Abstract: A method for manufacturing an electrical cable includes dividing a tube into a plurality of sectors by passage across a sectoring device, gathering the sectors into a stack by passage of the sectors through a gathering device, and surrounding the stack with an insulating layer. Additional strip features may be applied by application of one or more strip conditioners. Alternatively, strips may be supplied on individual reels for gathering or provided in a multi-end reel already stacked. Where a multi-end reel is provided, length differentials within the stack as it is unwound may be compensated for by application of a stretcher.

Abstract: A method for manufacturing an electrical cable includes dividing a tube into a plurality of sectors by passage across a sectoring device, gathering the sectors into a stack by passage of the sectors through a gathering device, and surrounding the stack with an insulating layer. Additional strip features may be applied by application of one or more strip conditioners. Alternatively, strips may be supplied on individual reels for gathering or provided in a multi-end reel already stacked. Where a multi-end reel is provided, length differentials within the stack as it is unwound may be compensated for by application of a stretcher.

Abstract: A coaxial cable includes: a metallic inner conductor formed of a first material and having a first thickness; a dielectric layer circumferentially surrounding the inner conductor formed of a second material and having a second thickness; a metallic outer conductor circumferentially surrounding the dielectric layer formed of a third material and having a third thickness; and a polymeric jacket circumferentially surrounding the outer conductor formed of a fourth material and having a fourth thickness.

Abstract: A coaxial cable includes: a metallic inner conductor formed of a first material and having a first thickness; a dielectric layer circumferentially surrounding the inner conductor formed of a second material and having a second thickness; a metallic outer conductor circumferentially surrounding the dielectric layer formed of a third material and having a third thickness; and a polymeric jacket circumferentially surrounding the outer conductor formed of a fourth material and having a fourth thickness.

Abstract: An electrical communications element having a foamed plastic insultation extruded about a conductor with said insulation including at least one component with more than 20% by weight of an ultra-high die swell ratio polymer (UHDSRP), preferably around 15% by weight. The UHDSRP is defined as greater than 55% die swell ratio and more preferably greater than 65% die swell ratio. The insulation also preferably includes at least a second component with a high degree of stress crack resistance, such that the combination of (minimally) these polymers will yield an insulation layer that has a unique combination of physical propeties yielding a high degree of foaming, small uniform cell structure, characteristically lower attenuation, and stress crack resistance capable of withstanding greater than 100 hours at 100° C. while coiled at a stress level of 1 times the insulation outside diameter without failure (cracking).

Abstract: An electrical communications element having a foamed plastic insulation extruded about a conductor with said insulation comprising at least one component with no more than 20% by weight of an ultra-high die swell ratio polymer (UHDSRP), preferably around 15% by weight. The UHDSRP is defined as greater than 55% die swell ratio and more preferably greater than 65% die swell ratio. The insulation also preferably comprises at least a second component with a high degree of stress crack resistance, such that the combination of (minimally) these polymers will yield an insulation layer that has a unique combination of physical properties yielding a high degree of foaming, small uniform cell structure, characteristically lower attenuation, and stress crack resistance capable of withstanding greater than 100 hours at 100° C. while coiled at a stress level of 1 times the insulation outside diameter without failure (cracking).

Abstract: A coaxial cable includes: a metallic inner conductor formed of a first material and having a first thickness; a dielectric layer circumferentially surrounding the inner conductor formed of a second material and having a second thickness; a metallic outer conductor circumferentially surrounding the dielectric layer formed of a third material and having a third thickness; and a polymeric jacket circumferentially surrounding the outer conductor formed of a fourth material and having a fourth thickness.

Abstract: A composite fiber optic and electrical cable having a core which loosely contains at least one optical fiber, one or more electrical conductors having an outer polymer insulating layer, one or more strength members and a surrounding protective jacket. The protective jacket is formed of a polymer material which forms a distinct mechanically separate phase from the polymer material forming the insulation layer surrounding the respective electrical conductors. For example, the jacket can be made of a polymer material having a melting temperature lower than the melting temperature of the insulating material of the electrical conductors. As a result, the polymer jacket does not bond with the insulating material during production of the cable. The jacket can, thus, be easily stripped from the electrical conductors during installation of the cable to facilitate the attachment of the electrical conductors to a signal repeater, or power source, or other electrical devices.

Abstract: A composite fiber optic and electrical cable having a core which loosely contains at least one optical fiber, a pair of copper clad steel electrical conductors having an outer polymer insulating layer, and a polymer jacket. The jacket is made of a polymer material having a melting temperature lower than the melting temperature of the insulating material of the electrical conductors. As a result, the polymer jacket does not bond with the insulating material during production of the cable. The jacket can thus be easily stripped from the electrical conductors during installation of the cable to facilitate the attachment of the electrical conductors to a signal repeater, or power source, or other electrical device. The cable is manufactured by advancing the core and electrical conductors through an extruder which forms the jacket around the core and electrical conductors.

Abstract: An aerial self-supporting fiber optic cable includes a pair of longitudinal strength members extending along respective opposite sides of a core, and a jacket surrounding the core and strength members, wherein the jacket has a generally elliptical outer cross-sectional shape. A major transverse axis of the generally elliptical jacket is generally aligned with an imaginary line defined between the pair of longitudinal strength members. The cable core includes at least one elongate buffer tube and at least one optical fiber disposed within the buffer tube. The strength members has a predetermined tensile strength to support the fiber optic cable between adjacent vertical supports. The jacket may have a generally elliptical shape with an enlarged central lobe surrounding the core, and a pair of relatively smaller lobes on opposite sides of the central lobe and surrounding respective longitudinal strength members.

Abstract: A fiber optic cable and method for making the cable includes a plurality of buffer tubes positioned around a central member with three levels of color coding to enhance identification of individual optical fibers within the cable. Each of the buffer tubes has a predetermined color for identifying each individual buffer tube from the other buffer tubes, and a plurality of optical fibers are positioned within each buffer tube and arranged in a plurality of optical fiber bundles within each buffer tube. Each optical fiber bundle includes a binder yarn surrounding respective ones of the optical fibers with each of the binders having a predetermined color for identifying each individual optical fiber bundle from the other optical fiber bundles within a respective buffer tube. In addition, each of the optical fibers has a predetermined color for identifying each individual optical fiber from other optical fibers within a respective optical fiber bundle.

Abstract: A coaxial cable of the type used for a drop cable for cable television includes flat reinforcing wires forming a reinforcing covering for a foil shield. The coaxial cable includes an elongate center conductor, a surrounding dielectric material, and an outer conductor including the foil shield and the plurality of flat reinforcing wires forming the reinforcing covering for the shield. The flat reinforcing wires may be braided or may be wrapped to form a served covering. The flat wires are preferably sized to have a greater strength than conventional round wires. Therefore, a method for manufacturing the cable may advantageously include the steps of applying the flat wires and extruding an outer protective jacket continuously in tandem to thereby increase manufacturing efficiency.

Abstract: A method for controlling excess fiber length (EFL) in a loose tube optical fiber buffer tube which includes traversing a just extruded plastic buffer tube, containing optical fibers and a filling compound, through a vertical cooling tower along a buffer tube path of travel in the cooling tower where the cooling tower contains a water blocking device disposed at a predetermined point along the buffer tube path of travel and the water blocking device has a body containing (a) a chamber with inlet and outlet ports, defining a buffer tube path of travel aligned with the cooling tower path of travel, a conical shaped portion circumscribing a part of the buffer tube path of travel and an annulus shaped portion circumscribing the buffer tube path of travel and a portion of the conical shaped portion; (b) a device disposed near the outlet port for providing a stream of gas directed at the buffer tube path of travel; and, (c) a drain port to remove accumulated water from the annulus-shaped portion.

Abstract: Improved sheaves to be placed on utility or telephone poles or towers to facilitate aerial installation of messenger cable systems, such systems comprising a strength messenger having a communication cable helically wrapped around the messenger.

Abstract: A method and apparatus for increasing the line speed of an S-Z strander by applying a tensile force to the elongated accumulator of the strander, between 124 pounds and less than the elastic limit of the material from which the elongated accumulator is made, while the elongated accumulator is rotated in a reversing manner about its longitudinal axis and coated optical fibers and/or elongated tubes containing optical fibers are S-Z stranded thereabout.

Abstract: Apparatus for controlling excess fiber length (EFL) in a loose tube optical fiber buffer tube which includes traversing a just extruded plastic buffer tube, containing optical fibers and a filling compound, through a vertical cooling tower along a buffer tube path of travel in the cooling tower where the cooling tower contains a water blocking device disposed at a predetermined point along the buffer tube path of travel and the water blocking device has a body containing (a) a chamber with inlet and outlet ports, defining a buffer tube path of travel aligned with the cooling tower path of travel, a conical shaped portion circumscribing a part of the buffer tube path of travel and an annulus shaped portion circumscribing the buffer tube path of travel and a portion of the conical shaped portion; (b) a device disposed near the outlet port for providing a stream of gas directed at the buffer tube path of travel; and, (c) a drain port to remove accumulated water from the annulus-shaped portion.