Abstract: A waterproofed, insulated conductor or cable and a method of fabricating the same using a new slushing compound is described. The waterproofed insulated conductor or cable includes a core with at least one conductor element, a polymeric insulation jacket, at least one textile covering over the polymeric jacket, and at least one waterproof coating on top of said at least one textile covering, the waterproof coating comprising a blend of from 15 to 40, preferably 20, weight percent of pine tar oil, the remainder being essentially natural (Trinidad) asphalt. The invention is especially suitable for fabricating armored cables in which armor wires, deposited on a textile yarn bedding, are embedded in a coating of the blend and further are covered by at least one textile yarn roving and a waterproof coating on top of each of said at least one waterproof coating.

Abstract: A shielded electric cable having a core including an insulated conductor. A first shielding member formed of an elongated ribbon of insulating material and a pair of elongated metal foil strips arranged in a parallel relationship with the ribbon and bonded to the opposite sides of the ribbon is applied longitudinally to the core and wrapped circumferentially therearound forming two concentric substantially closed shielded layers. A layer of foam material surrounds the first shielding member and a second shielding member surrounds the foam layer, the second shielding member being formed of non-braided metallic material. The shielded electric cable is provided with an outer jacket of non-conducting material and having an appropriate O.D. for receiving a standard connector.

Abstract: A transformer is disclosed which has a primary and a secondary winding disposed concentrically around a core via a flanged bobbin. Each winding has a conductor wire which is doubly or, preferably, triply sheathed with insulating tapes of different widths. The first or inmost insulating tape is wound overlappingly in a first direction around the conductor wire without being bonded thereto. The second or intermediate insulating tape, less in width than the first, is wound overlappingly in a second direction, opposite to the first direction, over the first insulating tape and bonded thereto via a preformed adhesive layer on the second insulating tape. The third or outmost insulating tape, still less in width than the second, is wound overlappingly in the first direction over the second insulating tape and bonded thereto via a preformed adhesive layer on the third insulating tape. The ratio of the overlap of each tape to the tape width becomes progressively less from the inmost toward the outmost tape.

Abstract: An improved flexible circuit assembly arranged in stripline cable or microstrip configuration with shielding and also being designed with a predetermined characteristic impedance. The flexible printed circuits function as printed cables, and employ spacers on either side of the circuit traces so as to provide ground planes at a predetermined dimensional spacing from the traces comprising the circuit pattern. The arrangement of the present invention further comprises placing two or three individual conductor panels on a common substrate, so as to accommodate folding of the circuit panels, one over the other, to form a multi-layer sandwich. Elongated slots are formed along the fold lines so as to improve the integrity of the assembly, and to reduce buckling.

Abstract: An electrical ribbon cable of parallel, coplanar conductive wires having an insulating layer of sintered porous PTFE tape around each of the wires, and a second insulating layer of porous sintered PTFE film around the wires. A conductive layer is then applied and then an outer insulating layer. The cable may be simply and quickly mass-terminated by means of standard tools and connectors. It is constructed such that the velocity of propagation of a signal along any wire is greater than 85% of the velocity of propagation of signals along similar wires suspended in air, and such that the time delay of signal propagation from one end of any wire to the other end is less than 1.17 nanoseconds per foot of length of the cable.

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 double-layered flat electrical signal assembly comprising a shielded insulated flat cable on each side of a perforated separator material which may be conductive metal or non-metal. Controlled impedance signal transmission through high density insulation displacement connectors to PCB's.

Abstract: An insulated conductor having improved arc propagation resistant properties. The insulation consists of a first layer of a composite tape of polyimide between two layers of polytetrafluoroethylene. The second overlaying tape layer is unsintered polytetrafluoroethylene. Further disclosed is a process for manufacturing a sintered wire product having a tin plated electrical conductor.

Abstract: The present invention provides a method of re-entering and reclosing a cable splice case enclosing a splice between first and second cables and comprising a wrap-around sleeve and a closure channel, the sleeve having opposing longitudinal edge portions, each bearing a rail, the edge portions having been brought together around the splice such that the rails are adjacent one another and the closure channel being positioned over the adjacent rails, which method comprises:(a) removing a portion of the sleeve from the splice, leaving an end portion of the sleeve attached to the first cable;(b) removing a portion of the channel from the rails of the remaining portion;(c) positioning over the rails of the end portion at a position where the portion of channel has been removed a hot-melt adhesive plug, the plug having a recess for receipt of the rails;(d) positioning a heat-shrinkable reclosure sleeve around the splice, the reclosure sleeve extending from the adhesive plug at the end portion; and(e) heating to cause

Abstract: A structure for an electrical cable which may be used as a high-frequency signal transmission line and which includes a jacket which is highly permeable by fluids to reduce the time required for stabilization of impedance and transmission speed of the cable upon placement into an environment characterized by a fluid dielectric having a different dielectric constant. The permeable jacket also facilitates electrical connection to a shield conductor of the transmission line, exposed through apertures in the jacket, by use of electrically conductive potting materials, and without the need to remove any portions of the jacket surrounding the shield conductor to which electrical connection is to be made.

Abstract: The method of making a miniature co-axial cable of the present invention includes the insertion of a pre-sized, conductive core into an outer cover with supporting material to center the core. The assembly is then heated and the thermoplastic cover and core supporting material is drawn down around the central core. The result is a miniature co-axial cable with a precise amount of air space, or dielectric region between the core and the outer cover.

Abstract: Coaxial electric cable and simplified process for making it, wherein large gauge center conductor is wrapped with extruded strands of porous expanded polytetrafluoroethylene, drawn through a die to reduce diameter and voids, tape-wrapped with porous expanded polytetrafluoroethylene, sintered, and shielding and extruded jacketing applied.

Abstract: An electric cable is disclosed that has improved burn resistance characteristics. The improved electric cable consists of an insulation portion that has a glass fiber yarn wrapped around the conductor. The glass fiber yarn is impregnated at an outer periphery by a first silicone mixture. A second silicone mixture is coated about the outer periphery of the glass fiber yarn. In an alternative embodiment, a silicone tape replaces the Fiberglas.TM. yarn. The improved insulation for electric cable is envisioned for use with both single strand and multi-strand wires.

Abstract: An electrical cable of conductive wire having an insulating layer of expanded, microporous sintered polytetrafluoroethylene around it, followed by a coating of a vinylidene fluoride-hexafluoropropylene copolymer surrounding the insulating layer, and an outer coating of polyvinylidene fluoride.

Abstract: An electric cable with spirally wrapped wires and wire-retaining strips thereon. The cable includes an insulated electrical conductor, an extruded semiconductive insulation shield overlying the insulated electrical conductor, a plurality of strips extruded and fused onto the insulation shield, and a plurality of wires wrapped around the insulation shield and the strips with sufficient tension to partially embed them into the strips to retain them therein and resist slippage. This arrangement also permits the selection of a first material having predetermined properties for the insulation shield and a second material for the strips having different properties from the first material composing the insulation shield. In one embodiment, the material selected for the strips has a higher softening or melting point than the softening or melting point of the material selected for the insulation shield.

Abstract: An electrical cable of conductive wire having an insulating layer of expanded, microporous sintered polytetrafluoroethylene around it, followed by a coating of a polyesterpolyurethane surrounding the insulating layer, and an outer film of thermoplastic polyester elastomer surrounding the coating.

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: An electrical cable of conductive wire having an insulating layer of microporous polymeric material around it, followed by a coating of a polyesterpolyurethane surrounding the insulating layer, and an outer film of polyetherpolyurethane surrounding the coating.

Abstract: An improved process and apparatus for making electric cable is disclosed that will result in electric cable with improved burn resistant characteristics. The improved process and apparatus consists of a first yarn wrapping portion, an impregnating section, a drying section, a coating section, a second drying section, and a coiling section for returning the wire to a reel. This process wraps a glass fiber yarn about an electric wire and then impregnates this yarn with a silicone mixture. The impregnated yarn is then dried and sent to a second coating chamber where an additional silicone mixture is coated about the outer periphery of the yarn. The wire goes into a second drying section and then goes on to the coiling section. In a second embodiment of this invention silicone tape is used to wrap around the electric wire than than the glass fiber yarn.

Abstract: A method for the manufacture of a high tension ignition cable wherein a tension member is passed through an extruder to form a settable plastic layer thereon. This extrusion takes place under conditions such that substantially no setting of the plastic layer occurs. Thereafter, winding a resistive conductor around the plastic layer to form a plurality of coils at least partially embedded in the layer. The coils are then coated with an insulation layer and a plastic layer is caused to set, thereby fixing the coils in position so that they do not move. The cable made by the foregoing process is also described.

Abstract: The present invention relates to a method of manufacturing printed circuit boards.The manufacturing method of printed circuit boards under the present invention is to detach a release paper from a metal board on which holes are provided and to which the adhesive sheet and a release paper are attached. Thereafter, the metal board is glued to a resin board having at least one circuit layer and at least either of through holes or lead wire holes, by means of the adhesive sheet by pressing.An alternative manufacturing method of printed circuit boards under the present invention is to provide lead wire holes at the centers of resin filled holes in a metal board material, and to which an adhesive sheet and a release paper are attached. From the metal board material, a metal board is made by finishing its outer configuration. The release paper is detached from the metal board.

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: An electrical component, such as a joint between bus bars, is insulated by wrapping therearound a sheet of gel-like material, and manually causing it to conform to the joint. The material is curable by ultra-violet radiation, and this is directed on to the wrapped sheet to cause it to harden. A recoverable tube may be mounted over the sheet, before or after curing, to provide additional protection.

Abstract: A method of manufacturing a flexible electric cable constituted by a polymer-coated stranded conductor made up of fine strands of aluminum or aluminum alloy having a diameter of less than 0.5 mm, or constituted by one or more insulated conductors surrounded by an electric screen itself constituted by fine strands of aluminum or aluminum alloy having a diameter of less than 0.5 mm and wrapped or braided about the conductor(s). The screen is surrounded by at least one insulating layer of polymer material, wherein the operation of stranding together the fine strands forming the conductor or of wrapping or braiding the strands surrounding the insulated conductor(s) and forming the electric screen is performed by using fine strands which are not annealed or which are only partially annealed, with the stranded conductor or the wrapped or braided electric screen then being covered with insulation and subjected to at least one final annealing operation.

Abstract: A cable shielding system is disclosed wherein corrugated metal shielding has its edges bent to a predetermined configuration prior to being formed about the cable. Upon being formed around the cable, the sheathing with the pre-bent edges forms a closed passage way within the seam for receiving an adhesive. The pre-bent edge configuration reduces the possibility that the edge of the metallic sheathing will damage an externally applied plastic sheath.

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: An electrical cable with a core comprising an electrical conductor surrounded by insulation and with both a screen of wires in open helix configuration on the core and at least one other wire extending longitudinally of the core and electrically contacting the wires of the screen. An insulating sheath surrounds the screen and may itself embed the wires or it may surround a layer of extruded material which at least partially embeds the wires. The material of the layer may be insulating or semi-conductive. Also, a process for manufacturing such cable.

Abstract: A high voltage, gas filled, pipe type electrical cable and method of manufacture thereof. The cable comprises a plurality of insulated conductors, each conductor having a central gas passageway and being gas permeable. The conductor is wrapped with tapes impregnated with an insulating oil, and the wrapped tapes are encircled by gas permeable layers and skid wires. Three of such insulated conductors are encircled by a gas impermeable pipe, and the pipe and the conductor passageways are filled with an insulating gas under pressure above atmospheric pressure so that both the interior and exterior surfaces of the wrapped tapes are subjected to such gas. Preferably, the gas is a mixture of sulfur hexafluoride and nitrogen at a pressure of at least 200 psig. The tapes are impregnated with the oil and drained before they are wrapped around the conductor so as to provide gaps between the tapes which are substantially filled with the gas.

Abstract: A flat multi-conductor power cable is disclosed which includes a plurality of generally parallel, spaced apart, flat conductors which are surrounded by two layers of insulation material. An internal layer is extruded around each of the flat conductors and is intimately bonded to each conductor. A single external layer is extruded around all of the internal layers and is intimately joined to all of the internal layers. Preferably, the external layer comprises a thermoplastic elastomer and the internal layer comprises a polyolefinic ionomer. A method and apparatus for making such a flat multi-conductor power cable is also disclosed.

Abstract: A lead sheathed power cable especially useful for powering electric submersible pumps in brine wells. The cable is easy to grip and support and resists damage during flexing and chemical attack. The cable comprises at least one power conduit, vulcanized filler material enclosing the power conduit, a lead tube enclosing the filler material, a spacer assembly enclosing the tube, and an outer armor sheath. The armor sheath has a helically grooved inner surface which is interfitted with a conforming helically grooved outer surface on the malleable tube. The outer surface on the tube is helically grooved during initial heating of the cable, which vulcanizes and thermally outwardly expands the filler material and outwardly expands the tube so that the groove on the armor sheath is impressed into the tube.

Abstract: A direct current electric cable with a conductor, a semi-conductive screen around and contacting the conductor, a plurality of layers of insulation formed by tapes of insulating material around the semi-conductive screen, a further semi-conductive screen around the layers of insulation and a metal sheath around the further semi-conductive screen, the layers of insulation being impregnated with a non-migrating, insulation composition having a dropping point temperature at least 5.degree. C. above the maximum operating temperature of the cable and having an electronegative gas dissolved therein, the gas having a coefficient of diffusion in the composition in the range from 3.times.10.sup.-5 to 3.times.10.sup.-6 cm.sup.2 /sec at temperatures below the dropping point temperature of the composition.

Abstract: A laminated construction comprising at least three extruded layers of polymer-based material in which an intermediate layer (4) between a first layer (3) and a second layer (5) is strippably bonded to the first layer (3) and fully bonded to the second layer (5) such that the second layer together with substantially all of the intermediate layer (4) is readily strippable from the first layer (3). In particular, the invention relates to an insulated electrical cable in which such a laminated construction is arranged substantially coaxially about a core conductor (1); the first layer (3) being an inner layer of insulating material, intermediate layer (4) being either of insulating material or of a semi-coductive shielding material and the second layer (5) being an outer layer of a semi-conductive shielding material. Preferably, an additional layer of semi-condutive shielding material is positioned between the core conductor (1) and the first layer (3).

Abstract: Magnet wire substrates (1) are described having a layer of glass fiber (2) wrapped thereon, which has a layer of spirally wrapped and bonded polyester insulation tape (3) as the outermost layer. The resulting insulated magnet wire in addition to having the requisite electrical properties has improved physical properties including increased flexibility and ease of strippability.

Abstract: A highly flexible, shielded electrical cable having exceptional pliability and limpness is provided for connection to devices such as hand-held medical instruments to minimize the resistance to movement of such devices imposed by such cable. The normal stiffness of shielded cables caused by a braided wire shield is minimized by eliminating the frictional resistance to relative movement between the shield and the dielectric covering of the conductor assembly inside the shield. This is accomplished by loosely braiding the shield around the dielectric covering so as to impose no transversely inward force on the dielectric covering. Preferably, a clearance is formed between the shield and the dielectric covering, and the density of the braided shield is maximized to render it self-supporting. The outer dielectric jacket of the cable likewise loosely encircles the braided shield to eliminate frictional resistance to relative movement between the shield and jacket.

Abstract: An improved flexible coaxial cable (24) and method of making same employs an inner conductor (22) having a helically wound dielectric beading (20) wound thereabout in a predetermined pitch dependent on the desired velocity of propogation for the cable (24). A heat shrinkable dielectric tubing (26) surrounds the helically wound beading (20) and locks it to the inner conductor (22) to provide a dielectric core (28) having a constant pitch for the helically wound beading (20) during flexing of the cable (24). A convoluted outer conductor (30, 32, 34, 36) is locked to the tubing (26) of the dielectric core (28) by crimping it to the dielectric core (28) between the helically wound convolutions of the outer conductor (30, 32, 34, 36).

Abstract: A semi-foamed polyethylene tape for use in the molding of foamed jacket pethylene cables. After tumble mixing low density foaming polyethylene, ethylene vinyl acetate co-polymer and polyethylene color concentrate, the tape is extruded on a thermoplastic extruder having a maddox mixing screw that effectively mixes polyethylene compounds and a slot die with a suitable opening dimension. The tape is then quenched. By controlling manufacturing variables the tape is foamed to 40% to 50% of its maximum. The tape is then foamed to 100% maximum during the manufacturing of a cable assembly.

Abstract: A method of producing a shielding for a flexible electric line employs at least one conductor having insulation upon which is wound at least one metal tape, the tape being separated into individual elements by cutting immediately before contacting the insulation.

Abstract: This invention provides a method of increasing the cut-through resistance of a PTFE insulated conductor. Unsintered PTFE is expanded and compressed and then applied to a conductor. The insulated conductor is then heated to a temperature above 345.degree. C. The compressed, expanded PTFE has one crystalline melt point above 375.degree. C.

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: An electric cable (1) for transporting very high current at low voltage, in particular a welding cable for use in robot welders, comprises at least one multi-strand conductor (2) and an outer sheath (4), cooling water circulates inside the cable, and the water gains access to the conductor strands to be cooled by virtue of the conductor being covered by a perforated envelope (3).

Abstract: Curable compositions which are useful for encapsulating electrical connections and for joining metals to metals, and which comprise a mixture of high and low molecular weight fluorocarbon elastomers. Preferred compositions comprise a mixture of three fluorocarbon elastomers, the first having a Mooney viscosity at 121.degree. C. of at least 120, the second a Mooney viscosity at 121.degree. C. of 80 to 110, and the third a Brookfield viscosity at 100.degree. C. of 1,000 to 4,000 centipoises, in amounts 5 to 50%, 25 to 70% and 5 to 50% respectively, based on the weight of the polymeric component. The compositions can be easily molded under heat and pressure, and after they have been cured, they have remarkable resistance to degradation by hot liquids, even under pressure. Consequently, the compositions are very useful in the manufacture of self-regulating heaters for use in heating the production tubes of oil wells.

Abstract: A flexible shielded cable. The cable includes an elongate flexible metal conductor and a layer of a flexible dielectric material disposed about the conductor. The cable has a flexible metallic shield positioned about the dielectric with the shield including a copper foil having overlapping edges and a copper braid about the foil. A layer of metal bonds together the overlapping edges, bonds the braid and the foil and closes the openings of the braid. A method of forming a metallic shield is also disclosed.

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: The flat multiconductor cable contains live, neutral and ground conductors lying generally parallel to each other and in side by side, single-plane relation. The live and neutral conductors are sealably surrounded by a relatively hard, polyetherimide material that is substantially free from attack from calcium hydroxide. An outer jacket or casing of polyvinylchloride (PVC) sealably surrounds the polyetherimide layers and contacts the ground conductor. The PVC is substantially free from attack in an alkaline environment. The polyetherimide layers are extruded over the live and neutral conductors providing a seal therearound and thereby a barrier to moisture. The PVC layer is then extruded over the conductors providing a further seal around the polyetherimide layers.

Abstract: An electrical cable includes a core having a plurality of conductors cabled together in a unidirectional lay and a jacket which surrounds the core. The conductors of the core are insulated from one another, and the jacket includes an internal braid or double counter directional serv. The angle of the lay of the conductors and the angle of the braid or serve, both with respect to the longitudinal axis of the cable, is such that the angle of the lay of the conductors is greater than the angle of the lay of the braid or double counter directional serv. The jacket serves an important function as that of primary load-bearing component of the cable and it adapts the cable to withstand severe mechanical and other abuse over a long life.

Abstract: A reinforced electrical cable having a plurality of conductor assemblies in an armor covering, and filler material filling the interstices between the conductor assemblies and the armor covering, and the method of forming the cable. Each conductor assembly includes a core of conducting material, a layer of insulation which surrounds the core, a second layer of chemical barrier material which surrounds the first layer and a layer of reinforcing material surrounding the insulation layer. The plurality of conductor assemblies are then arranged as desired and the filler material (in the unvulcanized state) is placed around and between the conductor assemblies. The quantity of filler material placed between and around the conductor assemblies is sufficient to fill the interior of the armor covering in its unvulcanized state. The armor covering is next placed around the conductor assemblies and the filler material. The unvulcanized filler material conforms to the interior of the armor covering.

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.