US 11,842,827 C1 (13,052nd)
Method of manufacturing electrical cable, and resulting product, with reduced required installation pulling force
Philip Sasse, Douglasville, GA (US); Terry Chambers, Ranburne, AL (US); Randy D. Kummer, Villa Rica, GA (US); John Armstrong, Villa Rica, GA (US); David Reece, Calhoun, GA (US); and Hai Lam, Douglasville, GA (US)
Filed by Southwire Company, LLC, Carrollton, GA (US)
Assigned to SOUTHWIRE COMPANY, LLC, Carrollton, GA (US)
Reexamination Request No. 90/019,570, Jul. 4, 2024.
Reexamination Certificate for Patent 11,842,827, issued Dec. 12, 2023, Appl. No. 18/062,258, Dec. 6, 2022.
Application 90/019,570 is a continuation of application No. 18/046,639, filed on Oct. 14, 2022, granted, now 11,942,236.
Application 18/046,639 is a continuation of application No. 17/661,697, filed on May 2, 2022, granted, now 11,527,339.
Application 17/661,697 is a continuation of application No. 17/217,530, filed on Mar. 30, 2021, granted, now 11,355,264.
Application 17/217,530 is a continuation of application No. 16/895,580, filed on Jun. 8, 2020, granted, now 11,011,285.
Application 16/895,580 is a continuation of application No. 16/015,688, filed on Jun. 22, 2018, granted, now 10,763,010.
Application 16/015,688 is a continuation of application No. 15/590,881, filed on May 9, 2017, granted, now 10,763,009.
Application 15/590,881 is a continuation of application No. 14/858,872, filed on Sep. 18, 2015, granted, now 10,763,008.
Application 14/858,872 is a continuation of application No. 14/144,150, filed on Dec. 30, 2013, granted, now 9,142,336.
Application 14/144,150 is a continuation of application No. 13/774,677, filed on Feb. 22, 2013, granted, now 8,616,918.
Application 13/774,677 is a continuation of application No. 13/274,052, filed on Oct. 14, 2011, granted, now 8,382,518.
Application 13/274,052 is a continuation of application No. 12/787,877, filed on May 26, 2010, granted, now 8,043,119.
Application 12/787,877 is a continuation of application No. 11/675,441, filed on Feb. 15, 2007, granted, now 7,749,024.
Application 11/675,441 is a continuation in part of application No. 11/120,487, filed on May 3, 2005, abandoned.
Application 11/120,487 is a continuation in part of application No. 10/952,294, filed on Sep. 28, 2004, granted, now 7,411,129.
Ex Parte Reexamination Certificate issued on Oct. 10, 2025.
Int. Cl. H01B 13/24 (2006.01); B29C 48/06 (2019.01); B29C 48/09 (2019.01); B29C 48/154 (2019.01); B29C 48/285 (2019.01); B29C 48/88 (2019.01); B29C 48/95 (2019.01); C08K 5/20 (2006.01); C08K 5/54 (2006.01); C08L 77/00 (2006.01); H01B 3/22 (2006.01); H01B 3/44 (2006.01); H01B 3/46 (2006.01); H01B 7/00 (2006.01); H01B 7/02 (2006.01); H01B 7/18 (2006.01); H01B 7/29 (2006.01); H01B 13/14 (2006.01); H01B 13/22 (2006.01); H02G 3/04 (2006.01); B29C 48/21 (2019.01); B29C 48/29 (2019.01); B29C 48/34 (2019.01); B29C 48/40 (2019.01); B29K 23/00 (2006.01); B29K 27/06 (2006.01); B29K 67/00 (2006.01); B29K 77/00 (2006.01); B29K 105/00 (2006.01); B29K 105/16 (2006.01); B29L 31/34 (2006.01); C08G 77/04 (2006.01)
CPC H01B 13/24 (2013.01) [B29C 48/06 (2019.02); B29C 48/09 (2019.02); B29C 48/154 (2019.02); B29C 48/95 (2019.02); C08K 5/20 (2013.01); C08K 5/54 (2013.01); C08L 77/00 (2013.01); H01B 3/22 (2013.01); H01B 3/443 (2013.01); H01B 3/445 (2013.01); H01B 3/465 (2013.01); H01B 7/0009 (2013.01); H01B 7/02 (2013.01); H01B 7/0216 (2013.01); H01B 7/1875 (2013.01); H01B 7/292 (2013.01); H01B 13/145 (2013.01); H01B 13/22 (2013.01); H02G 3/0406 (2013.01); B29C 48/21 (2019.02); B29C 48/288 (2019.02); B29C 48/2888 (2019.02); B29C 48/29 (2019.02); B29C 48/34 (2019.02); B29C 48/40 (2019.02); B29C 48/911 (2019.02); B29C 48/919 (2019.02); B29K 2023/06 (2013.01); B29K 2023/12 (2013.01); B29K 2027/06 (2013.01); B29K 2067/00 (2013.01); B29K 2077/00 (2013.01); B29K 2105/0005 (2013.01); B29K 2105/16 (2013.01); B29L 2031/3462 (2013.01); C08G 77/04 (2013.01); Y10T 29/49117 (2015.01)]
OG exemplary drawing
Attention is directed to the decision of 4:23-cv-00821 Encore Wire Corporation v. Southwire Company, LLC relating to this patent. This reexamination may not have resolved all questions raised by this decision. See 37 CFR 1.552(c) for ex parte reexamination and 37 CFR 1.906(c) for inter partes reexamination.
 
AS A RESULT OF REEXAMINATION, IT HAS BEEN DETERMINED THAT:
The patentability of claims 1-20 is confirmed.
1. A lubricated thermoplastic high heat-resistant nylon-coated (THHN) electrical cable having a reduced installation pulling force through a building passageway defined by a PVC conduit setup sized to accommodate the THHN electrical cable and having at least two 90° bends within the PVC conduit setup, the lubricated THHN electrical cable comprising:
at least one conductor capable of carrying an electrical current through the THHN electrical cable, wherein the conductor is formed at least in part from a metal; and
a sheath defining an interior surface and an exterior surface, wherein the sheath surrounds the at least one conductor such that the interior surface is adjacent the at least one conductor, and wherein the sheath comprises:
an insulating portion defining at least a portion of the interior surface, wherein the insulating portion surrounds the at least one conductor and provides electrical insulation to the conductor, wherein the insulating portion is formed at least in part from extruded polyvinyl chloride (PVC);
an outer portion defining at least a portion of the exterior surface, wherein the outer portion comprises an extruded nylon material; and
at least two lubricant components comprising:
a processing lubricant provided in at least one of the insulating portion or the outer portion; and
a pulling lubricant provided at the exterior surface to reduce the amount of force required to pull the cable through the building passageway; and
wherein the outer portion is both resistant to heat, moisture, oil, and gasoline and provides the THHN electrical cable with a physical characteristic of requiring at least about 30% less force to pull the electrical cable through the building passageway compared to an amount of force required to pull a non-lubricated THHN electrical cable having a sheath without the pulling lubricant present through the building passageway.