Abstract: A cable coupling, particularly for data buses, includes a transformer and resistors to which the cables are directly wired. The components and all electrical connections are enclosed in a heat shrinkable tubing or sleeve filled with liquid encapsulant. Upon application of heat, the tubing shrinks causing the encapsulant to fill all voids between components. The encapsulant is then cured to provide an uncased coupling assembly which protects the components and electrical connections from breakage, while eliminating the need for a separate rigid housing. An overbraided shield and environmental seal may subsequently be added to provide further protection for the coupling.

Abstract: A method of and apparatus for removing underground telecommunications cable which involves excavating the earth at predetermined intervals, such as 100 to 150 feet, to expose a segment of cable, severing the exposed segment of cable, placing an air-tight cap on each end of the cable to be removed, evacuating the air out of the cable until the cable has collapsed via a vacuum device coupled to one of the caps, removing the caps from both ends and hitching a winch to one end, and applying a pulling force with the winch. If the cable is being removed for scrap, it may be necessary to cut the cable into pieces of a size which is sufficient for transportation. It may also be deemed necessary to remove and reapply the hitch as the cable is being removed. The same method may be used to remove telecommunications cable from manholes without the excavation step.

Abstract: In the manufacture of a cable core comprising a moisture-impermeable multi-wire conductor, the conductor is stranded in a conventional manner and, after a fluid-impermeable layer of plastics material has been extruded over the conductor to form the core, the core is wound around the hub of a cable drum in such a way that each end of the wound core is exposed and accessible. One exposed end of the wound core is sealed and air is evacuated from the conductor interstices by a vacuum pump cemented to the other exposed end of the wound core. A source of semi-conductive moisture-impermeable compound in a liquid or semi-liquid state is then connected to the exposed end of the wound core and moisture-impermeable compound is drawn into and flows along the evacuated conductor interstices until the interstices are filled throughout the length of the core. The moisture-impermeable compound in the interstices is then permitted to solidify or thicken to such an extent that it will not readily flow from the conductor.

Abstract: Epoxy-grafted, low molecular weight amorphous polymer compositions are employed in pourable, liquid telecommunication cable encapsulation compositions. Also disclosed is a method for encapsulating telecommunication cables as well as cables encapsulated with such an epoxy-grafted liquid encapsulant.

Abstract: Method and apparatus are provided for sealing an open end of a sheathed cable. After removing a length of insulating jacket, the open end of the cable is placed in a pressure block and a viscous sealant material is injected into the block and into the open end of the cable. After injection, the cable is removed from the block and the sealant allowed to cure to a gel-like consistency. Fluid which may invade the interior of the cable above the seal is, therefore, prevented from passing by the seal and entering a transducer or other instrument secured to the end of the cable. In the preferred embodiment, a cable head, O-ring and transducer body are also provided to enclose the transducer in a substantially waterproof housing.

Abstract: A spliced fiber is recoated by injection molding a jacket segment over the bare splice region. The dimensions of the recoated fiber approximate those of an undisturbed fiber, and the coating material may be selected to match the physical and mechanical properties of the original fiber jacket. A fixture is shown for performing the recoating.

Abstract: A method for manufacturing an optical cable includes simultaneously introducing a light waveguide and filling material into a chamber of a central element with the waveguide having an excess length. Preferably, the central element is moved axially and rotated on the axis and the light waveguide and filling material are passed through a tube which is inserted in the chamber as the central element is moved relative thereto.

Abstract: A method of manufacturing a sensing element, comprising bringing a first body in the form of an oil-free cross-linked matrix of flexible elastomeric material, the matrix containing electrically conductive particles, into contact with a second body of flexible elastomeric material that is electrically insulating and that contains an oil compatible with the elastomeric material of the first body, and allowing oil to migrate from the second to the first body so as to cause swelling of the first body, the migration continuing until a state of oil phase equalisation between the two bodies is reached.

Abstract: A system and a method for converging and filling unfilled small unit cables into a single large cable in a single pass at a single station is disclosed. The single pass filling station comprises a pressure chamber in which the unfilled small pair count unit cables are filled with filling compound and the plurality of unit cables are converged into a single cable as the converged cable enters into a pressure tube where additional filling compound at at least slightly higher pressure is applied thereto. The assembled and filled large cable is then wiped of excess filling compound, wrapped, bound and collected on a take up reel.

Abstract: A high voltage electrical power cable with a longitudinally folded, smooth or corrugated, metal strip around a plurality of layers around the conductor and a water swellable material at least at the adjacent edges of the strip. Preferably, the water swellable material is included with a polymeric material which is flowable at a temperature at least as low as 100.degree. C., the polymeric material has a 100 gram needle penetration value in the range from 50-100 tenths of a millimeter at 25.degree. C. and the water swellable material has a particle size not greater than 200 microns.

Abstract: There is provided a method for restoring in-service electrical distribution cable having a stranded conductor and polyolefin insulation, comprising(i) drying the interstices of said conductor,(ii) exposing the interior of said cable to an anti-treeing additive till said additive is absorbed by the insulation,(iii) filling the interstices of said stranded conductor with a water block composition comprising (A) an Si-H endblocked polydiorganosiloxane fluid; (B) a polydiorganosiloxane fluid; (C) a siloxane crosslinker; (D) a hydrosilation catalyst; and (E) a polymerization inhibitor, and(iv) curing said water block composition to a non-flowing state. Proper selection of catalyst and inhibitor concentrations imparts a controllable viscosity-time profile to the composition and allows cables of various sizes and lengths to be filled before the water block composition cures.

Abstract: A method is described for making an electrical through connection between a first conduction line comprising a flat conductor to a second conduction line comprising a round conductor. The steps of such method comprise removing end portions of insulation layer from the flat conductor and the round conductor; placing a positioning ring about the exposed end of the round conductor; bonding the round conductor to the flat conductor; extending the bonded conductors with the positioning ring into an injection molding apparatus and axially fixing the round conductor by compressive engagment of the positioning ring by a plunger element; and injecting a plastic material into the injection molding apparatus to form an insulating seal longitudinally about the bonded conductors and the positioning ring.

Abstract: A method for sealing the interstices between individual cables of a cable bundle to achieve the sealing of the cable bundle in the longitudinal direction applying a liquid resin system to the area between the cables, the system comprising the reaction of a polyisocyanate and at least one fatty acid polyol having a hydroxy number of at least about 150 and an acid number of no greater than about 1.0, followed by curing thereof to a non-flowable state.

Abstract: A resin coating of a wire harness is shaped in the following manner. A laminated sheet formed by integrally laminating an outer skin sheet made of semi-hard resin and an unfoamed foamable sheet made of foamable resin material, is placed along a cavity wall surface of a shaping mold with the foamable sheet directed to the inside, a bundle of wires having terminals, connectors or the like attached to their opposite ends are disposed within a space defined by the laminated sheet, and by heating the shaping mold the foamable sheet is heated and foamed. A protective coating layer made of foamed resin and protective coating layer made of an outer skin sheet can be simultaneously shaped by the mold.

Abstract: This invention provides a foam barrier which prevents substantial migration of plasticizer from a plasticized polymeric article, such as a PVC cable jacket, into a gel sealing material in contact with the article and prevents substantial migration of oil from the gel material into the article while not significantly interfering with the sealing contact between the gel material and the surface of the article.

Abstract: Environmental sealing may be achieved by means of a flexible envelope having therein a sealing material having a cone penetration value preferably from 100-350 (10.sup.-1 mm) and an ultimate elongation of at least 100%. The material is preferably mechanically deformed preferably by shear and preferably causing it to be comminuted.

Abstract: A forced encapsulation system and method that can be advantageously used to encapsulate cable splices e.g., multiconductor communications cables. Containment means are formed around a substrate comprising part of at least one cable, and secured to the cable, thereby forming an enclosure into which liquid encapsulant can be introduced under pressure and in which the encapsulant can be maintained at pressure above ambient pressure. In a preferred embodiment, the containment means comprise a containment bag formed in situ from an elastomer sheet and sealed to the cable sheaths, with a reinforcing outer enclosure surrounding the containment bag.

Abstract: A method and apparatus for the application of moisture blocking compound to the interstitial spaces of a stranded conductor. The application of the compound is accomplished through the use of a cone die which regulates the amount of compound applied to the conductor.

Abstract: An article that may be employed to protect a substrate by wrapping the article around the substrate. The article comprises a flexible matrix which is composed of a first material and comprises a plurality of open interstices, the interstices having an average volume of less than 0.01 inch.sup.3 ; and an impregnant which is composed of a second material which has a cone penetration value of 100 to 350 (10.sup.-1 mm) and an ultimate elongation of at least 200%, and comprises a plurality of interconnected segments which lie within the interstices of the matrix. The matrix and the impregnant are such that, when the article is stretched, the matrix reaches its ultimate elongation before the impregnant reaches its ultimate elongation.

Abstract: There is provided a method of extending the serviceable life of a stranded conductor electrical distribution cable wherein the interstices of the conductor are filled with a curable silicone water block composition which is subsequently cured to a non-flowing state. The composition has a low viscosity and comprises (A) an Si-H endblocked polydiorganosiloxane fluid, (B) a polydiorganosiloxane fluid endblocked with an unsaturated organic radical, (C) a siloxane crosslinker, (D) a hydrosilation catalyst and (E) a polymerization inhibitor. Proper selection of catalyst and inhibitor concentrations imparts a controllable viscosity-time profile to the composition and allows cables of various sizes and lengths to be filled before the water block composition cures.

Abstract: A method for reconditioning a length of air core cable and for discharging moisture from the cable. Gas under pressure is forced into one end of the cable to cause discharge of moisture from an opposite end of the cable. A quantity of fluid solvent and lubricant is injected into the end of the cable and forced by gas under pressure as a unitary charge along the length of the cable.

Abstract: A moisture resistant splice assembly for communications and electrical cables is provided. The assembly employs a moisture activatable encapsulant.

Abstract: Shield tape (10) surrounds cable (20) in a sleeve-like fashion as it is fit through forming die (22) into cabling machine (28). Shield tape (10) is a metal foil mounted on a plastic substrate. Microencapsulated lubricant in a binder is incorporated on the outer surface of the metal foil portion of the tape (10).

Abstract: The invention provides an improved method for forming a cover layer over a joint of electrical wires. Portions of insulation layers of wires to be joined are stripped and the bared conductors of the wires assembled in a desired configuration to form a joint. The joint is placed in a transparent mold and the mold is filled with a photosetting resin. Radiation of an appropriate wavelength is then passed through the mold to harden the resin.

Abstract: A method and apparatus for enclosing a splice joining at least first and second cable segments prevents water from entering the splice. The apparatus includes a flexible reservoir sealingly attachable to a sealing surface of an end plate assembly. The end plate assembly is sealingly attachable to the cable segments. The pressurized splice closure sections sealingly engage one another and the end plates. The method includes forming a reservoir about the splice, sealing the reservoir to the first and second conductor segments or to the end plates, forming an opening in the reservoir, pouring a curable encapsulant into the reservoir, working the encapsulant into intersitices between the conductors in the cable segments, sealing the reservoir, enclosing the reservoir in a splice closure and pressurizing the splice closure. This method combines a curable encapsulant such as a two-part polyurethane with a pressurized closure such as a 2-type, gas pressurized closure.

Abstract: To reliably sheath two coupled conductors of two wires, a tube made of a light transmittable material is fitted to the two coupled conductors and adjoining wire insulating covers; a photohardening resin is put into a gap formed between the tube and the wires; and the photohardening resin is irradiated from outside the tube with an ultraviolet ray into hard polymer. The sheath thus formed is resistant against moisture and strong in mechanical strength.

Abstract: A method of preventing core water from tracking through an electrical cable to a cable splice area is disclosed. The method incorporates a pair of water blocks placed on each side of the cable splice area which blocks the core water thus preventing entry into the cable splice area. The cable blocks are formed by disposing a curable blocking compound around the cable adjacent each side of the cable splice area. The curable compound hardens to a solid form thereby blocking core water penetration.

Abstract: Electrical joint compounds for the protection of electrical connections are formed from a solution of polymer dissolved in solvent with or without conductive filler. Partially cured thermosetting polymers are preferred as they flow under service conditions to better seal the electrical joints. Thermosetting polymers which cure by an addition mechanism are preferred over those which cure by condensation, and polyimides are most preferred.

Abstract: An apparatus for treating air core cables such as air core plastic insulated telephone cables, which includes a treatment tank provided with air and liquid application piping; an air application saddle or fitting and at least one liquid application saddle or fitting applied to the telphone cable in spaced relationship, with air and liquid application connections extending from the saddles; and a cable block sealing a segment of the air core cable to be treated. Air and liquid are applied in sequence to the plastic insulated cable pairs located in the cable, in order to clear water and other fluids from the cable and restore electrical transmission through the cable pairs.

Abstract: A two-component settable liquid is mixed in a tube to start the setting of the liquid. A pair of electrical cables are separately fed through a retaining cap and a splice is made between the cables. The splice is inserted into the mixed settable liquid and the retaining cap is secured on the tube to hold the splice in the mixed settable liquid while the liquid sets to form a seal about the splice. Various structure is also shown to pressurize the contents of the tube to force the settable liquid into and around the splice.

Abstract: A closure and method for protecting a splice connecting at least two cables. The closure includes a flexible reservoir positioned around the splice, a curable liquid sealant introduced into the reservoir, a means applied to the reservoir for increasing the pressure therein and a pressure measuring tube communicating between the inside and outside of the reservoir.

Abstract: A joint between a mass-impregnated paper insulated cable and a plastic insulated cable is sealed to contain the mass impregnating, oil material by applying a heat-recoverable oil resistant tubing over the exposed paper insulation so as to leave a portion thereof uncovered adjacent the exposed conductor of the cable, applying an oil resistant mastic to said uncovered portion of the insulation and over an adjacent end of said tubing, and applying a further heat-recoverable tubing over the mastic and an adjacent portion of the oil resistant tubing.

Abstract: This invention provides articles and methods for surface protection which comprises a layer of a gel material having a cone penetration of about 100 to about 350 (10.sup.-1 mm) and an ultimate elongation of at least 100% and a covering layer of a flexible material which is flexible when installed on the surface to be protected and is hardenable or curable so that after installation the covering layer hardens to hold the gel layer in position and protect the gel layer from mechanical and other environmental conditions. This invention is particularly suitable for providing surface protection for underwater structures by applying the gel layer to displace the water from the surface which is underwater and providing a water curable covering layer which, after being applied to the surface, cures underwater to provide the required mechanical protection for the gel layer.

Abstract: The long term water intrusion resistance of cable splice systems that use a gelable encapsulant that is pressurized prior to geletion can be improved by providing pressurization means that maintain the pressure on the cured encapsulant above a given pressure p.sub.2 >p.sub.o, where p.sub.o is the ambient pressure. Absent such pressurization means, the pressure on the encapsulant typically decreases with time due to creep or relaxation of nominally rigid components, e.g., a polymeric closure around the encapsulated splice, or varies due to differential thermal contraction. The pressurization means comprises one or more energy storage elements, e.g., an elastic member such as a spring, or a volume of compressed gas.

Abstract: An exposed portion of an electrical cable is sealed by applying a sealant material to the exposed cable and then placing the ends of a split unitary cover over the sealant material in overlapped disposition. The cover is then compressed into contact with the sealant material. In repairing a damaged cable sheath, a reinforcing member may be placed over the sealant material prior to placing the cover thereover.

Abstract: A flooding compound for a waterproof communications cable is formed from a heated mixture of 92-94% by weight of a microcrystalline wax, 3-5% polyethylene and 2-4% of a rubber. The heated mixture is extruded between the plastic jacket and core sheath of a cable. The compound exhibits the adhesive and slip characteristics of, and is a replacement for, atactic polypropylene.

Abstract: The present invention is directed to a wrapper for surrounding an object such as a cable splice to form a cover or envelope containing an insulating compound characterized by a film having adhesive along two lateral edges for securing the film onto the object to form an enveloping cavity. The film has a container of a predetermined amount of the insulating compound which container is opened during the operation of wrapping the film onto the object so that upon completion of the wrapping, the container can be kneaded externally through the cover or envelope to remove the compound from the container and to knead the compound into the spaces and cavities of the object. Subsequently, additional layers such as a foil layer and a heat shrinkable protective sheath can be applied to the cover.

Abstract: A corrosion-resistant electric cable has a metallic conductor, a polymeric insulating jacket surrounding the metallic conductor, and a corrosion-inhibiting powder comprised of a hydrophobic material disposed between the metallic conductor and the insulating jacket. The corrosion-inhibiting powder may be comprised of a mixture of a hydrophobic fumed silica powder and a hydrophobic polyethylene powder.

Abstract: A method of and apparatus for making the cable core of a telecommunication cable water-tight in the longitudinal direction, in which a filling material having a base of petroleum jelly is heated to a temperature above the drop point, is supplied under pressure to a filling head (5), is divided into a number of jets distributed over the circumference of the cable core, is passed through the filling head (5) with simultaneous conversion of the static pressure into kinetic energy and is injected through the outer layer of the cable core into the heart of the cable core, in which a reconversion of the kinetic energy into static pressure is effected and all the interstices and gaps between the single wires of the cable core are filled with the filling material.

Abstract: A splice between two multiconductor cables is protected from ingress of water by a closure which contains a pressure means such as a bladder inside the closure capable of pressurizing a sealant present inside the closure to a pressure sufficient to force the sealant into the interstices of the splice and the interstices between the conductors in the cable, and maintaining the pressure until the sealant cures or hardens. The pressure means may also interact with seals at the end of the closure to seal the closure to the cable jacket.

Abstract: A method and apparatus for providing a sealed cable splice area is disclosed. The cable splice area is wrapped with an open cell spacer web. An adhesively coated liner is separately wrapped around the cable and the spacer web to form a pocket around the splice area. The pocket is filled with a cable encapsulating material which flows completely around the electrical conductors of the splice area. The filled pocket is then sealably wrapped to seal the cable splice area.

Abstract: A splice between two multiconductor cables is protected from ingress of water by a closure which is filled with an expanding foam sealant which provides pressure inside the closure sufficient to force the sealant into the interstices of the splice and the interstices between the conductors in the cable, which pressure is retained in the closure until the sealant cures or hardens.

Abstract: An exposed portion of an electrical cable is sealed by applying a sealant material to the exposed cable and then placing the ends of a split unitary cover over the sealant material in overlapped disposition. The cover is then compressed into contact with the sealant material. In repairing a damaged cable sheath, a reinforcing member may be placed over the sealant material prior to placing the cover thereover.

Abstract: A split recoating mold for use in recoating optical waveguide fibers with a UV-curable resin is provided wherein: (1) the mold, when closed, forms a cavity for receiving the portion of the fiber which is to be recoated, the cross-sectional size and shape of the cavity being essentially equal to the cross-sectional size and shape of the original fiber; (2) the mold includes an injection port for introducing a UV-curable resin into the cavity; and (3) the mold includes means for introducing ultraviolet light into the cavity so that resin located in regions of the cavity remote from the injection port will cure prior to resin located in regions of the cavity near the injection port.

Abstract: A splice between two multiconductor cables is protected from ingress of water by a closure which is filled with a sealant which is pressurized by a bladder inside the closure to a pressure sufficient to force the sealant into the interstices of the splice and the interstices between the conductors in the cable, and the pressure is maintained by the bladder until the sealant cures or hardens.

Abstract: A termination closure (20) for buried or underground service cable splice locations includes molded stepped end blocks (40--40) and a cover (100) which comprises a sheet adapted to be wrapped about service cables (28--28) having conductors (26--26) which are spliced to conductors (24--24) of a distribution cable (22) and secured by clamps. The closure also includes a pivotally mounted organizer (80) which is perforated to allow an encapsulant to be flowed therethrough into engagement with an enclosing bladder (90). The organizer effectively isolates splice connections from the distribution cable core (23). The bladder which is wrapped about the organizer is adapted to receive encapsulant from a tube which extends through one of the end blocks to allow it to be flowed into the interstices among the spliced conductors and distribution cable core. Air in the closure is pushed from one end of the closure and evacuated through a relief valve (59) in the other end block.

Abstract: In the production of an optical fibre cable a core (3) of thermoplastics material is extruded with a plurality of longitudinally-extending grooves (15) in its outer surface around an electrical conductor (1) and is initially cooled: then following the introduction of one or more fibres (11) in at least one of the grooves the core assembly is passed through an induction heating unit (17) in which the conductor is heated to an extent sufficient to soften at least the adjoining region of the core, and the core is twisted to cause the grooves to take up a helical or periodically reversing helical path, and is again cooled to leave the grooves in that condition.

Abstract: A method of forming a molded encapsulation around a sealed spliced region between two cables in which the cables pass through a mold with the splice region in the mold cavity and correctly centered before molding. To allow for the centering operation to be performed, apertures are provided in the mold. Hook members are passed through the apertures. These hook members are caused to engage both inner and outer mold surfaces and they also engage tie means at two circumferentially spaced positions around the splice region to centralize the region within the cavity. The mold is then filled with molten material and the hooks removed from the apertures with the material still molten. Hook removal may take place either when the cavity is completely filled or after sufficient molten material has entered the mold to hold the splice region in fixed position. The method is applicable to low pressure molding, i.e. below 100 psi and preferably below 50 psi.

Abstract: A viscous sealing material is applied to a communications cable by being forced out of a container by means of a heatable pressure plate having a bore and a pump adjacent to the bore; the sealing material is conveyed by the pump through a conduit to a chamber, in which the sealing material is introduced under pressure into and around an already stranded cable core; the pressure plate includes a plurality of preferably helically coil electrical heating elements separated from each other and projecting therefrom for penetrating into the sealing material in the container when the pressure plate applies pressure to the sealing material so that it is progressively liquified and can be pumped out of the container.

Abstract: A grease compatible cyclic olefin extended polyurethane comprising the reaction product of an isocyanate terminated polyisocyanate with a polyol in the presence of a cyclic olefin extender and, a plasticizer having a total solubility parameter of .[.between about 8.3 and 8.9 or.]. about 9.1 and 9.7. Certain extended polyurethanes are characterized as being reenterable, such that they can be used for repairing, encapsulation or reclaiming electrical or telephone cables. Alternate formulations can be used as hard volume encapsulants for general elastomer use.