Abstract: A method and composition for effecting splices of high voltage cable sections for use with a mold placed around the cable sections. The composition comprises a liquid polyolefin, a finely divided solid polyolefin and a chain extension agent capable of reacting to form addition polymer linkages with the liquid polyolefin.

Abstract: Powder filling of a cable, or cable unit, is improved by passing the cable, or unit through a fluidized bed of powder, and vibrating or shaking the cable, or unit in a direction substantially normal to the direction of movement of the cable, or unit, through the bed.

Abstract: A method and composition for effecting splices of high voltage cable sections for use with a mold placed around the cable sections. The composition comprises a liquid polyolefin, a finely divided solid polyolefin and a chain extension agent capable of reacting with condensation reaction moieties of the liquid polyolefin.

Abstract: For powder filling of cables, in a fluidized powder bed, it has been proposed to pass the cable core through the bed in a substantially closed condition. There is a limit to the number of conductors a core can have for effective filling. In the present invention the cable core is opened up into a number of core units by passing through an opening member. The opening member is freely ridable on the cable core and has a hole for each unit. The opener is held against a support member and an air bearing formed between the two members. Air is also usually fed to the holes in the opener member through which the core units pass to prevent flow of powder out from the bed. The opening member can be positioned in the fluidized bed or outside immediately prior to passage of the cable core through the bed. The units are each in a substantially closed condition in the bed and the units close to a single core also in the bed.

Abstract: A corrosion resistant rope in which the individual strands are sealed with a plastic foam impregnant and surrounded with a dense unfoamed plastic material is made by applying a foamable plastic to the individual wires of a series of wire strands, or, alternatively, to the individual strands as a whole, and closing the strands into a rope in a closing die while passing a nonfoamable plastic material into the closing die. Sealed plastic foam impregnated wire strands can be made in the same manner by passing nonfoamable plastic material into the stranding die during fabrication of the strand.

Abstract: The invention relates to the monitoring of the filling effectiveness during the filling operation of a waterproof or filled telecommunications cable on a manufacturing line, and includes measuring the capacitance change per unit length of an outer pair of insulated conductors in the cable, measuring the capacitance change per unit length of an inner pair of insulated conductors in the cable, determining any deviations in the measured capacitance changes and utilizing such deviations by feedback control to eliminate further deviation, as well as determining the point of deviation along the cable length.

Abstract: This invention provides a method of sealing and purging contaminants from the internal free spaces of an insulated electrical device by forcing into said free spaces a low viscosity material that acts to displace fluid contaminants from within said free spaces. The material later cures in situ to form a hydrophobic seal with good electrical properties. Also disclosed herein is a method for rehabilitating waterlogged plastic insulated multiconductor communications cables of the type employed in telephone system.

Abstract: This invention provides a method of sealing and purging contaminants from the internal free spaces of an insulated electrical device by forcing into said free spaces a low viscosity material that acts to displace fluid contaminants from within said free spaces. The material later cures in situ to form a hydrophobic seal with good electrical properties. Also disclosed herein is a method for rehabilitating waterlogged plastic insulated multiconductor communications cables of the type employed in telephone systems.

Abstract: An elongated flexible gas-insulated transmission line cable is fitted with pressure-tight termination assemblies at its opposite ends before it is placed on a reel for shipment. The cable is then filled with dry gas, such as nitrogen, at a relatively low positive pressure and the cable is then reeled and shipped. The cable terminal ends are adapted for easy connection to other circuit components without requiring access to the interior of the cable and the terminals permit the purging of the nitrogen gas and the installation of sulfur hexafluoride or some other electronegative gas before the cable is placed into operation.

Abstract: High-voltage power cables with extruded dielectric plastic insulation, installed underground, have their life shortened by the formation of electrochemical trees in the insulation. This invention provides a high-voltage power transmission cable constructed with sealant in interstices of a stranded conductor that are not filled by the semi-conducting material of a conductor shield of the cable. The construction prevents or greatly delays the formation of electrochemical trees in the insulation of the cable. The sealant prevents entrance of air into the cable at cable ends, and the passage of the humidity of the air through the conductor shield to an interface between the conductor shield and the inside surface of insulation that surrounds the conductor shield.

Abstract: A process and apparatus for forming the stranded conductor portion of a fully-filled electric cable in which the components of the strand in side-by-side relation are fed through an inlet die at one end of a chamber in which a filling medium at a temperature at least 5.degree. C above the dropping point temperature of the medium and under a pressure above atmospheric pressure is circulated in a direction opposite to the conductor feed direction. In the chamber, the components, preferably groups of conductors, are spread apart by a perforated disc through which they pass and are then twisted together at an outlet die at the opposite end of the chamber to form a strand with a coating of the medium and with the medium filling the spaces between components. From the outlet die the strand passes directly into a bath of the medium in a temperature controlled tank at atmospheric pressure but which maintains the medium at least 5.degree. C above its dropping point temperature.

Abstract: A novel apparatus and operational system for the improved waterproofing impregnation of an already stranded core of communication cable and the like with a jelly-like waterproofing compound by the application of vibratory energy is disclosed. The vibrational forces imparted to the jelly-like waterproofing compound enables such to more completely and/or more quickly penetrate the interstices of such stranded core.

Abstract: The invention relates to the monitoring of the filling effectiveness during the filling operation of a waterproof or filled telecommunications cable on a manufacturing line, and includes measuring the capacitance change per unit length of an outer pair of insulated conductors in the cable, measuring the capacitance change per unit length of an inner pair of insulated conductors in the cable, determining any deviations in the measured capacitance changes and utilizing such deviations by feedback control to eliminate further deviation, as well as determining the point of deviation along the cable length.

Abstract: A composition useful for filling communication cables is described which comprises petroleum jelly and a small amount of siliceous material which renders the petroleum jelly viscous at elevated temperatures, and prevents leakage of the petroleum jelly from a cable having a flaw, which is subjected to elevated temperatures; the composition is particularly useful in communication cables having cellularly insulated conductors where migration of the flowable filler composition into the cellular insulation is diminished.

Abstract: A method of rendering a cable having a core consisting of a plurality of conductors longitudinally watertight. A silicone rubber which vulcanizes upon exposure to moisture is used between the conductors either throughout the entire length or in blocks.

Abstract: Apparatus for forming the stranded conductor portion of a fully-filled electric cable in which the components of the strand in side-by-side relation are fed through an inlet die at one end of a chamber in which a filling medium at a temperature at least 5.degree. C. above the dropping point temperature of the medium and under a pressure above atmospheric pressure is circulated in a direction opposite to the conductor feed direction. In the chamber, the components, preferably groups of conductors, are spread apart by a perforated disc through which they pass and are then twisted together at an outlet die at the opposite end of the chamber to form a strand with a coating of the medium and with the medium filling the spaces between components. From the outlet die the strand passes directly into a bath of the medium in a temperature controlled tank at atmospheric pressure but which maintains the medium at least 5.degree. C. above its dropping point temperature.

Abstract: This invention is an improved filling compound for preventing moisture penetration along the interior of high voltage electric power cables. Amorphous polypropylene, mixed with carbon where it must be semiconductive, is an extremely good filling compound because of its electrical characteristics and also because of its good flow characteristics when extruding. When the cable is to be used under conditions where it must withstand temperatures so low that the polypropylene becomes brittle, it can be blended with polyisobutylene rubber to withstand lower temperatures, but the blend must be kept within limits to prevent loss of the good flow characteristics of the amorphous polypropylene.

Abstract: A two-part pourable composition capable of forming a dielectric, thermally stable, hydrolytically stable, moisture insensitive polyurethane gel comprising in a first part an aliphatic or cycloaliphatic isocyanate and an aliphatic/naphthenic hydrocarbon oil, and in a second part a polyalkadiene polyol, a dialkyl organotin catalyst, and the aliphatic/naphthenic oil. The gel is ideally suitable as a filler for communication cable splices since it is substantially inert toward molded polycarbonate connectors conventionally used in such splices.

Abstract: In a method of continuously producing a multi-stranded powder filled core for an electric cable, the conductors forming the core are kept apart over a length of their travel while powder is applied to them electrostatically, after which the conductors are brought together to form the core. Preferably the conductors are oil coated prior to the application of the powder, the formed core is passed through a powder bath, and a core wrap tape is oiled and applied to the core, the tape being also powder coated on its contacting surface if applied longitudinally to the core rather than helically. For a metal sheathed cable the metal tape forming the sheath may be oiled and powder coated on the surface contacting the core wrap prior to the application of the metal tape to the core unit, to form an intervening layer of powder between the core wrap and the sheath.

Abstract: A method and apparatus for forming pressure plugs in cable systems which are under continuous air pressure while maintaining a continuous air flow through the cable. A supplemental air source is connected to the pressurized cable casing on both sides of the area to be plugged to provide an auxiliary air pressure of sufficient quantity to override the normal pressure in the cable casing. Then, the pressure plug may be installed in the cable while the entire cable, and the selected portion of the cable being plugged, remain under adequate pressure to prevent any moisture from entering into the casing.

Abstract: A kit for use in forming pressure blocks in a cable including a fluid injector with a pressurizing plunger providing a discrete amount of pressure block forming material, such as self-setting plastic, a tap fitting with a fluid inlet port providing access to the interior of the cable, and a valve comprising a housing and a closure member movably mounted to the housing, the closure member including first, second, and third sections. The first valve section includes means establishing free fluid communication between the injector and the fluid port, the second section including means sealing the passage portions from one another and from the exterior, and the third section including means communicating the fluid injector to the exterior. The valve prevents creation of a vacuum internal of the fluid injector which hinders the withdrawal of the plunger in the fluid injector while coupled to the tap fitting.

Abstract: The mending of defective semiconductive components of insulated electrical cable, comprising filling and sealing voids or breaks within a body of semiconductive material with a curable semiconductive patching compound comprising the combination of chlorosulfonated polyethylene, conductive filler and lauroyl peroxide, and heating the patching compound to cure the same.

Abstract: The invention relates to a method of manufacturing phase cores for oil-filled cables and apparatus therefor, whereby a current-carrying core is obtained by means of twisting together a number of individual wires, then a paper insulation tape is wound around the current-carrying core and the insulated current-carrying core is reeled on a drum, after which the core is dried, impregnated with an insulating compound and placed in a provisional sealed housing for the period of storage and shipment to the site where the core is to be laid out and inside which the core is subjected to the required electrical measurements and insulation tests. The current-carrying core is placed inside the provisional sealed housing right after it is has been wound with the paper insulation tape.

Abstract: A d.c. high tension cable termination or joint and method of manufacturing same is described. The cable comprises an electric conductor, an electrically insulating layer which is concentrically applied over the conductor, and a semi-conductive layer which is concentrically applied over the insulating layer in close contact therewith. The cable termination or joint comprises an electrically insulating liquid impregnated into a portion of the semi-conductive layer which is located adjacent to an end of the insulating layer so as to present an electrical resistance which is higher than that of the non-impregnated portion of the semi-conductive layer but is lower than that of the insulating layer. The electric conductor is electrically connected with the end of that portion of the semi-conductive layer impregnated with the insulating liquid which is located nearer the conductor.

Abstract: A method of fabricating a compressed gas insulated cable which includes the steps of securing an electrical conductor to an insulating spacer; securing the spacer to a sheath section which forms a portion of circumference of the outer sheath of the gas insulated cable; and then sealingly securing the sheath sector together to form the outer shell.

Abstract: A method of making electric cable having a plurality of electric conductors stranded together with a deformable semi-conducting strand in each valley between the conductors and a shielding composition around and in intimate contact with the conductors and strands. The conductors and strands are stranded together into a stranding die and the plastic composition is forced around them while they are in the stranding die.

Abstract: Method of producing the insulation of a conductor bundle having a plurality of metallic conductors spaced one from another which includes immersing the conductor bundle into a mass of insulating material heated to liquid state, and withdrawing the conductor bundle coated with liquid insulating material out of the mass of liquid insulating material at a speed that is slower than the speed at which the liquid insulating mass drips from the conductor bundle; and device for performing the foregoing method.

Abstract: A water blocking compound for sheathed stranded cables, the compound being a gel consisting of a major proportion by weight of a substantially non-volatile liquid in which has been dispersed a minor proportion by weight of a solid gellant which is insoluble in said liquid and which does not melt below 100.degree. C, the gel being substantially devoid of any gellant which is soluble in the liquid and/or melts below 100.degree. C.

Abstract: In this method, a pre-formed insulating sleeve is placed about the adjacent ends of the two sections of high voltage cable that are to be joined. At opposite ends of the sleeve in locations between the sleeve and the original cable insulation, two rings of porous material are provided. Into the space between the sleeve and the surrounded cable portion, there is pumped a slurry containing suspended particles of insulating material. The liquid component of the slurry is allowed to discharge from said space via the pores in said rings, but the particles of insulating material are filtered out so as to build up a deposit of said particles from the internal surfaces of said rings. This pumping and filtering action is continued until the deposit fills the space between the sleeve and the surrounded cable portion.

Abstract: In the disclosed method of applying electrical insulation, a housing with a porous wall is placed around a conductor in spaced relationship thereto, and a slurry is pumped into the space between the housing and the conductor. This slurry comprises a liquid and particles suspended in the liquid having good electrical insulating properties. The liquid component is allowed to discharge from the housing via its pores, but the solid particles are filtered out within the housing so as to build up from the internal surface of the housing a deposit of the particles. This pumping and filtering action is continued until the space between the housing and the conductor is substantially filled with the deposit.

Abstract: A channeling wedge to be used for separating wires in a cable bundle and for separating the shield from the sheath to form passages affording resin or compound to more freely flow into the cable bundle and between the shield and the sheath and block the cable.

Abstract: Cable reclamation method and apparatus by which moisture is precluded from entering or is purged from an electrical cable by injecting a two-part polymerizable compound in liquid phase into and along the cable. Any moisture present is purged through an outlet port distant from the compound entry port. The compound takes a permanent soft-solid set at normal ambient temperatures within a few hours as a paste-like gel readily removable at any future time to permit cable splicing and servicing operations. This soft-solid gel forms a moisture-proof nonconductive sealing barrier precluding entry of moisture and restoring normal cable operating conditions. The compound supply tank is pressurized with air or gas to transfer the compound in liquid phase into the cable, the pressurized gas being used initially to agitate and intermix the compound constituents.