Abstract: A process and apparatus for fabricating an optical fiber communication cable are described herein. The optical fiber cable has a cable core including a metal containment tube and at least one optical fiber within the tube. The containment tube preferably is formed by drawing a strip of metal through at least one forming die. In a first aspect of the present invention, smooth operation of the forming die is promoted by first passing the metal strip through a shaving die to remove any shearing burrs along the strip edges and to maintain the width of the strip within a desired tolerance.In a second aspect of the present invention, various approaches for effectively sealing the containment tube are described. In a first embodiment, the tube is sealed using a wave soldering approach wherein a flow of moving molten solder is used to substantially fill a seam in the tube.

Abstract: The present invention relates to a process and apparatus for fabricating optical fiber cables having improved hermeticity. The optical fiber cables are formed by first reducing the water content of the buffer material surrounding each optical fiber. Thereafter, the dried optical fiber(s) are encapsulated into a metal or metal alloy tube. After fiber encapsulation, the tube may be sealed to prevent the ingress of moisture and/or water from the surrounding environment.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy consisting essentially of about 3% to about 20% nickel, about 5% to about 10% aluminum, and the balance essentially copper, is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 5% to about 40% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A technique for repairing or joining lengths of ultra-fine, small diameter optical fiber cables is described. The technique comprises: positioning a hollow cylindrical ferrule over one of two cable portions; forming a splice joint between the optical fibers to be joined together; forming a protective buffer layer about the splice joint; sliding the ferrule over the protective buffer layer and into overlapping relationship with each cable portion; and bonding the ferrule to each cable portion. An apparatus for performing the repair or joining technique is also described.

Abstract: A method for repairing or joining together optical fiber cables is described herein that uses a ferrule to connect two optical fiber cable lengths. Each cable length comprises a metal tube containing one or more optical fibers and a filler material. The ferrule is placed in overlapping relationship with each tube and a lap joint is effected between the ferrule and each tube. An outer sleeve having a length substantially equal to a gap between the tubes is formed about the ferrule and is bonded to each tube. The outer sleeve preferably has an outer periphery substantially corresponding to the outer periphery of the tubes so that the joined cable has a substantially continuous surface. A kit for performing the method is also described.

Abstract: A two-pole ruggedized optical fiber cable suitable for use in communication applications is described. The cable has a core assembly comprising a sealed inner copper alloy tube in which at least one optical fiber is encapsulated. Surrounding the core assembly is a layer of dielectric material, an outer metallic tube and, if needed, a protective jacket. The outer tube's primary function is to serve as the cable's primary strength member. The outer tube is preferably formed from a high strength, non-ferrous alloy having a relatively low modulus of elasticity. The outer tube is preferably a drawn tube having a substantially straight axial seam. If added hermeticity is required, the outer tube seam may be sealed. A process and apparatus for fabricating the cable is also described.

Abstract: The present invention relates to an improved die configuration. The die comprises a body member having an interior passageway defined by a bell portion and a land portion. To improve die efficiency, the bell and land portions are provided with a helical groove for removing solid particles which may dislodge from the workpiece during its passage through the die and may interrupt smooth die operation. A technique for using the die to form a tube is also described.

Abstract: An individually armored fiber optic core assembly having a diameter less than about 0.050" is provided as well as a process for making same. A fiber optic core comprising a fiber optic element and a surrounding protective layer is encased within a drawn metal sheath having a generally longitudinally extending seam. The ratio of the outside diameter of the fiber optic core to the inside diameter of the metal sheath is at least about 0.6:1.

Abstract: A process and apparatus for fabricating an optical fiber cable assembly without significantly increasing the light attenuation in the optical fiber or fibers is described. An optical fiber assembly formed in accordance with the present invention comprises at least one optical fiber encapsulated within a metal or metal alloy tube. The tube is preferably formed using a draw forming technique of pulling a metal or metal alloy tape through at least one forming die. To compensate for the compressional strain induced in the fiber or fibers by tube springback upon relaxation of the pull force and to minimize increased light attenuation in the fiber or fiber, a back tension is imparted to each optical fiber during cable assembly. In a preferred embodiment, the back tension is imparted to each fiber by an accumulator about which the optical fiber is wound.

Abstract: A process for die forming a tubular member from a metal or metal alloy strip at a reduced drawing force is described herein. The process uses shaping of at least one edge portion of each strip prior to drawing each strip through a die. The shaping reduces the drawing force exerted on the strip material and/or any joint.

Abstract: A process and apparatus for fabricating an optical fiber communication cable are described herein. The optical fiber cable has a cable core including a metal containment tube and at least one optical fiber within the tube. The containment tube preferably is formed by drawing a strip of metal through at least one forming die. In a first aspect of the present invention, smooth operation of the forming die is promoted by first passing the metal strip through a shaving die to remove any shearing burrs along the strip edges and to maintain the width of the strip within a desired tolerance.In a second aspect of the present invention, various approaches for effectively sealing the containment tube are described. In a first embodiment, the tube is sealed using a wave soldering approach wherein a flow of moving molten solder is used to substantially fill a seam in the tube.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A process and apparatus for providing metal material having an improved structure for forming into a desired article is disclosed herein. The improved structure is obtained by slurry casting a material into a continuous member and then hot working the slurry cast material. Upon reheating to a semi-solid state, the hot worked, slurry cast material will exhibit finer particles and fewer eutectic melting rosettes than would be exhibited by the slurry as-cast material in an unworked and heated condition. The hot working of the slurry cast material produces an article having a deformed structure exhibiting directionality.

Abstract: A method and apparatus for assembling an optical fiber communication cable comprises forming a tubular member out of a strip of metal or metal alloy and sealing the tubular member. After the tubular member has been sealed, at least one optical fiber and a cushioning material are deposited into the member.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A system for machining and sizing optical fibers is described herein. The system uses a laser beam to machine oversized regions of a buffer material surrounding an optical fiber to create a coated optical fiber having a substantially uniform maximum outer dimension that is within a desired tolerance specification. The machining of the buffer material to size the optical fiber is accomplished by generating at least one laser beam transverse to the buffer material, rotating the beam or beams about an axis coaxial with the optical axis of the optical fiber, and moving the fiber past the rotating laser beam or beams. The rotating laser beam or beams vaporize any excess or oversized regions of buffer material and substantially provide the optical fiber with the desired outer dimension or diameter.

Abstract: A method and apparatus for assembling an optical fiber communication cable is disclosed herein. The cable has a tubular core formed from a strip of composite material. The composite material has a first layer of high strength metal or metal alloy, a plurality of electrical conductors formed by a material having a conductivity in excess of 50% IACS, and an electrical insulating material separating the first layer and the electrical conductors. At least one optical fiber is located within the tubular core.

Abstract: A method and apparatus are disclosed for fabricating an optical fiber communication cable having a metal containment tube and at least one optical fiber in static compression therein. The containment tube is preferably formed by applying a tensile load to a strip of metal and drawing the strip of metal through at least one forming die. Each fiber is inserted into the forming tube without the application of any significant tension. As a result, each fiber is in a substantially no-load condition at the same time that the strip is undergoing maximum plastic extension and said tube is undergoing elastic tension from the applied tensile load. Upon release of the tensile load, the tube will shrink and each fiber is placed into static compression.

Abstract: An apparatus and a method for forming a semi-solid thixotropic slurry. The apparatus includes a duplex mold arrangement for postponing solidification within the mold until the molten metal is within a magnetic field for providing magnetohydrodynamic stirring. The duplex mold includes a first portion of low thermal conductivity and a second portion of high conductivity.

Abstract: A process and apparatus for continuously and semi-continuously casting molten metals and alloys. Control of the initial stages of solidification is carried out through application of a thermal insulating layer on the coolant side of a casting mold wall. The layer modifies the heat flux characteristics of the mold along a selected length thereof.