Abstract: A combination 37-wire unilay stranded conductor includes a 19-wire stable unilay construction includes two layers of wires on a core wire, each having a diameter D, to define a hexagon that circumscribes the 19 nineteen wires. A corner wire is positioned at each corner of the hexagon, the corner wires being formed to provide bearing surfaces facing radially outwardly and defining a circle having a diameter of approximately 4.7 D. A third layer of wires includes a smaller diameter wire having a diameter of approximately 0.8 D contacting each bearing surface, and pairs of two wires each having diameters D are positioned between the smaller wires and are nested in a recess formed by two wires in a preceding underlying layer to define a substantially circular outer cable configuration.

Abstract: Apparatus and method for manufacturing helically wound insulated conductors with filament fillers includes first and second payoff stations for paying off a plurality of insulated conductors and elongate filaments of filler materials. These cable components are guided from the payoff stations to a closing die, and are arranged in positions suitable for twisting into a cable by a double twist machine to form a cable of twisted insulated components forming radially outwardly facing helical interstices each of which is substantially filled with another one of the filaments of filler material. Differential or incremental lengths of filler material are metered upstream of the double twist machine to compensate for the differences in the radial distances of the insulated conductors and filaments of filler material on the center or cable of the axis.

Abstract: An apparatus is disclosed for manufacturing communication cables with improved, more uniform impedance characteristics at signal frequencies up to and above 600 MHz. The apparatus includes an “inside-out” rigid twisting machine and at least two bobbins supported within each such machine. Each rigid twisting machine includes a drive for spinning each of the bobbins about their respective axes, and fly-off arrangement is provided for flying off an insulated conductor wire wound on each of the bobbins with substantially no tension in the wire when the bobbin attains a first rotational speed. Guides are provided for guiding the wires from each of the bobbins to a closing point where the wires are closed. A double twist bow arrangement is provided which includes second drive for twisting the closed wires at a second rotational speed to form a twinned cable.

Abstract: A multi-wire stranded conductor is formed of a bare wire central core. An intermediate SZ stranded wire is wound on the core, while an outer layer is helically wound on the intermediate SZ wound layer. The intermediate and outer layers assure that the composite conductor maintains a substantially circular cross-section while the helical outer layer also assures the mechanical integrity of the intermediate SZ layer.

Abstract: A filament applicator includes a frame which defines a machine axis through which an elongate element may be guided at an application station at which filaments are to be applied to or introduce into the elongate element, such as an optical cable. A plurality of chambers are provided, each of which defines a chamber axis substantially parallel to the machine axis and mounted on the frame for rotation about the machine axis. Each chamber is substantially closed and has a panel at an axial end of the chamber which is movable between an open position for inserting and removing a wound package of filament material within the chamber and closed position for substantially sealing the chamber and preventing air turbulence within the chamber upon rotation about the machine axis. Each panel has an opening therein through which the filament material can be removed from the wound package.

Abstract: An apparatus is disclosed for manufacturing communication cables with improved, more uniform impedance characteristics at signal frequencies up to and above 600 MHz. The apparatus includes an "inside-out" rigid twisting machine and at least two bobbins supported within each such machine. Each rigid twisting machine includes a drive for spinning each of the bobbins about their respective axes, and fly-off arrangement is provided for flying off an insulated conductor wire wound on each of the bobbins with substantially no tension in the wire when the bobbin attains a first rotational speed. Guides are provided for guiding the wires from each of the bobbins to a closing point where the wires are closed. A double twist bow arrangement is provided which includes second drive for twisting the closed wires at a second rotational speed to form a twinned cable.