulation of standard rubber

B.2.3 Storage

Store the standard sheets in a cool, dark place and wrap them with materials which protect the sheets from aπack by ozone (for example polyethylene)

B.2.4 Quality

" See ASTM D 1765 For referee purposes, the current Industry Reference Black should be used but this may give slightly different The mass losses for two different batches of standard rubber results determined in accordance with clause 8, shall agree to within ± 10 %.

B.2.2 Mixing and vulcanization

NOTE — It has been found that the standard rubber gives an abrasion

The equipment and procedures used for preparation, mixing toss of about 150 mg wnen tested in accordance with clause 8. using a and vulcanization shall be in accordance with the relevant rerotating test piece

Dimensions in millimetres

Rgure 1 — Schematic illustration of apparatus

Dimensions in millimetres

(Scale 1 : 11 Hardened

(Scale 10 : 1 )

Figure 2 — Hollow drill for test piece preparation

Claims

What is claimed is:

COATED CABLE 1. A cable for harsh and abrasive environments, the cable compπsing: (a) at least one conductor within a jacket; and (b) a urethane-based coating over the jacket.

2. The cable according to Claim 1, wherein thejacket compπses a mateπal selected from the group consisting of Chloπnated Polyethylene. Chlorosulfonated Polyethylene, Polychloroprene, or Natural Rubber

Thermoplastic Mateπal 3 The cable according to Claim 1, wherein the urethane-based coating is a thermoplastic mateπal.

4. The cable according to Claim 3, wherein the thermoplastic matenal is polyether based.

5 The cable according to Claim 3. wherein the thermoplastic mateπal is polyester based

6 The cable according to Claim 3, wherein the thermoplastic mateπal is extruded over a pre-existing jacket on the cable

7 The cable according to Claim 3, wherein the wall thickness of the coating is at least 0.13 cm

8 The cable according to Claim 7, wherein the wall thickness of the coating is about one third (33%) of the thickness of the jacket.

9 The cable according to Claim 3, wherein the thermoplastic mateπal has a tensile strength at break in the range of 20 to 55 MPa

10. The cable according to Claim 9, wherein the thermoplastic mateπal has a tensile strength at break of about 32 Mpa nominal.

11. The cable according to Claim 3, wherein the thermoplastic mateπal has elongation at break in the range of 150 to 700 percent.

12. The cable according to Claim 9, wherein the thermoplastic mateπal has elongation at break in the range of 400 to 600 percent.

13. The cable according to Claim 3 , wherein the thermoplastic mateπal has durometer hardness in the range of 60 Shore A to 75 Shore D.

14. The cable according to Claim 13, wherein the thermoplastic mateπal has durometer hardness in the range of 85 Shore A to 95 Shore A

15. The cable according to Claim 3 , wherein the thermoplastic mateπal has an abrasion resistance in the range of 0.01 to 0.05 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

16. The cable according to Claim 3, wherein the thermoplastic mateπal has: a tensile strength at break in the range of 20 to 55 MPa; an elongation at break in the range of 150 to 700 percent; a durometer hardness in the range of 60 Shore A to 75 Shore D; and abrasion resistance in the range of 0.01 to 0.05 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

17. The cable according to Claim 16, wherein the thermoplastic mateπal has: a tensile strength at break of 32 nominal MPa; an elongation at break in the range of 400 to 600 percent; and a durometer hardness in the range of 85 Shore A to 95 Shore A.

18. The cable according to Claim 3, further compπsmg an adhesive between thejacket and the thermoplastic mateπal.

19. The cable according to Claim 18, wherein the adhesive compπses a mateπal selected from the group consisting of: cyanoacrylates and epoxy systems.

Thermoset Mateπal 20. The cable according to Claim 1 , wherein the urethane-based coating is a thermoset mateπal.

21. The cable according to Claim 20, wherein the thermoset mateπal is polyether based.

22. The cable according to Claim 20, wherein the thermoset mateπal is polyester based.

23. The cable according to Claim 20, wherein the thermoset mateπal is co-extruded with the jacket.

Thermoset Matenal with Filler System 24. The cable according to Claim 20, wherein the thermoset mateπal further compnses a filler system selected from the group consisting of: carbon black, non-black inorganic filler, and any combination thereof.

25. The cable according to Claim 24, wherein the carbon black has a particle size range from about 1 to about 50 nanometers.

26. The cable according to Claim 25, wherein the carbon black has a particle size range from about 20 to about 30 nanometers.

27. The cable according to Claim 24, wherein the carbon black compnses m the range of 10 to 40 percent by weight of the thermoset mateπal.

28. The cable according to Claim 27, wherein the carbon black compnses about 20 percent by weight of the thermoset mateπal.

29. The cable according to Claim 24, wherein the non-black inorganic filler is selected from the group consisting of- kaolin, talc, silica, and any combination of the foregoing.

30 The cable according to Claim 29, wherein the non-black inorganic filler is silica.

31 The cable according to Claim 30, wherein the silica has in the range of about 120 to about 160 square meters per gram surface

32. The cable according to Claim 31, wherein the silica has in the range of about 150 to about 160 square meters per gram surface.

33. The cable according to Claim 29, wherein the non-black inorganic filler compnses in the range of 5 to 25 percent by weight of the thermoset matenal.

Thermoset Vulcanization 34 The cable according to Claim 20. wherein the thermoset matenal is vulcanized using organic peroxides

Thermoset Matenal Properties 35. The cable according to Claim 20, wherein the thermoset mateπal has a tensile strength at break in the range of 14 Mpa to 31 MPa.

36. The cable according to Claim 35, wherein the thermoset mateπal has a tensile strength at break of > 24 MPa nominal.

37 The cable according to Claim 20, wherein the thermoset mateπal has elongation at break in the range of 150 to 750 percent

38 The cable according to Claim 37, wherein the thermoset material has elongation at break in the range of 400 to 600 percent.

39. The cable according to Claim 20, wherein the thermoset mateπal has durometer hardness in the range of 40 Shore A to 95 Shore A.

40. The cable according to Claim 39, wherein the thermoset mateπal has durometer hardness in the range of 70 Shore A to 80 Shore A.

41 The cable according to Claim 20, wherein the thermoset matenal has an abrasion resistance in the range of 0 050 to 0 10 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

42 The cable according to Claim 20, wherein the thermoset matenal has an abrasion resistance of less than 0.08 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

43. The cable according to Claim 20, wherein the thermoset mateπal has: a tensile strength at break m the range of 14 Mpa to 31 MPa; an elongation at break vn the range of 150 to 750 percent; a durometer hardness in the range of 40 Shore A to 95 Shore A. and abrasion resistance in the range of 0.050 to 0.10 cm³ volume loss measured using the method outlined in ISO-4649-1985(E).

44. The cable according to Claim 43, wherein the thermoset mateπal has: a tensile strength at break of greater than 24 Mpa nominal; an elongation at break in the range of 400 to 600 percent; a durometer hardness in the range of 70 Shore A to 80 Shore A

Cable Structure 45. The cable according to Claim 20, wherein the wall thickness of the coating is at least 0.13 cm.

46. The cable according to Claim 45, wherein the wall thickness of the coating is about one-third the thickness of the jacket.

47. The cable according to Claim 1 , wherein the conductor is an electπcally conductive mateπal for conducting electricity.

48. The cable according to Claim 1, wherein the conductor is a fiber-optic conductor for conducting optical signals.

49. The cable according to Claim 1 , further compnsing: a plurality of conductors intertwined with each other in a generally helical arrangement within the jacket.

50. The cable according to Claim 49, further compnsing a filling matenal that fills the interstices between the intertwined plurality of conductors.

THERMOPLASTIC PROCESS 51. A process of coating a cable adapted for harsh and abrasive environments, the process compnsing the steps of (a) selecting a urethane-based coating that is a thermoplastic mateπal: and (b) extruding a thermoplastic urethane-based coating over a pre-existing jacketed cable.

52. The process according to Claim 51 , wherein the pre-existing jacket compπses a mateπal selected from the group consisting of: Chloπnated Polyethylene, Chlorosulfonated Polyethylene, Polychloroprene, or Natural Rubber.

53. The process according to Claim 51 , wherein the thermoplastic matenal is polyether based.

54 The process according to Claim 51 , wherein the thermoplastic matenal is polyester based.

55. The process according to Claim 3, wherein the wall thickness of the coating is at least 0.13 cm

56. The process according to Claim 55, wherein the wall thickness of the coating is about one-third the thickness of the jacket.

57. The process according to Claim 51, wherein the thermoplastic matenal has a tensile strength at break in the range of 20 to 55 MPa.

58 The process according to Claim 57, wherein the thermoplastic matenal has a tensile strength at break of 33 MPa nominal.

59. The process according to Claim 51, wherein the thermoplastic mateπal has elongation at break in the range of 150 to 700 percent.

60. The process according to Claim 59, wherein the thermoplastic mateπal has elongation at break in the range of 400 to 600 percent

61 The process according to Claim 51. wherein the thermoplastic mateπal has durometer hardness in the range of 60 Shore A to 75 Shore D.

62. The process according to Claim 61, wherein the thermoplastic mateπal has durometer hardness m the range of 85 Shore A to 95 Shore A.

63. The process according to Claim 62, wherein the thermoplastic mateπal has an abrasion resistance in the range of O.Olto 0.05 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E)..

64 The process according to Claim 51, wherein the thermoplastic mateπal has: a tensile strength at break in the range of 20 to 55 MPa; an elongation at break in the range of 150 to 700 percent; a durometer hardness in the range of 60 Shore A to 75 Shore D, and abrasion resistance in the range of O.Olto 0.05 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

65. The process according to Claim 64, wherein the thermoplastic mateπal has: a tensile strength at break of 33 MPa nominal; an elongation at break in the range of 400 to 600 percent; a durometer hardness in the range of 85 Shore A to 95 Shore A.

66 The process according to Claim 51. further compnsing the step of- applying an adhesive between the jacket and the thermoplastic mateπal

67 The process according to Claim 66, wherein the adhesive compπses a matenal selected from the group consisting of' cyanoacrylates and epoxy systems

68. The process according to Claim 51 , wherein the extrusion process parameters are: the extruder (L/D) is in the range of 15: 1 to 32: 1 ; the compression ratio is in the range of 2.5:1 to 3.0: 1; and the thermoplastic melt temperature is in the range of 165 to 177 °C

Product by Process 69 The cable produced according to the process of any one of Claims 51-68.

THERMOSET PROCESS 70. A process of coating a cable cable for use in harsh and abrasive environments, the coating process compnsing the steps of: (a) selecting a urethane-based coating that is a thermoset matenal; and (b) co-extruding the thermoset matenal with the jacket matenal over at least one electncal conductor to form a jacketed cable having a urethane-based coating on the outside of the jacket.

71. The process according to Claim 70, wherein the jacket mateπal compnses a mateπal selected from the group consisting of. Chloπnated Polyethylene, Chlorosulfonated Polyethylene, Polychloroprene, or Natural Rubber

72. The process according to Claim 70, wherein the thermoset matenal is polyether based.

73. The process according to Claim 70, wherein the thermoset matenal is polyester based.

Thermoset Matenal with Filler System 74. The process according to Claim 70, wherein the thermoset mateπal further compnses a filler system selected from the group consisting of: carbon black, non-black inorganic filler, and any combination thereof.

75. The process according to Claim 74, wherein the carbon black has a particle size range from about 1 to about 50 nanometers.

76. The process according to Claim 75, wherein the carbon black has a particle size range from about 20 to about 30 nanometers.

77. The process according to Claim 74, wherein the carbon black compπses in the range of 10 to 40 percent by weight of the thermoset mateπal.

78. The process according to Claim 77, wherein the carbon black compnses about 20 percent by weight of the thermoset matenal.

79. The process according to Claim 74, wherein the non-black inorganic filler is selected from the group consisting of: kaolin, talc, silica, and any combination of the foregoing.

80. The process according to Claim 79, wherein the non-black inorganic filler is silica.

81. The process according to Claim 80, wherein the silica has in the range of about 120 to about 160 square meters per gram surface.

82. The process according to Claim 81, wherein the silica has in the range of about 150 to about 160 square meters per gram surface.

83. The process according to Claim 79. wherein the non-black inorganic filler compnses in the range of 5 to 25 percent by weight of the thermoset mateπal.

Thermoset Vulcanization 84 The process according to Claim 70. wherein the thermoset mateπal is vulcanized using organic peroxides.

Thermoset Matenal Properties 85. The process according to Claim 70, wherein the thermoset matenal has a tensile strength at break in the range of 14 to 31 MPa.

86. The process according to Claim 85, wherein the thermoset matenal has a tensile strength at break of > 24 MPa nominal

87. The process according to Claim 70, wherein the thermoset mateπal has elongation at break in the range of 150 to 750 percent.

88. The process according to Claim 87, wherein the thermoset mateπal has elongation at break in the range of 400 to 600 percent.

89. The process according to Claim 70, wherein the thermoset mateπal has durometer hardness in the range of 40 Shore A to 95 Shore A.

90. The process according to Claim 89, wherein the thermoset matenal has durometer hardness in the range of 70 Shore A to 80 Shore A.

91. The process according to Claim 70, wherein the thermoset matenal has an abrasion resistance in the range of 0.050 to 0.10 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

92. The process according to Claim 70, wherein the thermoset matenal has an abrasion resistance of less than 0.08 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

93. The process according to Claim 70, wherein the thermoset mateπal has: a tensile strength at break in the range of 14 to 31 MPa; an elongation at break in the range of 150 to 750 percent; a durometer hardness in the range of 40 Shore A to 95 Shore A; and abrasion resistance in the range of 0.050 to 0.10 cm³ volume loss measured using the method outlined in ISO-4649- 1985(E).

94. The process according to Claim 93, wherein the thermoset mateπal has: a tensile strength at break of greater than 24 Mpa nominal; an elongation at break in the range of 400 to 600 percent; a durometer hardness in the range of 70 Shore A to 80 Shore A.

Wall Thickness 95. The process according to Claim 70, wherein the wall thickness of the coating is at least 0.13 cm.

96. The process according to Claim 95, wherein the wall thickness of the coating is about one-third the thickness of the jacket.

Product by Process 97. The cable produced according to the process of any one of Claims 70-96.

Base Cable Structure 98. The process according to Claims 51 or 70, wherein the conductor is an electrically conductive mateπal for conducting electncity.

99. The process according to Claims 51 or 70, wherein the conductor is a fiber-optic conductor for conducting optical signals.

100. The process according to Claims 51 or 70, further comprising: a plurality of conductors intertwined with each other in a generally helical arrangement within the jacket.

101. The process according to Claim 100, furthercomprisingafillingmaterialthatfills the interstices between the intertwined plurality of conductors.