Abstract: An exposed portion of an electrical cable is sealed by applying a sealant material to the exposed cable and then placing the ends of a split unitary cover over the sealant material in overlapped disposition. The cover is then compressed into contact with the sealant material. In repairing a damaged cable sheath, a reinforcing member may be placed over the sealant material prior to placing the cover thereover.

Abstract: An electrical cable for a submersible well pump has an internal fabric layer for providing additional hoop strength. The cable has a plurality of conductors. Each conductor is surrounded by an insulating layer that is permeable to gas. A woven fabric layer surrounds each insulating layer. An elastomeric jacket is extruded over and preferably bonded to each fabric layer. The jacket has flocked fibers to allow gas desorption while pulling the cable to the surface.

Abstract: A splice between two multiconductor cables is protected from ingress of water by a closure which is filled with a sealant which is pressurized by a bladder inside the closure to a pressure sufficient to force the sealant into the interstices of the splice and the interstices between the conductors in the cable, and the pressure is maintained by the bladder until the sealant cures or hardens.

Abstract: In the production of an optical fibre cable a core (3) of thermoplastics material is extruded with a plurality of longitudinally-extending grooves (15) in its outer surface around an electrical conductor (1) and is initially cooled: then following the introduction of one or more fibres (11) in at least one of the grooves the core assembly is passed through an induction heating unit (17) in which the conductor is heated to an extent sufficient to soften at least the adjoining region of the core, and the core is twisted to cause the grooves to take up a helical or periodically reversing helical path, and is again cooled to leave the grooves in that condition.

Abstract: A method for improving the electrical insulation of an electrode in a power transformer included in a converter plant of a high voltage direct current (HVDC) transmission system. The method involves winding around the electrode, layers of tape of woven or non-woven fibrous structure of non-conducting cellulose material, inorganic plastics material, or inorganic insulating material. This means that ions approaching the electrode, which are migrating under the influence of a high d.c. field outside the electrodes, do not sense the porous tape insulation as any noticeable obstacle, while at the same time the insulating layer is sufficiently dense to increase the breakdown value in the case of electrical surges.

Abstract: Magnet wire insulated with dielectric tape material of polyester overwrapped with aromatic polyamide is described. The tape can be spirally wrapped at high speeds onto the magnet wire substrate. The initial layer of polyester provides secure bonding of the subsequently wrapped polyamide layer. The wire is particularly useful in environments where abrasion resistant, high temperature stable magnet wire is needed which is capable of submersive use in oil and maintains its integrity when exposed to other corrosive environments.

Abstract: A bonded ASP cable includes a multiconductor core which is filled with a waterproofing material. The core is enclosed by a plastic layer (28) which is flooded with a waterproofing material. Wrapped longitudinally about the plastic layer is a corrugated inner shield (31) having a longitudinal seam (35) and having an outer surface covered with a waterproofing material. The inner shield is enclosed by a corrugated outer shield (36) which has an overlapped longitudinal seam (38) and which has an outer surface coated with a layer of an adhesive material. As the outer shield is being formed, a sealant material is introduced into engagement with the inner shield in the vicinity of the longitudinal edge portions of the outer shield. Then as the longitudinal edge portions of the outer shield are overlapped and engaged with each other, the sealant material is caused to flow into cavities between the two shields adjacent to the seam of the outer shield to form a gasket (66).

Abstract: An apparatus and method for making an armored electrical cable from a plurality of reinforcing struts and a plurality of electrical conductors covered by an armored jacket. The apparatus includes a series of stations along an assembly line that feed, converge, orient, combine, compress and wrap the struts and conductors into the cable configuration. The cross section of the cable so formed is rectangular, although this rectangular shape can be made arcuate by bending.

Abstract: A relatively small pair size cable (20) comprising at least one conductor (22) which is insulated with polyvinyl chloride plastic material is provided with a flame retardant, smoke suppressive sheath system (30). The sheath system has a relatively low thermal conductivity and provides a predetermined delay prior to the thermal decomposition of the conductor insulation. It includes a layer (31) of an impregnated woven glass material which has an air permeability that is sufficiently low to minimize gaseous flow through the layer of woven glass material and to delay heat transfer to the core for a predetermined time. The woven glass layer is wrapped about the core to have a longitudinal overlapped seam and is enclosed by an outer jacket (40) of a fluoropolymer plastic material which is extruded about the woven layer.

Abstract: Disclosed is a unitary re-enterable shielded jacket assembly for a plurality of insulated conductors provided with a dielectric spacer of nonconductive netting arranged and effective to provide a layer of air cells between the jacket shielding and the embraced conductors thereby to stabilize the impedance of the cable assembly from end to end thereof. One lateral edge of the dielectric spacer is attached to the jacket adjacent the inner shielding layer thereof and is sufficiently wide for its opposite edges to overlap when the jacket seam is closed. The dielectric spacer may be pleated lengthwise thereof to provide pockets for separate ribbon cables, the pleats being interconnected by hinges formed by groups of severed transverse strands which groups are separated by at least one unsevered transverse strand.

Abstract: A method of producing a leakage graded coaxial cable having a braided shield, in which ends of the shield wire are dropped as braiding progresses. Gaps in the shield having progressively increasing size are produced through which the radio frequency field leakage occurs, which facilitates providing a constant radio frequency field around the cable. The cable is coated with a jell flooding agent prior to extrusion of its protection jacket, which fills the interstices and gaps of the shield, and solidifies to a waxy, semi-resilient consistency. The resulting cable can be coiled and flexed, maintaining its shield reliability, and rejects water and fluids in case pinholes in the jacket occur.

Abstract: Methods and apparatus are provided for controlling the quantity and distribution of a waterproofing material (26) on an advancing strip (76) of plastic material which is wrapped subsequently about an advancing cable core (22) to form a core wrap. When the plastic strip is wrapped about the core, which has been filled with the same waterproofing material, the waterproofing material on the strip fills any spaces between the strip and the core, between the strip and an inner metallic shield (31) and a longitudinal overlapped seam of the core wrap. In another cable structure, a controlled amount of waterproofing material is disposed along a longitudinal edge portion of the advancing strip of plastic material to insure a sealed seam when the strip is wrapped about the core.

Abstract: A relatively small pair size cable (20) comprising at least one conductor (22) which is insulated with polyvinyl chloride plastic material is provided with a flame retardant, smoke suppressive non-metallic sheath system (30). The sheath system has a relatively low thermal conductivity and provides a predetermined delay prior to the thermal decomposition of the conductor insulation. It includes an inner layer (31) of an aramid fibrous material which has a relatively high compressibility, a relatively low heat absorptivity, and a relatively low air permeability. The inner layer is enclosed by an outer jacket (40) of a fluoropolymer plastic material which is extruded about the inner layer.

Abstract: The conductors of multi-conductor, medium voltage, power cables, at locations where the cable insulation has been removed, are insulated by positioning between the conductors or cores, an insert, at least the surface of which comprises a first void-filling material capable of forming a substantially void-free interface with each conductor, placing a second void-filling material over the conductors and recovering a dimensionally recoverable polymeric sleeve over the resulting assembly. The method is particularly useful to provide insulation between conductors of a joint between two multi-conductor, medium voltage power cables.

Abstract: A high voltage coaxial cable wherein a corona-free configuration is produced by applying a room temperature-curable silicone elastomeric material under pressure to the outer surface of the cable braid so that the material is forced between the voids of the braid and adheres to the primary insulation material at the insulation/braid interface.

Abstract: A bonded ASP cable includes a multiconductor core which is filled with a waterproofing material. The core is enclosed by a plastic layer (28) which is flooded with a waterproofing material. Wrapped longitudinally about the plastic layer is a corrugated inner shield (31) having a longitudinal seam (35) and having an outer surface covered with a waterproofing material. The inner shield is enclosed by a corrugated outer shield (36) which has an overlapped longitudinal seam (38) and which has an outer surface coated with a layer of an adhesive material. As the outer shield is being formed, a sealant material is introduced into engagement with the inner shield in the vicinity of the longitudinal edge portions of the outer shield. Then as the longitudinal edge portions of the outer shield are overlapped and engaged with each other, the sealant material is caused to flow into cavities between the two shields adjacent to the seam of the outer shield to form a gasket (66).

Abstract: A method of making an electrical cable in which an inner electrical conductor is loosely carried within the interior of an outer sheath. The inner conductor has a length in excess of the length of the sheath such that the cable is better able to withstand stretching and bending without damage to the inner electrical conductor.

Abstract: A method and apparatus for coating telephone cable or other continuous lengths of cylindrical objects with a continuous coating of molten thermoplastic sealant material. The cable or cylindrical object is passed through an annular array of nozzles operative to apply multiple beads of molten thermoplastic material to the surface of the cable or object. A liquid impervious casing is then placed over the bead coated cable while the beads are still in a molten state. The casing compresses the beads and forms them into a continuous coating of thermoplastic material surrounding the cable or object and contained within the liquid impervious casing.

Abstract: A reinforced insulated electrical cable and a method of forming the cable, which is especially useful in oil wells. The reinforcement comprises a thin tape of thermosetting material imbedded with an open-mesh fabric, the tape being spirally wrapped directly around the cable's insulation. The tape is wrapped in unvulcanized form and is then vulcanized in place over the insulation. The layer of open-mesh fabric is spaced from the outer surface of the insulation so that, during vulcanization, the insulation can radially outwardly expand without contacting and thus deforming the fabric, and at the same time the insulation can push part of the thermosetting material through the spaces in the fabric.

Abstract: A shielded ribbon cable is formed either by trimming a conventional ribbon cable to expose one or both edge conductors, and coating the cable by painting it with a conductive paint or covering it with an extruded conductive plastic layer, or by forming a ribbon cable of individually-coated wires, one or both edge conductors having a conductive coating, and subsequently painting it with a conductive paint or covering it with an extruded conductive plastic layer. One or both edge conductors thus serve as drain wires for the shield formed by the external covering of conductive paint or conductive extruded plastic.

Abstract: Disclosed is a method of making an insulated wire, the insulation of which can be easily removed from at least one location. The wire is covered at the desired location with a foil which does not adhere to the wire. The entire wire and foil are then covered with insulation. The insulation can be easily stripped from the wire at the location of the foil by cutting into the insulation at that location and peeling it off. Also disclosed is an insulated wire made by this method.

Abstract: Gas pressurized electrical cables, having a portion of an outer sheath removed for repair or splicing, are sealed while under pressure by providing at the exposed cable portion a gas pressure escape vent having a vent opening of area less than that of the cable exposed portion. Sealant tape is wrapped around the exposed cable portion and the vent exterior effectively sealing the entire exposed cable portion with the exception of the vent opening through which the gas escapes while such sealant tape is applied. The vent opening, being smaller than the original exposed cable portion, is readily sealably closed as by suitably plugging such vent opening and covering same with a sealant material.

Abstract: A method of forming an encapsulated splice region between two cable ends in which, after end portions of the core have been exposed beyond the jacket and sheath or shield, the conductors are splayed outwards and the cable end portions are brought close together. Splices are then formed between conductors of the two cables and the conductors are folded over either one cable jacket or the other to locate each splice upon and supported by the jacket. Each splice is individually covered with sealing material and end regions of the cables are encapsulated so as to encapsulate the splices and fluid tightly seal them.

Abstract: A process and apparatus for manufacturing a cable having a composite shield and armor sheath design is disclosed. The process comprises the steps of corrugating a laminated tape formed by bonding a plastic coated aluminum tape to a wider steel tape with one edge of the aluminum tape registering with one edge of the steel tape, forming the corrugated laminated tape around a cable core with the uncovered portion of the steel tape overlapping the registering edges of the laminated tape, and extruding an outer jacket of polyethylene over the corrugated laminated tape.

Abstract: Aluminum-shielded coaxial cable is repaired by using a wraparound metallic sheet, such as copper, having a contact means on the sheet, such as "dragon skin" brass strips, and a sealing means, such as a mastic. The metallic sheet provides the electrical continuity and radio frequency shielding and the sealing means provides the environmental seal to prevent moisture from entering the opening in the aluminum shield. The sheet and contact means are held in position by compression means, such as clamps, and the sheet and compression means can then be covered with a wraparound heat-recoverable closure to protect the entire assembly.

Abstract: The present invention comprises an improved apparatus and method for fabricating coaxial cable. Coaxial cable fabricated in accordance with the present invention comprises an inner conductive member encased in an annular electrical insulator, an outer electrically conducting sheath being annularly disposed about the insulator providing electrical shielding for the inner conductor. The improved apparatus and method for fabricating coaxial cable directs flattened malleable conductive strands for braiding the outer electrical sheath. The individual strands forming the braided sheath are each disposed about a cylindrical bobbin and fed about a pair of directing pins and positioners which position the flattened sheath material for entry into a braiding cone. Denatured alcohol lubricates the braiding cone during the braiding process in order to provide for uniform distribution of the braided sheath about the electrical conductor and insulator.

Abstract: A wraparound recoverable closure, wherein a portion of the closure is not recovered against a substrate, which has a flap to seal across the gap between the abutting edge portions of the closure. Where the closure does not recover against and contact a substrate, the flap does not seal adequately for some applications. This invention provides means for supporting the flap to improve the seal. The preferred embodiment is a bag inside the closure which contains a resilient liner which supplies pressure on the flap to seal the flap across said gap.

Abstract: A cable splice, branchout or termination has a heat recovered member (30) around one or more cable portions (33) extending out of an end of the member (30). The cable portion (33) is protected from physical damage and heat by placing around it individually a metal foil member (1), preferably aluminium of thickness 150-250 microns. The metal foil member is preferably coated with a hot melt adhesive (2) and a mastic (5) at distinct locations. A pressure sensitive adhesive (4) may also be provided to help secure the foil member (1) around the cable portion (33) before recovery of the outer member (30). Apertures (44) may be provided in the foil member (1) to allow passage therethrough of hot melt adhesive provided on the inner surface of the recoverable member (30).

Abstract: Methods and apparatus are provided for making a laminate which is used to form a corrugated outer shield (60) of a sheath system (50) for a lightguide fiber cable (20). A strip (81) of a corrosion-resistant metallic material having a relatively high elongation, an oxide surface layer (65) and a relatively coarse outer surface is preheated to a temperature within a predetermined range. Afterwards, a composite adhesive strip is brought into engagement with the metallic strip and moved between a pair of rollers (91--91) which are maintained at a first temperature and which causes the strips to be subjected to a predetermined pressure. Then the two strips are moved between another pair of rollers (97--97) which are at a second temperature greater than the first and which subject the strips to the predetermined pressure. The resulting laminate (61) is corrugated by a device (104) and formed into the outer shield (60) about an inner shield (51) which is made of a highly conductive metallic material.

Abstract: A low mechanical noise coaxial cable for suppressing noise due to mechanical movement of the cable wherein the cable includes a central conductor, a dielectric surrounding the conductor, electrical shielding embedded in conductive material surrounding the dielectric and preferably, jacketing structure holding the above recited elements in place.

Abstract: There is disclosed a method for fabricating an undersea communications cable containing optical fibers. The cable is fabricated so that fiber optical loss characteristics vary only slightly with changes in strain in the cable. During fabrication an adhesive bonds the cable core containing the optical fibers to a layer of steel wire for preventing creep therebetween.

Abstract: A strip (56) of non-metallic material and one (59) of a metallic material are wrapped simultaneously about an advancing cable core (32) to enclose partially the core. Then longitudinal edge portions (71, 72) of the strip of non-metallic material are separated by a shoe (150) which permits movement of the edge portions in a direction circumferentially of the core. One longitudinal edge portion (72) of the non-metallic strip becomes confined in a guideway (118) of a tool (99) and longitudinal edge portions (73, 74) of the metallic strip (59) are guided along guideways (117, 118) of the tool as the strips are moved through a converging passageway (103). This controls the relative circumferential movement between the edge portions as the strips are moved through the passageway to form a core wrap (33) and a shield (34).

Abstract: The insulating spacer for an h-f cable is extruded on the inner conductor, at approximately the correct dimensions, followed by a sizing step in which insulation powder is deposited on the horizontally running, insulated conductor core and melted in a funnel-shaped die to obtain a coating or film which establishes the final dimensions. The outer conductor is formed on top of that coating.

Abstract: A flexible lightweight short pulse power cable assembly for electrical power transmission, e.g., for transmission of electrical power at 20,000 volts at short pulse D.C. halfwave currents of 30,000 amperes. The cable for electrical transmission utilizes an inner conductor and an outer concentrically disposed conductor, the inner and outer conductors having substantially equal cross-sectional areas and consequent resistances to equal and opposite current flows in the respective conductors thereby placing the cable current forces in compressive balance and further reducing electro-magnetic interference from transmission of power through the cable.

Abstract: A cable breakout article (78) which is formed of a polymeric material and which is preferably heat-recoverable comprises a body portion and at least two tubes or outlet portions (91 to 94) leading from apertures in the body portion. The length and flexibility of the tubes (91 to 94) is such that at least one of them can be bent away from the other(s) to allow operations such as heat recovery to be carried out on an end portion of one of the tubes in isolation from the others.Preferably one or more of the tubes (95) is corrugated at least near its end adjacent to the body portion (78) so as to assist bending.

Abstract: A splice between at least two multi-wire electric cables is protected from ingress of water by forming a compressible reservoir about the splice, filling the reservoir with a curable liquid sealant, compressing the reservoir to force the liquid sealant to penetrate into the interstices between the individual wires of the splice bundle and into the adjacent cable core and maintaining the reservoir under compression at least for a time sufficient for the sealant to cure.

Abstract: An optical fiber submarine cable is made by extruding a metallic pressure tube by a friction extrusion technique, compressing the tube, applying tensile strength members, applying a conductive tape over the strength members and extruding plastic dielectric material over the tape. Armoring can subsequently be applied for shallow water application.

Abstract: A method of manufacturing a molded coil for use in an electric apparatus such as a molded transformer or a reactor. The method includes the steps of covering a winding with an insulating prepreg, curing the prepreg under heat, and casting a synthetic resin around the prepreg. The method makes it possible to minimize any thermal stress that may develop in the molded resin layer.

Abstract: A cable core, comprising conductors with insulation and carrying a conductive shield layer is protected and shielded by a corrugated metal tube cooperating either with individual, electrically conductive sealing rings, or a conductive helical sealing ribbon with foam filling any gaps. The construction ensures adequate space for thermal expansion of the insulation without undue tensioning of the tube. A method of making the assembly is described and examples for the ribbon and the foam are given.

Abstract: A dimensionally recoverable body, which is preferably heat-recoverable, has a body wall which is provided with a plurality of locking elements that are engageable with each other, or are engageable with corresponding elements located on a separate partition, to furcate the body into a plurality of channels.The body may be used for enclosing branch-offs in electrical cables in order to protect the enclosed branch-off from the environment.

Abstract: A shielded cable is provided having good electrical properties and which may be easily terminated. The cable includes an insulated conductor which is encased within a thermoplastic tape, a supported tape, and a metallic shield. The tapes are bonded together during a heating step so that any gaps or voids are eliminated by thermoplastic flow. They may also be peeled as a unit from the insulation during a terminating operation.

Abstract: An improved method of joining insulated conductors and providing a water-tight seal. The area about the joined conductors is filled with a putty-like insulation filler material and an O-ring placed on the conductor insulation, some distance from the joint. The joint, including the O-ring, is overtaped with resin-rich insulation tape and the tape is surrounded by a shrinkable polyester film. Heat is applied to partially cure the insulation tape, and to cause the polyester film to contract tightly about the joint.

Abstract: A remote control cable has a central core formed from two conducting wires separated over their entire length by a textile element with which the wires are in intimate contact, preferably slightly embedded therein, the whole being covered by a coating of a thermofusible material. The central core is strengthened by filamentary reinforcing elements arranged in parallel to the conducting wires and by at least one, preferably two, layers of braiding over the reinforcing elements. The central textile element maintains the conducting wires separated and parallel to each other during manufacture and under conditions of use. The cables may be used for transmitting signals, e.g. electrical pulses, to remote objects, for example, to transmit directions for controlling objects moving at high speeds, e.g. up to 300 m/second or higher and over distances up to 4000 meters or more.

Abstract: A method and apparatus to apply pulp to a telecommunications conductor with an adhesive which is formed from acrylic resin solution. The solution is applied in a bath and is passed between wiping rolls with the feed speed of the conductor and the differential speed between the peripheral surfaces of the wiping rolls and the conductor being controlled together with the contact angle between the conductor and the rolls. This control results in a dried thickness of resin of no greater than 0.00015 inches and as little as 20 microns after further stages in the method. These steps include drying the solution in a solution drying oven, coating the adhesive with pulp and drying the pulp coated conductor.

Abstract: A dielectric system for coaxial electrical conductors is provided. The dielectric system separates an inner and outer conductor and is composed of a first layer of braided high tensile strength polymeric fluorocarbon filaments in an open weave surrounding the inner conductor. Surrounding the layer of braided filaments is a continuous layer of a polymeric film which is in turn surrounded by a continuous layer of a crosslinkable polymeric lacquer enclosing both the layer of braided filaments and the layer of polymeric film.

Abstract: An armored cable and a method of manufacturing an armored cable, said cable having a helically wrapped zinc-plated steel armor. The steel armor band has zinc protective layer on its two sides, and uncoated edges, to reduce manufacturing costs and improve cathodic protection. The zinc protective layer thereby comprises a first layer portion consisting of a zinc-iron alloy and a second layer portion, on top of said first layer portion consisting of essentially pure unalloyed zinc and having a thickness of at least 90% of the total layer thickness.

Abstract: A closure for a telecommunications splice case is provided, which comprises a wraparound sleeve secured for example by a rail and channel closure. Re-entry is achieved by cutting of the old rails and channel and removing a central portion of the sleeve, and shrinking a new sleeve across the butts of the old sleeve. If the new sleeve is to seal properly, there must be no leak path along any gap between the remnants of the old rails. Deformations are provided on the flap of the original sleeve, or at the base of the short rail, to allow adhesive on the inside of the sleeve to fill the area between the rail.

Abstract: An improved power cable for a heating system that utilizes the skin effect of alternating current, and a method and apparatus for joining lengths of the improved cable. Lengths of the improved cable are joined by first removing predetermined portions of the insulating and semiconductor layers from a terminal end (50) and a feed end (52) of respective cable lengths. The exposed conductors (30') are mechanically joined and covered by a spirally wrapped carbonized TFE tape (60). An insulating layer (62) is formed over the junction by spirally wrapping uncured, nonadhesive tetrafluoroethylene tape with a 50% overlap and then heat fusing the layer. Shield extensions (66), (68) are formed by spirally wrapped, carbonized TFE tape that extend into noncommunicating, isolated overlapped relationship from the respective shield layers (38) of each cable end. The entire splice is covered with a layer of insulation (73) formed by uncured, nonadhesive TFE tape which is subsequently heat fused.

Abstract: A semiconductor packing substance for an undersea cable transporting electrical power, said cable having a core made of conductors 1 disposed axially, surrounded by a polyethylene layer 3 which is made semiconductive, then by a layer of insulating polyethylene (4). The packing substance is obtained by reticulating liquid nitrile rubber with carboxylic bonds and an epoxy resin to both of which is added a carbon black with a specific surface area at least equal to 100 m.sup.2 /g, an anti-oxidizing agent and a reticulation accelerator.

Abstract: A device and method for wrapping a wrapping material to form S-shaped shields around a cable core of two side-by-side core units in which two tubes are provided for passage of the core units. A space between the tubes accepts the thickness of a central region of the wrapping material which has side portions extending away from the central region. Concave turning surfaces extend partially around the tubes and approach each other as they extend towards an outlet end of the tubes. The core units pass along the tubes and the wrapping materials passes along between the tubes while the turning surfaces progressively turn the side portions inwardly towards and around the tubes whereby the side portions are turned around the core units when these emerge from inside the tubes. In a practical arrangement, the turning surfaces are formed by the inside surface of a frusto core.