Abstract: A lightguide fiber preform is made by depositing optically suitable layers of doped silicon dioxide on an inner wall of a rotating glass substrate tube (31) which is exposed to a moving zone of heat during a deposition mode and during a mode when the tube is collapsed. During each of a plurality of passes of a torch assembly (50) in the collapse mode following deposition, a contact device (101) is in continuous engagement with the tube and is caused to apply forces to each successive increment of its length following exposure to at least an initial portion of the zone of heat to collapse incrementally the tube. Between successive ones of the plurality of passes, the contact device is moved inwardly of the tube so that each increment of length is exposed to forces which as between the successive passes are applied at points incrementally closer to the longitudinal axis (36) of the tube.

Abstract: An elongated metallic conductor is insulated with an inner layer of a plasticized polyvinyl chloride composition and an outer layer of a plasticized, irradiation cross-linked polyvinyl chloride composition. The outer layer has a low coefficient of friction to facilitate pulling in central office racks, has mechanical properties which are required for installation and use and, in a preferred embodiment, has a thickness which is substantially less than that of the inner layer. The layers are extruded in the same extruder crosshead that seemingly causes the outer layer to bond to the inner layer to facilitate stripping of the composite insulation from the conductor.

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: A preform from which lightguide fiber is drawn is made by depositing optically suitable layers of doped silicon dioxide on an inner wall of a rotating glass substrate tube which is exposed to a moving zone of heat during a deposition mode and during a collapse mode. During at least a first pass following the deposition mode, a contact device is caused to engage each successive increment of length of the tube during exposure to the zone of heat. The contact device causes any sagged or offset portions of the tube to be reconfigured and causes the tube to have a central longitudinal axis which is a straight line which extends between stocks of a lathe by which ends of the tube are supported. The contact device may also be used to cause the tube to have a predetermined configuration along its length.

Abstract: A cable shielding method and apparatus are disclosed wherein adhesive 42 is applied to a strip 40 of shielding material within a shield forming die 20 as the strip 40 is being formed about a cable core 10 with an overlapped shield seam.

Abstract: A modular tricoupler (30) is provided for interconnecting lengths of inside wiring in series within walls, for example, of customer premises and to a network interface device (42, see FIG. 3B). The tricoupler also includes provisions for receiving a modular plug (31) which terminates a cord (36) that is connected to customer station equipment. The tricoupler includes a housing (80) having first and second generally opposed plug-receiving cavities (82, 83) and a third cavity (87). A plurality of metallic wire-like contact elements (90-90) are disposed in the housing of the tricoupler and maintained spaced apart by partitions (96-96). One end portion of each contact element extends into the second cavity and the other end portion into the third cavity. Blade-like terminals (60-60) of a modular plug which is inserted into the first cavity engage loop portions (131-131) of the contact elements. The loop portion of each is designed and is supported so that the entire loop shifts when engaged by the terminal.

Abstract: An electrical connector which is capable of being used to interconnect insulated conductors (21--21) the field or in a factory during in-line processing includes a base (22) and contact element (24). The contact element which is used to establish an electrical connection between the conductors includes a center (24) portion and two opposed bifurcated beams. A portion of each beam is upstanding from the plane of the contact element. Furcations of each beam define a slot (47) for receiving one of the conductors to be interconnected. The contact element is attached to the base which includes at least one deformable tang (31) at each end. End portions of conductors to be connected are each positioned across an end of the base. The tangs are wrapped about the conductors, the conductors are moved into the slots of the beams, and excess portions of the lengths severed.

Abstract: A terminal arrangement for interconnecting electrical conductors includes a plastic block (121) in which are supported a plurality of terminals (20--20) arranged in rows and columns. Each terminal is formed from a flat strip (81) of metallic material as the strip is advanced through a progressive punch and die apparatus. The terminal includes a first portion 21 which has a seam 33 that is welded to join butted longitudinal edges of that portion after it has been formed into a cylindrical shape from a flat blank on the strip. After its seam has been welded, the first portion is internally threaded to receive a terminal screw. A second portion 51 of the terminal, which is formed integrally with the first portion, has a generally square cross-section. The second portion of each terminal is disposed in a similarly configured cavity (127) of the plastic block to prevent relative rotational movement between the terminal and the block.

Abstract: Retractile cords disposed in a U-shaped configuration are arranged about the periphery of a turntable with the ends of each cord adjacent to the peripheral edge being terminated with modular plugs. As a cord having its ends terminated with modular plugs is moved into a last work station, a pickup arm removes the cord. As the plug-ends are moved outwardly from the turntable, a middle section of the U-shaped cord is engaged by a snagging pin that is moved into one portion of a foldable tray to hold the middle section of the cord as the plug ends are moved farther along above the tray. The plugs are released, and the cord retracts and drops into the tray. Then the snagging pin is retracted, and the tray is caused to be folded to form an opening beween portions of the tray. The cord descends through the opening into an open end of a bag formed between two plies of a plastic material. The plies are bonded together adjacent to the open end and the bag is separated from its supply.

Abstract: In an accumulating and a splicing apparatus (30), a nearly exhausted tape (31) is advanced at a line speed along a path which extends between two groups (49, 51) of rollers. One of the groups of rollers is moved upwardly to a position above the other group of rollers and a length of the nearly exhausted tape is accumulated in a sinusoidal path just prior to splicing. The nearly exhausted tape is clamped at an input side of the accumulator after which a severing device (104) is moved transversely across that tape to form a trailing end portion. The severing device is allowed to be spring-returned to a position above the nearly exhausted tape and to one side thereof which permits joining facilities to carry a leading end of a tape (35) of a new supply downwardly to be spliced to the trailing end portion of the nearly exhausted tape.

Abstract: A protector module (30) for protecting tip and ring conductors of a telephone loop includes a pair of protector assemblies (40-40') which are supported within a common housing (32). A voltage protection subassembly (42) of each protector assembly is connected electrially to a grounding subassembly (44) for causing current associated with excessive voltage surges to be conducted to ground. Each protector assembly also includes a current protection subassembly (41) which comprises a dielectric base and a line pin (61) and a central office pin (57) with the line and central office pins being connected together electrically to establish electrical contact between a conductor of the circuit and its protector assembly. A shunting element (62) is disposed concentrically about the line pin and is releasably secured to one end of the line pin in an initial position by a fusible bonding material.

Abstract: Apparatus for detecting a twisted pair (21) of conductors includes contact means (60) in the form of a generally semi-circular rocker. One diametrical end portion of the rocker rides on portions of the twisted pair of conductors as they are advanced over a sheave (34). The opposite diametrical end portion of the rocker is caused to be supported in alignment with a sensor (81). Should one of the conductors be missing, perhaps because of a break or equipment malfunction, the rocker is no longer caused to be maintained in a position such that the opposite end portion is aligned with the sensor. This causes the sensor to provide a signal indication of a break and because of its changed position to provide a visual indication to an operator.

Abstract: A contact element for establishing an electrical connection between two insulated conductors includes a tubular member having at least one open end and being made of an electrically conductive material. The tubular member includes surfaces that define a slot which extends from the open end and which has a width that is less than the diameter of the conductive elements of the insulated conductors. The tubular member has sufficient stiffness and the slot is configured to cause at least portions of the surfaces that define the slot to nick the conductive element of each of one or more conductors that are moved into and along the slot. Any deflection of the slot surfaces which accompanies the movement of one or more insulated conductors into the slot is substantially negligible.

Abstract: In the manufacture of a lightguide fiber cable (21) in which a lightguide fiber core (32) is loosely disposed in a composite sheath 40 it is important to control the ratio of the lengths of the core and sheath. A core which is shorter than the sheath and which follows a shortened path on a reel may be unduly strained when the cable is installed in the field. This problem is overcome by coupling the core to the sheath by a system (25) which includes a constant speed linear capstan (146) and a relatively large variable speed sheave (150) that is positioned between the linear capstan and a takeup reel (154). The coupling of the core to the sheath is accomplished on the sheave after the sheath is elongated between the linear capstan and the sheave. The coupling and the elongation cooperate to compensate for the inherent shortfall in core length which otherwise would occur when the cable is wound on a reel.

Abstract: During the manufacture and/or packaging of insulated conductors, insulation defects are detected, measured, and classified by the methods and apparatus of this invention. As a twisted pair of insulated conductors (21-21), for example, is advanced along a manufacturing line (25), the insulation covers (23-23) are engaged by a probe (32) which is connected to a source of electrical power and to an electrical circuit (30). The circuit is adapted to process signals received from the probe and to make comparisons with stored signals to indicate the occurrence of pinholes, faults or bare wire in the insulation covers. In order to be accurate in its comparison and classification, the circuit includes provisions for correcting for current flow between the probe and the metallic conductors prior to and subsequent to the pair being moved through the probe and for the thickness of the probe.

Abstract: A cable which is capable of being made in a large pair size and yet which has excellent mechanical properties that maintain its integrity notwithstanding extremes in temperature during installation and shipping as well as during the rigors of installation includes a sheath system having a corrugated steel outer shield that is adhesively bonded to a plastic jacket. The corrugated steel shield which is formed to have a longitudinal overlapped seam that is preferably unsealed encloses an aluminum inner shield that in turn encloses a multiconductor core. Advantageously, the sheath system includes a plastic jacketing material which is capable of resisting biaxial stresses which are aggravated in a bonded sheath system. This results in jacket integrity about the longitudinal seam of the outer shield notwithstanding a notched cross-section and an unsupported bridged portion of the plastic jacket adjacent to the seam.

Abstract: An elongated metallic conductor is insulated with an inner layer of a plasticized polyvinyl chloride composition and an outer layer of a plasticized, irradiation cross-linked polyvinyl chloride composition. The outer layer has a low coefficient of friction to facilitate pulling in central office racks, has mechanical properties which are required for installation and use and, in a preferred embodiment, has a thickness which is substantially less than that of the inner layer. The layers are extruded in the same extruder crosshead that seemingly causes the outer layer to bond to the inner layer to facilitate stripping of the composite insulation from the conductor.

Abstract: A tinned conductor is advanced through each of a plurality of successively smaller die openings in a drawing apparatus to reduce the diameter of the tinned conductor after which it is annealed. After the tinned conductor has been annealed, it is moved through the opening of a die which is slightly smaller than the final die opening in the drawing apparatus. This reconfigures any of the tin coating that may have reflowed during annealing and formed protrusions to remove any such protrusions and form an essentially smooth surface. As a result, the adhesion of a subsequently extruded plastic covering to the tinned conductor is controlled to be within a predetermined range and to be substantially uniform along the length of the conductor.

Abstract: A cable of this invention includes a number of pulp-insulated conductor pairs per unit of cable cross-sectional area which is substantially greater than in prior art cables. Each pulp-insulated conductor includes a metallic conductor enclosed in a composite insulation cover which has a controlled dielectric constant and a controlled adhesion of the cover to the conductor. The composite cover comprises a pulpous material and a layer of adhesive material which is interposed between the conductor and the pulpous material. The layer of the adhesive material bonds the pulpous material to the conductor and allows a reduced thickness of pulpous material without degrading the transmission characteristics of the cable. Also, the mechanical integrity of the insulation cover permits the moisture content of the pulpous material to be reduced and the density increased over that achieved in prior art pulp-insulated conductors without causing bare spots in the insulation.

Abstract: A trifurcated terminal (10) which is mounted in an aperture (52) in a plastic terminal block (51) is made from flat metallic material and includes a base having a center beam and two lateral beams (18-18) extending therefrom. Portions of the beams define conductor-receiving slots (31-31) having entries (23-23) which establish electrical engagement with insulated conductors (11-11). The center beam includes a locking element (71) which protrudes from one side thereof and which is received in a recess (72) that communicates with the aperture in the plastic block to support the center beam against substantial deflection during insertion of the conductors in either slot. This arrangement permits the beams to be proportioned to engage and retain the conductors without damaging them while having widths which do not cumulatively exceed the width of priorly used terminals in order to preserve the density of a plurality of terminals in a predetermined geometrical arrangement in the terminal block.