Process for producing sealed electrical members

Claim 1

IN THE PROCESS OF PREPARING AN ENCAPSULATED ELECTRICAL MEMBER, THE ELECTRICAL MEMBER COMPRISING AN ELECTRICAL CONDUCTOR WITH SOLID INSULATION APPLIED THERETO, THE ELECTRICAL MEMBER HAVING IRREGULAR SURFACES, AND RELATIVELY LARGE APERATURES AND RECESSES OPEN AT THE EXTERIOR SURFACES OF THE MEMBER, THE STEPS COMPRISING CLOSING THE APERATURES AND RECESSES WITH A PASTY COMPOSITION SO AS TO LEAVE EXPOSED NO SURFACE OPENINGS GEATER THAN ABOUT 0.1 INCH ACROSS, APPLYING A FILLET OF THE PASTY COMPOSITION ABOUT ANY PROJECTIONS AND SHARP CORNERS WHEREBY TO PRODUCE A SMOOTHER, MORE ROUNDED SURFACE ON THE ELECTRICAL MEMBER, THE PASTY COMPOSITION COMPRISING ESSENTIALLY ONE PART OF BY VOLUME OF A FIBROUS INSULATING MATERIAL, FROM ONE TO FIVE PARTS BY VOLUME OF A FINELY DIVIDED INORGANIC SOLID, FROM 0.01 TO 0.1 PART BY VOLUME OF A HARDENABLE RESINOUS BINDER, AND SUFFICIENT VOLATILE SOLVENT TO RENDER THE MIXTURE PASTY SO THAT IT MAY BE MANUALLY APPLIED WITHOUT RUNNING OFF, THE PASTY COMPOSITION HARDENING TO A POROUS MASS WHEN HEATED, HEATING THE ELECTRICAL MEMBER AND THE APPLIED PASTY COMPOSITION TO DRIVE OFF THE ORGANIC SOLVENT AND TO LEAVE THE COMPOSITION IN A HARDENED, POROUS STATE, APPLYING A REMOVABLE CHANNEL-FORMING MEMBER TO THE UPPERMOST PORTION OF THE ELECTRICAL MEMBER AT A POINT WHERE THERE ARE FINE APERATURES LEADING TO THE INTERIOR OF THE ELECTRICAL MEMBER, COVERING THE ENTIRE OUTER SURFACE OF THE ELECTRICAL MEMBER WITH A COMPLETELY REACTIVE RESINOUS COMPOSITION OF A VISCOSITY TO BRIDGE ALL THE FINE APERATURES IN THE MEMBER WITHOUT SUBSTANTIALLY PENETRATING INTO THEM, POLYMERIZING THE COMPLETELY REACTIVE COMPOSTION TO PROVIDE A COMPLETE COVERING ABOUT THE ELECTRICAL MEMBER, WITHDRAWING THE CHANNEL-FORMING MEMBER THEREBY LEAVING AN OPENING THROUGH THE COVERING, VACUUM IMPREGNATING THE COVERED ELECTRICAL MEMBER THROUGH THE OPENING WITH A SECOND FLUID COMPLETLEY REACTIVE RESINOUS COMPOSITION OF A VISCOSITY WHEREBY IT PENETRATES AND FILLS ALL THE INTERIOR INTERSTICES OF THE ELECTRICAL MEMBER AND IMPREGNATES THE HARDENED COMPOSITION PREVIOUSLY APPLIED AS A PASTE, AND POLYMERIZING THE SECOND RESINOUS COMPOSITION.