Note: Descriptions are shown in the official language in which they were submitted.
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Background of the Invention
1. Field of the Invention
; The present invention rela-tes to methods of and
apparatus for manufacturing waterproof cable, and more
particularly, to a method of and apparatus for filling the
interstitial voids of a cab~e core with a waterproofing
compound and sealing the compound in and around the cable
core.
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2. Background and Prior Art
10In the manufacture of communications cable, and
more particularly, the manufacture of cables intended to be
buried beneath the ground, it is a desirable practice to fill
~` the interstitial spaces between the insulated conductors of
the core as weIl as other portions of the cable to prevent
the ingress of moisture into the cable core.
, One method and apparatus for filling a cable core
is disclosed in E. L. Franke, Jr. et a]. patent 3,767,454,
which issued on 23 October, ]973. The Franke, Jr. et al.
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system discloses a technique whereby a cable core having ~ -
stranded twisted pairs of insulated elongated conductors is
moved longitudinally through a series of in-line chambers ;~
having interconnecting dies to facilitate the evacuation of
air from voids in the interstitial structure of the core and
the pressure application of a waterproofing compound of jelly~
like consistency into the air evacuated voids. Thereafter,
the compound filled cable core may be passed through various
stations where core wrap and sheathing materials are placed
about the core in combination with additional applications of
the waterproofing compound. A plastic jacket is extruded
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about the sheathing and is cooled prior to takeup of the
jacketed cable onto a reel.
In the application of the core wrap and sheathing
materials to a cable core filled with waterproofing compound
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in accordance with the Franke, Jr. et al. disclosure, among
other techniques, it has been found that the cross-sectional
outer or peripheral contour oE the filled cable core is
irregular. When a core wrap is applied thereto, it must
conform closely to the irregular contour of the cable core in .
- 10 order to avoid creating voids between the periphery of the
cable core and the subsequently applied core wrap. These
voids can be minimized by utilizing a supple`and easily
formable core wrap material, for example, a core wrap formed
from randomly arranged nonhygroscopic fibers of the type
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disclosed and claimed in R. S. Elliott patent 3,509,269.
~ Howeverl though the use of an easily formable core wrap
`~ minimizes the creation of any voids between the core wrap and
the cable core, it does not avoid them completely.
Furthermore, the combination of a cable core
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`~ 20 enclosed in a highly formable core wrap, has an irregular 3
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peripheral contour, making it difficult to form an armor
~ sheath, for example, a sheath of corrugated aluminum or steel, ~-
; in water tight relationship about the cable core and the core
wrap. As a result, the finished cable may not be completely ;
impervious to water ingress and migration.
~` L. D. Moody patent 3,733,255 teaches passing a
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wrapped cable core having an irregular peripheral contour -
longitudinally through an elongated forming tube in which an ~`
armor sheath is formed about the core and introducing ~elly-
like waterproofing compound into the forming tube at a point
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-~ spaced from its entrance end and under relatively high
pressure to produce a waterproof layer of the compound
which coats the wrapped core and provides a smooth
cylindrical surface about which the sheath can be formed
as the wrapped cable core assembly exists from the form-
ing tube. The pressure at which the compound is intro-
duced into the forming tube forces the compound between
the overlapped edged portions of the sheath to seal and
waterproof the seam formed by the edge portions. This
method, however, does not insure the absence of voids or
air pockets between the core wrap and the filled cable
core.
Summary of the Invention
One object of the invention is to provide a new
and improved method of and apparatus for applying a water-
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proo~ing jelly-like compound to an elongated strand.
Another object of the present invention is to
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provide a new and improved method of and apparatus for
sealing a cable core filled with waterproofing jelly-like
~0 compound.
A further object of the present invention is
to provide a new and improved method of and apparatus for
providing a waterproof cable construction having an
improved percent fill over prlor ar-t waterproof cable
; constructions.
In accordance with one aspect of the present
invention there is provided a method of continuous:Ly
filling the interstices of a core of a stranded cable by
:
introducing material in a fluent state under super- ;
atmospheric pressure into the interstices of the cable
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and solidifying the material thus introduced, wherein a
first petrolatum base compound is forced in fluent state
into successive portions of the stranded cable and a portion
of the compound is maintained in a substantially viscous
sta-te, whereafter a second compound at a temperature
inferior to the temperature of the first compound is
applied in viscous state at super-atmospheric pressure
around the filled cable Eorcing the first compound further
into the interstices of the stranded cable, and cooling :~
the stranded cable to solidify the first and the second ~`~
compounds.
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In accordance with another aspect of the present ~:
invention there is provided an apparatus for applying a ~ ~
waterproofing compound to a cable core consisting of a -
plurality of stranded conductoxs having interstices
therebetween, which comprises: at least first and second
chambers fox receiving the watexproofing compound; means ~- :
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~, for maintaining a portion of said compound in a substant- :
ially viscous state; means for applying said portlon of
said compound in said subs-tantially viscous state under
pressure above atmospheric to successive portions of the
advancing cable core to impregnate the same; means for
maintaining additional of said compound in a substantially `:
`~ more viscous state than said previous compound; means for
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applying said additional compound in said second chamber ;:
over said previous compound while still viscous in said
. substantially more viscous state than said previous com- ~;~
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pound under pressure above atmosphere into contact with ~:
. successive portions of the advancing impregnated cable core
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to coat, fill any voids and seal said previous viscous
compound from said f.irst chamber therein; and means for :
cooling the advancing cable core subsequent to both
applications of compound to substantially solidify the
applied compounds.
srief Description of the Drawings
: A complete understanding of the present invention
may be obtained from the following detailed description o~ ~
a preferred embodiment thereof, when read in conjunction ~ -
; 10 with the accompanying drawings, wherein~
.. ~ FIG. 1 is an e]evational view of an overall .
~- apparatus for injecting and sealing a waterproofing com- ~
pound in the intersticés of and around a cable core in ~ ~:
accordance with the principles of the present invention;
FIG. 2 is a schematic illustration of a plan
view of the improvement forming part of the apparatus of
FIG. 1 embodying the principles of the present invention; :
FIG. 3 is a detailed illustration, partly in ~ :
-~-. section, of par-t of the apparatus of FIG. 2;
. 20 FIG. 4 is a sectional view of the apparatus of
-~ FIG. 3 taken along the line 4-4 thereof;
FIG. 5 is a sectionai view of a cable core
filled in accordance with the principles of the prior art;
and
FIG. 6 is a sectional view of a cable core
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~: filled in accordance with the principles of the present .
`; invention.
; Detailed Description
Refer.ring to FIG. 1, there is shown an apparatus
10 for injecting and sealing a waterproofing compound into and
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around the interstices of a cable core 11 passed therethrough
longitudinally.
The apparatus 10 preferably includes a lead-in
tube 12 connected to one or more vacuum chambers 13 through
` a constrictor section or die 16 where the interstitial voids
in the core 11 are substantially evacuated.
The core 11 is thereafter passed through a die 17
and a pressure yradient or insulated cooling chamber 18, " ~ `
which may have a cooling medium, for example, water
clrculated therearound through an inlet 21 and an outlet
22. Under some opera-ting conditions, it may be found de-
sirable to circulate a heating medium instead.
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After the pressure gradien-t chamber 18, the core
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11 is passed through a die 23 into a compound-applying or
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pressure chamber 26 where substantially fluent waterproofing
compound is injected under pressure, for example, 20 p.s.i.,
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into the evacuated voids in the cable core 11. The temper-
ature of the compound in the filling chamber 26 may vary
between 100-300F for a compound having a mixture of -
petrolateum or petroleum jelly in the range of 80-98% and ~
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low density polyethylene in the range of 2-20%, but is ~
preferably in the range of 200-230F for a mixture of 92~ -
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.l petrolatum or petroleum ~elly and 8% low density poly- ~
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` ethylene. If, instead, a single component compound of
petrolatum is used, the temperature may be in the range of
100-250F, but preferably in the range of 1iO-200F.
The apparatus 10 as thus far described is sub-
stantially identical to the apparatus disclosed in E. L.
Franke, Jr. et al. patent 3,767,454. In the Franke et al.
. 30 apparatus, it is taught that the core 11 then passes into a
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temperature-gradient chamber and then to a cooling or
chill chamber 28 through a suitable constrictor section
or die where successive sections of the core 11 are cooled
and become somewhat solidified to the extent that the
compound therein does not flow but has assumed a jelly-
like consistency to permit the compound to be retained in
the core 11 as the core exits from the downstream end o
the chill chamber 28 into the atmosphere.
.
The apparatus described above has been modified,
in one respect, to eliminate the vacuum in the vacuum
chamber 13. By doing this, the hot compound in the
pressure chamber 26 is permit,ted to flow, counter to the
direction of travel of the cable core, through the pressure
gradient chamber 18 and into the non-operating vacuum
chamber 13. Any excess compound in the chamber 13 is bled
therefrom through an aperture (not shown) in the bottom of
the chamber 13 to a collection tank (not shown) from which
it is then pumped into the main supply of compound for the
system. -
- 20 The elimination of the vacuum in the chamber 13
has the effect of increasing the overall length, and thus -
the period of time, under which the cable core 11 is under
pressure of the waterproofing compound and also serves to
preheat -the core 11 ln its travel towaxd the pressure ~ ;
- chamber 26, without adversely effecting the vacuum system. ;
In a further modification thereto, and in accord-
ance with the principles of the present inventlon, there is
; provided between the filling chamber 26 and the chill
chamber 28, a die 31 and a cool compound chamber 32. ;~
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~ s will be understood from the description below,
the combination of the die 31 and the cool compound chamber
32 provides an improved percent fill of the evacuated voids
in the core 11 and, in addition, seals the filling compound
into the core 11 without relying on the chill chamber 28 to
cool the compound. Furthermore, the core 11 is better ;~
conditioned for the subsequent application of core wrapping
material thereon, improving the peripheral contour oE the
core 11, eliminating irregularities therearound and the
attendant possibility of voids between the filled core 11
and the core wrapping material. `~
As shown in FIG. 1, the apparatus 10 may be
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` supported on a base 33, either individually or through a pair ; !
of parallel rods 34 onto which various sections or chambers
of the apparatus 10 may be adjustably clamped.
Referring to FIGS. 2-4, the cool compound chamber ;
32 includes an inlet conduit 35 and an outlet conduit 36 -~
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~ communicating with a passageway 37 for receiving the cable
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core 11. Cool waterproofing compound, identical to the
mixture of petrolateum and low density polyethylene of the
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filling compound but at a lower temperature, for example, ,
60-170F, but preferably 130-160F, and substantially at
` the same pressure as in chamber 26,~for example, 2D p.s.i.,~`;
~~ is introduced into the passageway 37 in a substantially
viscous state. If a single component compound of petrolateum ;
is used, the temperature should be in the range of 110-140F.
Cool water, for example, at a temperature of 55F,
;~ is continuously circulated through a chamber 38 flowing
through an inlet pipe 42 and an outlet pipe 43 communicating
therewith, to maintain the temperature stabilit~y of the
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compound in the cool compound chamber 32.
As shown in FIG. 2, the higher temperature com-
pound is pumped into a conduit 46 through a valve 47 into
a T-fitting 48 connected into a conduit 51 and a conduit 52.
As shown in FIG. 3, the conduit 51 may communicate with one
or more openings 53 in the filling chamber 26-to in~ect the
compound therein to fill the interstitial voijds in the cable
core 11. Excess compound exits the filling chamber 26
-through a passageway 56 formed in the chamber 26 for receiving -
the highex temperature compound under pressure and may pass
through the pressure gradient chamber 18 and the vacuum
chamber 13 from which it exits. Apertures 57 and 58 are
provided for instrumentation purposes, not shown, such as for
instance; to measure and monitor pressure and temperature.
The chamber 26 is preferably provided with an
annular chamber 61 for circulating steam to maintain the ~
temperature stability of the higher temperature compound. ~;
The die section 31 is interposed between the filling
-~ chamber 26 and the cool compound chamber 32. The die section31 includes first and second metal wiping dies 62 and 63 and
~` a resilient die 66, which is preferably formed from a frusto-conical rubber element; as an alternative the resilient die
66 may be replaced by a metal wiping die, such as die 63.
As the cable core 11 is advanced through the filling
chamber 26, through the die section 31 and into the cool ~ ;
compound chamber 32, the lower temperature compound in the
; cool compound chamber 32 coats the core 11 with a laminate of
waterproofing compound. Similarly, as the cable core 11
passes into the cooling chamber 32 through the die section 31,
the pressure in the chamber 32 will cause the resilient die 66
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to enyage the cable core 11, tending to further urge the hot .
compound into the interstices of the core 11.
As shown in FIG. 2, a valve 67 interposed in the
conduit 52 controls, at start-up, the amount of waterproofing
compound advanced to a pump 68 in a conduit 69 -through a
T-fitting 71. The compound is pumped through a heat
exchanger 72, in a conduit 73, which abstracts sufficient
heat from the compound to cool it to the desired temperature,
introducing it into the inlet 3S of the cool compound
chamber 32 through a valve 76. The cool compound exiting
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the outlet 36 of the cool compound chamber 32 is returned
to the conduit 69 through a valve 77 in a conduit 78. A
pressure relief conduit 81 may be fitted to the conduit 46
through a T-fitting 82. ;
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:: After the system and equipment are operating, the :~
" valve 67 is closed. At this time, none of the hot compound
~ from the conduit 46 is advanced to the pump 68, but instead,
: the pump 68 circulates compound in the conduits 69, 73 and ;~
78. The operation of the pump 68 will also cause compound ;;
from the pressure chamber 26 to be drawn through the die
section 31 and into the cool compound chamber 32, a portion
of which will be drawn off through the exiting conduit 78, ~.
-. for recirculation. There is not sufficient hot compound .
.. entering the cool compound chamber 32 to adversely affect :
.. the desired result, namely, the coating of the cable core 11 ~
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with a laminate of waterproofing compound~
After the core 11 exits the cool compound chamber
- 32, it enters the cooling or chill chamber 2S, advancing
through a passageway 83 therethrough which is maintained at
a temperat~lre, for example, 55F, to cool and solidify both
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applications of co~pound to a putty-like consistency by
circula-ting cold water through an inlet 86 into a circum-
ferential passageway 87 and out an outlet 88.
The exit portion of the chill chamber 28 may be
fitted with a suitable sizing die to provide a smooth ~;
peripheral con-tour 89 to the cable core 11 as shown in FIG.
6.
Referring to FIGS. 5 and 6, there are shown,
, respectively, for comparison, a prior art filled eable core ~,
:; 10 11 (FIG. 5),and a cable core 11 (FIG. 6), filled and sealed
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,, in aeeordance with the principles of the present invention.
~,~ As shown in FIG. 6, the present method and apparatus
', provides a sheath or coating 89 of waterproofing compound
around the cable core 11 to condition it for the subsequent
application of a core wrapping material and suitable armor
~ sheathing, the latter, preferably in accordance with the ''~ `~
,,,, teachings of the L. D. Moody patent, referred to previously.
' The cable core 11 may be preheated in a drying
, apparatus or the like, to prevent its acting like a heat
sink for the filling compound prior to entry into the ';
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apparatus 10.
It will be appreciated that various modifications
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; and improvements of the foregoing described invention will
~-~ be obvious to those having ordinary skill in the art which
come within the spirit and scope of the invention as defined
in the annexed claims. ;
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