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.