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Abstract

An electrostatic spray system including a spray device having an electrode for electrostatically charging coating particles emitted from the spray device toward an article to be coated, a high voltage electrostatic supply, and a high voltage insulated electrical cable interconnecting the electrostatic supply and the spray device electrode. The high voltage cable includes a fibrous resistive core, preferably fabricated from silicon carbide fibers, a fiber-restraining layer of insulative thread tightly wrapped spirally around the entirety of the core to prevent fiber ends from projecting outwardly from the core, an outer dielectric sheath, and an intermediate sheath sandwiched between the spirally wound inner fiber-restraining layer and the outer dielectric sheath and having a resistivity lying between that of the inner resistive fiber core and the outer dielectric sheath. The intermediate sheath provides uniform voltage stress distribution in the region surrounding the resistive core, thereby avoiding internal corona sites which cause degradation of the outer dielectric sheath, which might otherwise occur due to the very small diameter of the resistive core coupled with the very high operating voltages used in electrostatic spray coating operations. The intermediate sheath also avoids high voltage stresses at the ends of stray resistive fibers projecting through the spirally wound layer, which might otherwise occur due to the extremely small diameter of the projecting fibers.

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