When most people think of aluminum wire, what immediately comes to mind is either the blackboard-like material that's seen on commercial buildings and private residences to help with decorating or the light gauge wire that's used in electricians' work. While the uses of these two forms of wire are indeed commonplace, there is another type of wire that can be used as well. The material, called polyesterimide, is made from a combination of plastic and aluminum.
Polyesterimide is different from ordinary aluminum in that it doesn't require the metal ions in order to be formed. Instead, this wire is formed by a chemical reaction between the aluminum and the enamel of plastic. This creates the electrochemical properties necessary for conducting electricity. In this particular material, an aluminum foil layer is used as the topmost layer of the wire. Over this foil, the plastic and the wire to form a composite material that has the ability to insulate against heat, flame, and the harsh corrosive properties of water.
Although the process of producing polyesterimide wire may resemble that of the formation of enameled aluminum, the primary difference is that there is no need for an aluminum foil to be used for the top layer. Instead, the material consists of a thick layer of polyethylene plastic attached to the aluminum wire. The plastic, which is typically produced in large sheets, consists of several thousands of tiny pores. These small pores allow heat to be conducted through the wire, which in turn allows the wire to be protected from moisture. In addition to being able to conduct heat, this material is also flexible and ductile, which allows it to be wrapped around pipes and other metallic objects. A great example of how this material is used commercially can be found in the plumbing industry, where some commercial plumbing companies apply it to their piping to help increase the life of the pipes and reduce the risk of leakages.
Polyester fiber is the main ingredient in the manufacture of wire harnesses. This material is made by taking fibers of cotton, hemp, nylon, and acrylic and wrapping them around a high grade polyester material. During the manufacturing process, this material is mixed with a liquid compound that will give the wires flexibility and prevent it from drying out. The result is a long, flexible wire that is extremely durable. While this product is certainly used in the plumbing industry, it is becoming more popular as an alternative fuel for both trucks and cars. This is because the material does not produce significant amounts of pollution and it is highly resistant to fire.
The industrial uses of these enameled aluminum wire harnesses can be found almost everywhere. Automotive manufacturers use them on the bodies of their vehicles. Truck manufacturers also make use of them because of the extreme heat resistance. Wire harnesses are also widely used in forklift trucks because they help make the towing of heavy objects easier. They provide safety to people working at height.
Another common application for the wire harness is in the aerospace industry. They are used extensively on airplanes and helicopters. The material has become almost as popular as fiberglass in some instances because it is more affordable and it is virtually immune to corrosion. The only disadvantage of using this type of wire is that it tends to rust when exposed to water.
Polyester is another material commonly used in the manufacturing of wire harnesses. It is flexible and waterproof but it is unable to insulate against severe weather events such as rain, sleet, or snow. As a result, aluminum wire harnesses are often coated with an ultra-violet protection film. In addition, the wire is wrapped with an elastomeric insulation compound.
An enameled wire harness has the additional advantage of not needing to be painted or finished. It will continue to look like it was initially manufactured simply because it is so highly resistant to the elements. It is also very dense, which makes it easier to handle. These types of wire harnesses have also been found to be less susceptible to fraying than other types of wire.