Note: Descriptions are shown in the official language in which they were submitted.
~ Z 5
The present invention relates to environmental protec-
tion of junctions in elongate substrates, such as splices in
cables, particularly in telecommunications c:ables.
In particular the present invention relates to a method
of making a hollow pressure vessel around an elongate substrate.
This application is a divisional application of copend-
ing application No. 444,699 filed January 5, 1984.
It is ~requently necessary to protect such ]unctions
against the environment in order that the cables or other sub-
strates may continue to funct~on properly. Protection generally
has to be provided against moisture, corrosive chemicals as well
as insect and anlmal damage, etc. The intention when enclosing a
junction such as a cable splice is to make good the original
cable insulation thak had to be removed in order to connect the
conductors, and it is generally required that the life-time of
the seal provided by the new enclosure be comparable to that of
the original cable insulation. It will be appreciated thereore
that the material o~ the enclosure must provide a highly resis-
tant barrier for a considerable period of time.
One way of providing such a barrier is to install
around the cables a splice case comprising an imperforate sleeve
of a modified polyolefinic material in conjunction with a high
performance adhesive. Such sleeves are conveniently produced by
extruding a continuum of material. The sleeve is preferably made
recoverable so that it can be shrunk ~or otherwise recovered)
into close contact with the cables.
There is a further consideration relevant to the
-- 1 --
7~25
p
-2- RK169
design of enclosures for cable splices, and that is the
ability to retain pressure. Many types of cables and
splice cases are pressurised during use, are assessed
in terms of pressure retention to determine their
quality, or become subject to incidental pressurisation
during use. The importance of this consideration is of
course different in each of these three situations, but
it is accepted that the ability to retain some degree of
pressure is a necessary feature of a splice case if
enviromental protection is to be achieved.
The most stringent requirements are for a splice
case for pressurised cablesr such as main cables in a
telecommunications system. These cables are pressurised
to prevent ingress of water in the event o damage and
to provide a means of ~ault detection~ Here the product
must withstand a pressure of the order of 10 psi (70
kPa) throughout its life, and a functional test designed
to mirror such long term performance requires impermeability
at, say, 70 kPa over 10 eight hour cycles between
-40C and ~60C in air (Bell cycle). An alternative cycle
is in water over four hours at 105 KPa between 5 and
50C.In addition to this cyclical environmental test,
the product may be tested for integrity by pressurisation
at 150 kPa in water for about 15 minutes at 23C. No
leak should be observable. A product that is to operate
continuously at pressure should also possess long
term creep resistance if it is not to become significantly
distorted during use.
In telecommunications distribution cables, for
example, an ability to retain pressure is required as an
indication of completeness of environmental sealing,
although the cables are not pressurised during use.
Various temperature/pressure cycles have been devised
1~L7~3~5
--3--
for this purpose, and one that is preferred is a modified
Bell Cycle which involves temperature variation from
-40 to 60C over 8 hours at an air pressure of 40 kPa.
The splice case should show no leak after 10 cycles. An
alternative cycle is a temperature variation between
room temperature and 70 C at a pressure of 105 KPa
over ~ hours.
These and other cable splice cases may become
pressurised through being exposed to sunlight, or
through the heat involved in the last stages of heat
recovery when the seals to the cable have been ormed.
In such cases it is necessary that the splice case be
able to maintain this temporary, and generally rather
low, pressure if the environmental seal is not to fail.
Many of today's splice cases for pressurised cables
are large and heavy, and consist of many components. For
example, cast iron case halves are bolted together
around the cable splice, the cable entries being sealed
by a complex arrangement of compression collars, clamps,
sealing washers and tape. ~ariations on this system
exist but there remains the problem of sealing the
cables to the splice case at their points of entry. A
large stock of parts must be kept if various sizes of
cables are to be joined, or if the number of cables per
splice case is likely to vary. A further problem is that
installation is difficult and lengthy. The problems
associated with such multi-part, rigid, splice cases
are avoided by the use of recoverable sleeves :
installation is quick, and a variety of sizes and
numbers of joined cables can be enclosed with a small
number of parts. The use o a continuum of a suitable
polymeric material, together with an adhesive can provide
excellent environmental sealing and pressure retention.
The sleeve is preferably used in conjunction with a
`~ ~ Z ~ 5
liner which surrounds the cable splice and underlies the sleeve.
The liner provides mechanical strength, gives the splice case its
shape, facilltates re-entry, and may protect the conductors from
damage during heat recovery.
However, in unfavourable circumstances and where pres-
sure retention is a primary design consideration, it may be
thought desirable to increase the wall thickness of such recover-
able polymeric sleeves in order to ensure no movement or creep
over long periods of time. A greater wall thickness unfortu-
nately makes the product more difficult and thus more costly to
manufacture, due to cost of material and to problems in cross-
linking and expanding the material. Also, heat-shrinkage of a
thick-walled product takes longer, and requires a more careful
application of heat if damage to the cables or other substrates
is to be avoided.
What we have now discovered is that a splice case or
other hollow pressure vessel capable of high pressure retention
can be made from a recoverable fabric.
In copending application No. 444,699 there is disclosed
and claimed an assembly for enclosing a junction between elongate
substrates, especially between cables, which comprises: tA) a
sleeve comprising a recoverable fabric; (B) means for rendering
the fabric substantially impervious when the fabric is recovered;
and (C) a liner for the sleeve, the liner having a central region
of larger cross-section, and end regions of smaller cross-section
which provide transitions from the central region to the sub-
strate and which locate the liner with respect to the substrate.
The copending application also discloses and claims ajunction between two 010ngate substrates, especially a splice
between two cables, enclosed by the assembly of the invention.
The present invention provides a method of making a
782~
hollow pressure vessel around an elongate substrate, which com-
prises: (A) providing around the substrate a hollow article hav-
ing at least one recoverable outlet portion such that the sub-
strate extends through said outlet portion, the article compris-
ing a composite structure recoverable by virtue of a recoverablefibre component thereof; (B~ recovering into engagement with the
substrate one or more outlet portions only of the structure.
The substrate may be a cable splice in which case the
hollow article will have two outlet portions (or more if spare
blanks are provided for future use or if a branch-off is to be
sealed)~ Where a cable termination or radial type closure is
provided, the article may have a single outlet.
The extent to which the fabric need be impervious will
of course depend on the use of the assembly. Where the assembly
is used to seal a splice between pressurized cables a high imper-
viousness will be desirable if energy and pressurization medium
are not to be wasted. In other situations imperviousness to
water, oil, fuel or hydraulic fluids may be re~uired. A degree
of perviousness will, in general, be tolerable depending on the
nature of the substrate and on the length of time that tne
assembly will be in use.
The means for rendering the fabric substantially imper-
vious may, for example, be a polymeric material used in conjunc-
tion with, bonded to, or extending throughout the recoverable
fabric, or it may be the liner
-- 5 --
1~7~5
where the liner is of substantially sheet form rather
than, say, a cage, or it may be some means whereby the
nature of the fabric is altered~ The first of these
possibilities is preferred, and we therleore prefer that
a true composite structure be formed between the recoverable
fabric and a polymeric matrix material by means of which
it is rendered impervious. We prefer that the matrix
material and the fibre material be chemically and/or
physically compatible. By physically compatible we
mean that the relevant properties of the two materials
are similar or identical during lamination, recovery and
use. Chemically similar materials are preferred~ for
example both fibre and matrix may be polyolefins, and
preferred materials are high density and low density
polyethylene respectively~ The skilled man would be
able to select other suitable pairs of materials.
We have found that a recoverable fabric rendered impervious
can have excellent pressure rentention where imperviousness
to air is required. The ability of the sleeve to retain
pressure is not simply a question of porosity of the
material, although it must ultimately be substantially
free from holes, but is determined also by the ability
of the material to withstand hoop stresses that are
generated by pressure within the sleeve. It is with
regard to this second effect that recoverable fabrics
have been found to be particularly good. Fabric sleeves
of small thickness have been found to be able to resist
high pressures without sig~iicant ballooning or creep.
It is furthermore surprising that this beneficial
feature can be made use of in spite of the initial
porosity of fabrics.
Fabrics also offer considerable advantages over, say
e~truded, sheets in the ease with which they can be
reinforced by the insertion of special fibres.
~47~25
--7--
The sleeve and any liner may each be made in
tubular form or wrap-around form. Wrap around sleeves
and liners are preferred since they can be installed
around substrates having no free ends. This is particularly
useful when a splice in a telephone cable is to be
enclosed a~ter the repair of only a fe~ of the many
conductors it contains. If the sleeve and liner were
tubular, the entire cable would have to be severed for
installation. Wrap-around products are also useful where
space is limited; a wrap-around sleeve can be installed
where the amount of substrate exposed merely equals the
width of the sleeve, a tubular sleeve however requires
room for it to be positioned along the substrate away
from the splice region while the splice is being made.
The techniques by which the sleeve may be held in the
wrapped configuration can be regarded as of four broad
types. Firstly, a lap or other bond may be made
between opposing edges of the sheet, optionally with a
patch to prevent peel-back. Here the bond will generally
be between opposing regions of the polymeric matrix
material used to render the fabric impervious, and one
must therefore ensure that the recovery forces are
properly transmitted from the fibres to the matrix material.
In a second possibility, some means which penetrates
the fabric may be used, for example stitching, stapling,
riveting, the use of pre-inserted catches such as press-
studs, or the use of means which may be positioned
adjacent a lap joint in the sheet and which has a plurality
of projections which penetrate the sheet. The means
which penetrates the sheet may join a closure element to
each edge, which closure elements then hook or otherwise
join together.
The third method of closure involves forming
~29~7~ S
--8~
the edges of the sleeve in such a way that they may be
held together by some form of clamping means, such as
the C-shaped channel disclosed in UK patent No 1155470 9
or by a re-useable tool.
The last closure technique to be mentioned comprises
forming the fabric in such a way that the recoverable
fibres do not terminate at the opposing edges to be
joined, but instead double back. An example is to use
a recoverable we f t on a shuttle loom and insert a
closure member into the weave at each edge. A further
possibil ity is to weave closed pockets at each edge of
the sleeve.
Several matters are to be borne in mind when
designing the recoverable sleeve, and the first to be
considered will be recovery ratio. The recovery ratio
should be sufficient to allow the sleeve to be installed
over the largest parts of the substrate and to recover
into contact with the smallest parts. In a splice
between telephone cables, the splice bundle will in
general be from ~-6 times the cable diameter, and a
sleeve having a recovery ratio of at least this size
will be suitable. The sleeve preferably does not
recover into engagement with the splice bundle, since if
it did damage would result. Also, it is desirable that
the splice case be re-enterable without damage. Thus,
the final structure is preferably hollow. The extent
of recovery can also be expressed by quoting the change
in a dimension as a percentage of the recoverable
dimension before recovery. Expressed thus, recovery is
preferably at least 20%~ more preferably at least 40%,
particularly at least 50~, more particularly at least
7s%. A sleeve having a lower recovery ratio than the
ratio between the size of the splice and that of the
cables may be used if the sleeve is made in a
s
- 9
shape more or less corresponding to the shape oE the
cable splice. If a shaped sleeve is used it will usually
have to be wrap-around since it will not be capable of
being slid over the splice bundle. Since greater
recovery may be needed at the ends where the sleeve is
to seal to the cables, the fabric may be made having
zones of higher and lower recovery. This may be achieved
by using zones of different fibres or a single fibre
type that has been differentially treated, such ag by
subjecting it to different degrees of irradiation~ The
differential treatment may comprise the di~ferential
incorporation of prorads or antirads, since in this way,
unform irradiation will produce zoning of recovery ratio
or of recovery stress.
The type of fibres and construction of the fabric
will now briefly be considered, although it is envisaged
that any weave or knit or non-woven agglomeration of any
fibres may be used providing the required degree of
recovery can be induced and providing the fibre density
is sufficiently high that the fabric can be rendered
substantially impervious. For the present purposes the
term weave is to include braids, since the products are
similar although the methods of production are different;
the terms warp and weft are not strictly applicable to
braids but when used herein with reference to weaves can
be considered to relate also to braids by arbitrary
selection o~ fibre directions. Recoverability is preferably
provided by weaving or knitting fibres that are already
recoverable, rather than by deforming a fabric woven or
knitted from dimensionally stable fibres. In the first
of these possibilities, the recovery ratio of the fabric
will depend not only on the recovery ratio of its
fibre~, but also on the type of weave or knit and on the
means employed to provide substantial imperviousness.
~7~25
--10--
The article as a whole will therefore recover, on
heating or other treatment, towards an origi~al shape
from which it has previously been deforrned, or towards a
new shape governed by the recovered configuration of
the fibres it contains, or towards another a new
configuration from which the article as a ~hole has not
been previously deformedO
The article will generally comprise a shrinkable
(preferably heat-shrinkable) sleeve cornprising preferably
polymeric fibres exhibiting (in the final product at
least) the property of elastic or plastic memory, which
property is describedt for example, in ~S patents
2027962; 3086242 and 3597372. As is made clear in, for
example, US patent 2027962, an original dimensionally
lS heat-stable form may be a transient form in a continuous
process in which, for example, an extruded tube is
expanded (or in the present case a fabric tube is
expanded or fibres are stretched, generally during their
formation) to a dimensionally heat unstable form in a
2~ separate stage.
In the production of polymeric heat-recoverable
articles in general, the polymeric material may be
cross-linked at any stage in the production of the
article that will improve temperature stability while
enhancing the desired dimensional recoverability. One
rnanner of producing a heat-recoverable article comprises
stretching or shaping the polymeric material into the
desired heat-stable form, subsequently cross-linking
the polymeric material, heating the article to a temperature
above the crystalline melting point or, for amorphous
materials the softening point, as the case may be, of
the polymer, deforming the article and cooling the
article whilst in the deformed state so that the deformed
state of the article is retained. In use, since the
~gL7~3;2 5
deformed state of the article is heat-unstable, application
of heat will cause the article to assume its original
heat-stable shape.
When the fibre is cross-linked by irradiation it is
convenient to incorporate the cross-linking step into
the overall manufacture of the fibre. The fibre can be
extruded, stretched at a temperature below its melting
temperature, preferably by an amount of from ~00-2000~,
then subjected to irradiation to effect cross-linking. A
less preferred way of making the fibre is to extrude the
material, irradiate to cross-link, then heat the fibre
preferably to above its meltir,g temperature, stretch the
fibre, and then cool. HDPE fibres are preferably irradiated
with a dose of from about 5 to about 35 megarads, more
preferably ~rom about 5 to about 25 megarads, and most
preferably from about 7 to about 18 megarads especially
from 10 to about 18 megarads. The gel content that
results is preferably at least 20~, more preferably at
least 3Q%, and most preferably at least 40~. In practice
a maximum of about 90~ will be sufficient for most
purposes.
In other articles, as described, for example, in
British Patent 1440524, an elastomeric member is held in
a stretched state by a second member, which, upon
heating weakens and thus allows the elastomeric member
to recover.
When recoverable by heat, the recovery temperature
is preferably 60 C or more, more preferably from
80-250C, such as 120-150C.
In general, the fabric will be constructed so
that the recoverable fibres can effectively run at
least in the direction where recovery is required. In a
~ 7~3ZS
-12-
weave, therefore, the warp only, or the weft only, or
both weft and warp, may be recoverable. In more complicated
weaves! such as a triaxial weave, one or both of the
warps may be recoverable. An advantage of the use of
fabrics is that perfect uniaxial recovery, or a chosen
split in recovery between two directions, may be achieved.
Where the fabric is knitted, use of a recoverable fibre
will produce recovery in all direc~ions~ although
selective recovery can be provided by controlled
warp or weft insertion.
Different effects, in terms of for example, final
recovery ratio, strength and flexibility, will result
from different types of weave or knit even if the same
fibres are used. E~amples of type of weave include
plain, twill, broken twill, herring bone satin, sateen,
leno, hop sack, sack,matt and combinations of these.
The weave may be single ply, or if higher density or
thicker fabrics are desired multiple ply weaves may be
used. For the present preferred purposes, where a warp
recoverable fabric is to recover over a liner having a
transition, high warp recovery combined with low crimp
in any single weft insertion is required. Hence fabrics
of high float, such as satins or sateens, which can
accommodate high weft density combined with low crimp,
and which retain excellent recovery are to be preferred.
The fibres used to produce the recoverable fabric
may be monofilaments, multifilaments or spun staple
yarns. Greater flexibility can be attained using
multifilament yarns, although problems can be encountered
in cross-linking due to the high surface area. Examples
of polymeric materials that may be used include polyolefins
such as polyethylene (especially HDPE) and polypropylene,
polyamides, polyesters and fluoropolymers such as FEP,
ethylene perfluoro copolymer, polyvinylidine fluoride
~ '7~3~S
-13-
and TFE copolymers. The recovery temperature, by which
we mean the temperature at which recov~ery will go
substantially to completion, is preferably 60C or
more, more preferably from 80-250C, most preferably
from l20-l50C.
A non-recoverable fibre may be used as a reinforcement
or supplement to the recoverable fibres, or may constitute
the major component in one or more dimensions of the
fabric~ The following non-recoverable materials may be
regarded as illustrative : glassfibres, carbon fibres,
wires or other metal fibres, polyesters, aromatic
polymers such as aromatic polyamides for example Kevlar
(trade name), imides and ceramics. The non-recoverable
component may be permanent, giving the recovered article
enhanced strength etc., or may be present in c1iscrete
form only to locate the recoverable component during
installation.
The means by which thè fabric is rendered substantially
impervious may be a polymeric matrix material which
extends throughout the fabric, and the following discussion
is in terms of the use of a polymeric material. Such a
system, which is disclosed in UK Patent application
No. 8300218, preferably comprises a composite structure
of a heat-recoverable fabric and a polymer matrix
material wherein:
(a) the heat recoverable fabric comprises fibres that
will recover when heated, the fibres having a recovery
stress Y of at least 5 X lO, 2 preferably at least
5xlO 1 more preferably at least 1 MPa at a temperature
above their recovery temperature ; and
(b) the polymer matrix material has an elongation/
temperature profile such that there exists a tempera-
-14-
ture (T) which is at or above the recovery tempera-
ture of the ibres at which temperature the polymer
matrix material has an elongation to break of greater
than 20% preferably greater than 100~, especially from
400-700~ and a 20~ secant modulus X of at least 10
MPa ( measured at a strain rate of 300% per minute),
and at which temperature the inequality i.s satisfied:
X ( 1-R ), is less than one, preferably
Y R less than 0.5, more preferably less
than 0.05.
wherein ~ is the mean effective volume fraction of
heat-recoverable fibres in the composite structure along
a given direction based on the total volume of the composite
structure, or relevant portion thereof.
In a further embodiment, components (A) and (B)
of the invention are provided by a recoverable composite
structure comprising a cross-linked polymeric material
and cross-linked recoverable fibres by virtue of which
the composite is recoverable.
Such a recoverable composite structure can be
made by applying to the cross-linked recoverable fibres
the polymeric material, and then cross-linking the
polymeric ~aterialO
The fibres are desirably cross-linked to increase
their post-recovery strength, and a recovery stress of at
least 1 MPa, preferably 1.5 to 5 MPa will generally be
suitable. The polymeric material is desirably cross-linked
to prevent it dripping or running during heat recovery,
particularly during heat recovery by means of a torch.
Too much cross-linking of the polymeric material will,
however, reduce the recovery ratio of the composite
~ ~7~5
-15-
structure. This can give rise to a problem since a
different extent of cross-linkin~ treatment may be
required in the fibres and the polymeric material. This
is the reason for the two cross-linking steps being
carried out separately in the embodiment just described.
The problem may arise due to different cross-linking
responses (beam response in the case of irradiation
cross-linking, for example) of the types of material used
for the fibres and the polymeric material, or it may
result from the trea~ment undergone by the fibres and
polymeric material. This second effect includes the
reduced beam response of the fibres that results
from their moleuiar orientation produced by drawing to
make them recoverable.
t5 The composite structure may, nonetheless, be produced
using a single cross-linking step if the beam response
of the recoverable fibres relative to that of the
polymeric material in such that a post-irradiation
recovery stress of the fibres, per se, of at least 1 MPa
can be reached before the recovery ratio Or the composite
structure is reduced to a value o~ 70~ of that o~ the
unirradiated composite structure.
The relative beam response may be produced
by the presence of prorads in the recoverable fibres
and/or antirads in the polymeric material.
In a preferred embodiment of the invention the
fabric is incorporated into a flexible recoverable
composite structure comprising the recoverable fabric
and a polymeric matrix material laminated thereto, in
which:
(a~ the recoverable fabric comprises a cross-linked
recoverable polyolefin having a recovery stress o~ t.5 to
5 MPa
~Z~7i 32~
-16-
(b) the matrix is cross-linked such that the recovery
ratio available in the composite is at least 65~ of that
available in the free fabric, and the polymeric matrix
material, per se, after irradiation has room temperature
elongation 40Q-700% measured at a strain rate 300~.
Irradiation, in addition to providing one means
of cross-linking, can provide other features in the
composite structure. If the fibres are irradated,
particularly in the presence of oxygen, before application
of the polymeric material then a change in the surface
properties of the fibres may occur ~such as oxidation)
which improves adhesion between the fibres and the
polymeric material. An irradiation step after application
of the polymeric material may also aid such bonding by
forming a cross-linked bond between the two components
of the composite structure.
The polymeric matrix material may be thermoplastic
or elastomeric. Examples of thermoplastic materials
include : ethylene/vinyl acetate copolymers, ethylene/ethyl
acrylate copolymers, LLDPE, LDPE, MDPE, HDPE, polypropylene,
polybutylene, polyesters, polyamides, polyetheramides,
perfluoroethylene /ethylene copolymers, and polyvinylidene
fluoride The following is a list of preferred elastomeric
materials : ABS block copolymers, acrylics including
acrylates, methacrylates and their copolymers, high
vinyl acetate copolymers with ethylene, polynorbornene,
polyurethanes and silicone elastomers. These materials
(or part of them) are preferably cross-linked, and this
is conveniently carried out by subjecting the fabric to
a suitable cross-linking agent after the fabric has been
rendered impervious by incorporating the polymeric
material.
The material can be cross-linked by irràdiation
-
~Z47~3~25
~17-
or by other means such as chemical cross-linking using,
for example, a peroxide cross-linking agent, provided
that the physical properties of the matrix at the
recovery temperature of the fibres are as required after
the cross-linkiny step. Where irradiation is used a
dose of 10 megarads or less, in particular from 3-7
megarads is preferred. The recovery ratio o~ the
resulting composite structure after irradiation is
preferably at least 50~, especially at least 70% of that
before irradiation. These dose values may be regarded
as typical for olefinic polymers of low orientation, and
the skilled man will be able to select suitable doses
depending on the presence of various concentrations of
prorads or antirads, if any.
The precise technique by means of which the fabric
is rendered substantially impervious will of caurse
depend on whether, for example, a polymeric material is
simply used in conjunction with the fabric, is adhered
to a surface (preferably an inner surface) of the
fabric, extends throughout the fabric, or is introduced
in some other way. The extent of mechanical interaction
required between the fabric and the polymeric material
will depend on the extent of bonding that can be
achieved during manufacture, and this is a function of
the difference between the melt or softening temperature
of the polymeric material and the recovery temperature
of the fabric. Unless a further stretching operation is
to be carried out later, recovery should not occur at
this stage. Recovery could of course be avoided by
mechanically holding the fabric, but this tends to make
incorporation of the polymeric material rather complex.
Suitable techniques for coating the fabric with a
polymeric material which achieve at least some penetration
include press lamination, hot coating from the melt
between rollers, spray coating, dip coa~ing and powder
~Z~7~32~ `
coating.
The amount of polymeric material used should be
sufficient to render the fabric substantially impervio~s
to air when it is recovered. It is possible, therefore,
for the polymeric material to be a discontinuous coating
or impregnation before recovery, and optionally to
melt or soften sufficiently and be brought together on
recovery to provide a substantially impervious barrier. We
prefer, however, that the composite of fabric and
polymeric material be substantially impervious before as
well as after recovery. The thickness of the palymeric
material should be great enough to allow the desired
pressure, if any, to be retained, but small enough to
allow the fabric to recover to the desired extent. The
composite desirably recovers as a unit with no appreciable
drawing-through of fabric within the matrix. A suitable
thickness o~ polymeric material is 0-0.6mm preferaby
about 0.3mm either side of the fabric~ We have found
that an unstressed layer of a polymeric material of
thickness of at least 0~03mm especially 0.2 to 2.0mm on
an external surface of the fabric provides a considerable
improvement in the ease with which the fabric can safely
be recovered using a torch such as a propane torch.
Such polymeric layer will generally soften during
recovery but has a sufficiently high viscosity that is
is retained by the fabric~ This is disclosed in
UK patent application No. 8300217.
The composite is preferably coated with an adhesive
on that side which will face the substrate to be enclosed,
although the polymeric material providing imperviousness
may be adhesive under installation conditions. Heat-
activatable adhesives are preferred/ especially hot-melt
;
~2~7~3;25
- 1 9-
adhesives such as polyamides and EVAs. An ideal polyamide
adhesive, which is disclosed in UK patent publication
2075991, contains up to 10~, preferably up to 1~ o~ an
acrylic rubber and has excellent adhesion to untreated
polyethylene, and good low temperature flexibility. The
activation temperature of the adhesive should be chosen
to correspond to the recovery temperature of the fabric,
so that the single step of heating ~chieves both recovery
and bonding . The adhesive need not extend over the
entire surface of the sleeve, and in certain situations
need only be present at its openings.
A single layer of fabric may be used, or the
sleeve may comprise a laminate of two or more layers of
fabric, optionally bonded together with a simple layer
of adhesive or including a thicker layer interposed
between the fabrics.
The other major component which allows the recoverable
fabric described above to enclose a substrate such as a
cable splice, and which provides impact and other
mechanical strength, is a relatively rigid liner. Such
liners, which comprise a larger central section and
smaller end sections, may be made in many ways. A
canister comprising aluminium or other half shells
having shaped ends can be provided with hinges or
interlocking longitudinal edges for wrap-around installation.
This type of canister may be made of sheet material, or
may have the appearance of a cage and comprise supporting
end rings and a series of longitudinal struts joining
them. Such a liner is disclosed in UK patent 1431167,
the disclosure of which is incorporated herein by
reference. An alternative liner may be made from a
roll of rather stiff material which is wrapped around
the splice with a degree of overlap which depends on
the degree of heat and mechanical protection required.
,
~478;~
-20-
The material used may comprise a laminate o~ cardboard
or of a plastics material together with layers for
reducing heat or moisture vapour transfer. Such liners
may therefore include a support layer (preferably
cardboard or plastics material), a foam layer for heat
resistance, a metal oil layer for water-vapour resistance,
and optionally one or more thin films of a poly~eric
material for further protection. A liner based on
cardboard is described in published UK patent application
2059873 and one based on a thermoplastics material is
disclosed in published UK patent application 2069773.
These disclosures are incorporated herein by reference.
The structure just described may constitute merely the
central or larger part of the liner as required for this
invention, the ends which provide the transitions down
to the cables being provided by separate end pieces
which serve to support the central region and to provide
the desired smooth transitionsO Alternatively, the
lon~itudinal edges of the roll of liner material
may be provided with a series of slits or may be crowned
in order that the edge portions of the installed roll
may be collapsed to taper gradually down to the cables.
The liner is preferably shaped to avoid any sharp
angular change between the central portion and the
slope, and between the slope and the cables. If the
liner has tapered fingers at its ends a gradual, rounded
transition is ensured by the gentle increase in flexibility
and consequently in bending along the length of each
finger. As mentioned above, these fingers may be part of
a unitary liner or may constitute or be part of separate
end supports which cary the larger central region of the
liner. The angle of the transition (that is of the
sloping part relative to the axis of the cable~ is
preferably less than 60 more preferably less than 45
We have surprisingly found that recoverable fabrics can
be produced which are stable over transitions steeper
3 ~7
'.
than 60 or more, by which we mean that unacceptable
parting of the fibres by sliding down the transition can
be avoided. Where a particularly large transition angle
is desired, it may be desirable to provide crimp in the
fibres running in the direction along the splice case
since this reduces the chance of the longitudinal
fibres becoming straight and alowing the circum-
ferential recoverable fibres to fall to one side. The
weave type also has an effect, and we have found greater
stability for high float fabrics where more longitudinal
fibres can be accommodated; hence sateen is preferable
to twill, which in turn is better than plain weave.
The liner preferably carries a valve, which may be
used to pressurise the splice case of which it forms
lS part, or merely to test pressure~ The feature will of
course be primarily useeul in conjunction with pressurised
telephone cables. The valve preferably has a screw-threaded
body and is sealed to the liner by means of sealing
washers and a nut. The use of a fabric rather than a
continuous material as the sleeve has a particular
advantage here; it is possible to force a hole (generally
after gentle heating) through the fabric without
breaking any fibres, and as a result there is no question
of any split propagating later during recovery. Even if
a hole is drilled or otherwise cut to make way for the
valve only a limited number of fibres are severed and
the damage will not spread. ~he valve may be passed
through the liner and then through the hole in the
fabric sleeve so that its base abuts against the inside
of the liner. Various sealing washers are installed and
tightened down by means of a nut. Improved sealing can
be achieved if the washer which overlies the fabric
has a larger hole than the hole in the fabric, since in
this arrangement an annular portion of fabric becomes
pinched between the top washer and the valve bodyO The
'7~5
-22-
valve can serve also as an earth or screen grounding
point, or as a lug for locating the sleeve with respecct
to the liner. The last of these features is particularly
useful where the liner is cage-like, and the sleeve is
wrap-around and has a closure which must overlie one of
the bars of the cage~ For ease of assembly in the ield,
the sleeve may be supplied attached to the liner or to
part of it by means of the valve.
The liner may be constructed to facilitate re-entry,
by which we mean at least partial removal of an old
recovered sleeve in a way that does not damage the
underlying cables, and rebuilding of the splice case
with a new recoverable sleve. One technique is to cut
the old sleeve circumferentially at each transition, and
longitudinally between the two circumferential cuts. It
is therefore desirable that there be a gap between the
liner and the underlying cable splice. This allows a
central portion of the old sleeve to be removed, leaving
behind its ends which remain sealed to the cables. Where
the old sleeve was a wrap-around sleeve having an
upstanding closure means~ it is usual to cut-off this
closure means before making the cuts referred to above.
After the cable splice has been attended to a new sleeve
is installed to bridge the remaining butts of the old
sleeve. It is desirable that the central portion of the
old sleeve can be removed without destroying the liner.
To this end UK patent publication 209340~ proposes that
a liner be provided with an overlying moisture-barrier
foil layer which can become bonded to the overlying
sleeve but which remains separable from the liner.
Where the assembly of the invention is used, for
example, to enclose a splice between pressurised cables
a further component is preferably included. Pressure
lZ'~7B~5
-23-
within a splice case tends to put any seal or other
engagement bet~een the recovered sleeve and the ingoing
cables into peel. This problem was recognised and a
solution found in UK patent publication 2040106, where
it was proposed that one should use one or more flexible
auxiliary members interposed between the sleeve and the
cable and so positioned as to be able to be deformed by
forces generated by the internal pressure so that one
portion of the member is forced against the sleeve and
another is forced against the cable portion. As a
result, peel between the outer sleeve and the cable is
replaced by shear between the au~iliary member and the
cable and between the auxiliary member an~d the sleeve.
In general, any means will be desirable that can be
positioned around the substrate (here a cable~ and the
outlet portion of the sleeve which can reduce the
tendency of the enyagement between sleeve and outlet
portion to be reduced by the internal pressure.
One embodiment of the auxiliary member disclosed in
UK patent publication 2040106 is a strip of substantially
U or V shaped cross-section which is wrapped around the
cable at the region where the sleeve meets the cable.
One limb of the U or V becomes bonded to the cable and
the other to the sleeve, with the opening facing into
the splice case. The auxiliary member may contain an
adhesive, such as a hot-melt adhesive, a strip of foil
for heat protection, and release paper to cover the
adhesive until it is needed.
An alternative embodiment, which allows the auxiliary
member to be cut to a length according to the circumference
of the cables, includes a highly elastic rubber or a
foram instead of the U or V shaped strip. The rubber or
foam is bonded to a strip of adhesive~ the other side of
which is atached to a strip of aluminium foil.
:~247~Z5
--24--
The rubber or foam may be coated with a pressure sensitive
adhesive ~o aid installation. Pressure within the splice
case acts on the rubber or foam causing it to splay out
against the cable and the sleeve.
Where an enclosure has to be built around a simple
end-to-end joint between two cables a simple sleeve can
be used which shrinks into contact with each cable.
However, problems may arise where two or more cables or
other substrates have to be sealed at one position. This
problem, which is known as branch-off, occurs in a cable
splice where one cable is divided into two. This problem
can be overcome by providing means for holding together
circumferentially spaced portions of an outlet of the
fabric sleeve to close at least partially the crutch
region between the diverging cables. The seal is
conveniently completed by an adhesive on the inner
surface of the sleeve which melts or otherwise becomes
activated as the sleeve recovers. A solution is proposed
in VK patent publication 2019120r where a branch-off
seal is formed by:
(a) positioning a clip having at least two elongate
legs over the outer surface of a recoverable sleeve at
an end thereo~ so as to form at least two terminal
conduits;
(b) positioning substrates within the conduits;
and
(c) applying heat so as to effect recovery and
to form the desired seal.
The branch-off clip preferably has three legs,
the central leg being coated with an adhesive and being
positioned within the sleeve. This allows a greater
amount of adhesive to be provided in the crutch region.
The clip, preferably its central leg, may be hollow and
provided with a pressure access point, or with means for
8;~5
-25-
monitoring temperature in the crutch region.
The problem of branch-off can, however, be overcome
by producing the fabric sleeve in the correct shape
to accomodate two or more branching substrates. This
solution is particularly applicable to fabrics, and
offers significant advantages. A fabric can be produced,
especially by knitting, which has for example one outlet
at one end and two at another end. Such an article can
still be wrap-around since closure mechanisms may be
provided for each outlet.
An alternative technique involves installing around
the cables a flexible seal which comprises an envelope
containing a composition which can undergo a change from
lower to higher viscosity. The seal transforms the
concave surfaces in the crutch region to a flat or
convex surface to which the fabric can seal. This is
disclosed in copending ~K patent application 8221597.
The outlet of the sleeve is therefore recovered into
engagement with the cables via the intermediary of the
flexible seal.
The following example is given to illustrate a pressure
vessel built from preferred materials.
Example
The following two HDPE monofilaments are chosen to
provide the recoverable component of a variety of different
weaves.
26~
Fibre t Flbre 2
Mn 24500 19100
Mw 135760 163100
M~ 459000 2060000
Mp 64400 53200
D 5.378 8.510
Initial Moduius (MPa)3881.3 2959
Tensile Strength (MPa)534.4414.9
~ Elongation (21C) 21 30
Monofilament dia (MM~0.38 0~9
These fibres were irradiated using 6 MeV electrons
at a dose rate of 0.24 Mrads/Min.
Table 1 shows the properties of these fibres
for various total doses of radiation.
TABLE 1
Fibre Properties
Radiation Dosage (Mrads)
Fibre Property 0 8 16 _ 32
1 100% Modulus (MPa) O.t3 0.3 0.42
Tensile Strength (MPa)0.93 1.4 1.46
Elongation to Break (%)1480 924 754
Gel Content (%) 27.0 58.0 67.0
Recovery ~orce (MPa) 1.17 1.2 1.3
Recovery (~) 89 88.5 88.5
~Z4L7~3~5
-27-
2 100~ Modulus (MPa) 0.. 27 0.21 0.34
Tensile Strength (MPa) 1.36 1.93 2.98
Elongation to Break (~) 752 487 777
Gel Content (~) 10.0 40.0 61.0
Recovery Force (MPa) 0.57 0.6 0.65
Recovery (%) 89 87 85
Each of these two HDPE fibres was woven with a
non-recoverable fibre to produce various different
weaves. In each case the recoverable HDPE was the warp
fibre. Table 2 shows the % recovery for each fabric
type. Kevlar, referred to under fabric 11, is a Trade
Mark for an aramide fibre yarn.
32S
a~
~ ~ r ~ ` ~D I ~ r` o~ ,~
C~
-
Q~
~i ct~ ~D O O u~ 1 0 0 ~ 0 1` Ul t~ N
~ O
U7
a ~r u~ a~ o ~ D 1` 0 ~O
: O
r
C
m
~Y h Q) a)
.,. v v v v In
QJ V
H ~J ~
0
o~
. ~ V ~ ~
~U -- O ~ O ~O O ~ ~O ~ ~ ~ ~D ~ ~ 9.~
(1) o~ ;~ o~ ~ o~ ~ o~ ~ o~
~a:~ 0 ~ ~ ~ 0 ~ C ~ E~
V ,~
~ ~ ~ ~ ~ ~ ~ V ~ ~ ~ ~ ~ ~ V ~ ~
~ X x X X ~ X ~ ~ X ~: X X X ~ ~ ~ X -~ ~1 9
~ ~ c~ v ~ c
o o
~V
~4 ~
1 ;2'iL7825
-~9-~
Fabrics 5 and 11 above were rendered substantially
impervious by combining them with various polymeric
resins to produce a composite. The resins were in the
form of extruded sheets of 0.5mm thickness with little
to no orientation, and lamination was carried out in a
press between silicone rubber sheets. The resulting
composites were subjected to irradiation with 6 MeV
electrons in air at room temperature at a dose rate of
0.24 Mrads/min for times sufficient to produce a radiation
dose of 2.4 or 6 Mrads. Table 3 shows the laminating
conditions and final percentage recovery for four composites.
,
TABLE III
~minati~ Co~itions
Temperature Pressure Time %
Cbmposite
o. Fabric Polymer (~C) (~/cm2) (mins.) Recovery
1 5 EV~ 460 lQ5 45 5 70
2 5 ~ 250 100 45 3 69
3 5 Sclair 2109 150 22.5 5 68
4 5 D ~ -3 150 22.5 5 60
-30-
The tear strength of each of these fabrics was
tested in an Instron tensometer employing a draw rate of
100mm/min. A strip of composite was used, the length of
which ran parallel to the recoverable warp, and the
S width parallel to the non-recoverable weft glass or
kevlar, which is an aromatic polyamide. This test
served therefore to measure the strength o~ the glass
and kevlar and to compare them. The strip was used in
the Instron as follows. A cut was made lengthwise down
the middle of the strip for about three quarters of its
length. The two legs that result were then pulled in
opposite directions by attaching one to the fixed and
one to the moving jaw of the Instron.
In all cases an excellent tear strength in excess
of 30N was easily achieved, and for the kevlar based
fabric the figure was considerably higher at 150N. This
test is regarded as highly demanding since the fibres
are being bent through a far sharper angle than would be
experienced in a sleeve for enclosing a substrate such
as a cable splice.
Components 1 and 4 above were used to produce a
splice case suitable for enclosing a splice between two
pressurised telephone cables. Four sheets were prepared
having thickened portions running along opposite weft
edges so that a radially recoverable wrap-around sleeve
was produced. These thickened edge portions acted as
rails which were later secured together by an elongate
channel in the manner shown in UK patent 1155470, the
disclosure of which is incorporated herein by reference.
Each of these sheets of composite was then coated
with a hot-melt adhesive on that side which would be
inwardly facing when in the wrapped around configuration.
325
--3 1--
The adhesive used was a polyamide, modified with up to
1% of an acrylic rubber, applied to a thickness of
0.5mm. The resulting four sleves had the dimensions
shown in Table 4, and were for use in conjunction with
the cable sizes indicated.
TABLE 4
Cable Width between Le~th Thickness
Sleeve Ccm~site Size rails
1 1 50 pairs 19m 38cm .08cm
2 l 200 33cm 38cm .08cm
3 4 200 33cm 38cm .08cm
4 1 400 43cm 50cm .08cm
Each of these sleeves was used in conjunction with
a liner which comprised an aluminium canister of about
75% of the length of the sleeve and having crowned ends
; which could be deformed to provide smooth 30 transitions.
The diameters of the canisters were chosen to be about
75-90% of the diameter of the assembled sleeve in order
to ensure some degree of unresolved recovery. ( The
recovery ratio of the sleeves was about 4:1~ based on
the recoverable size and the change in size, which
corresponds to a percentage change of 75% and although a
wide range is possible we prefer recovery from 20-90~.)
Pressure tests were then carried out on splice cases
built up using the above liner and sleeves recovered
over a polyethylene jacketed telephone cable. The cable
had a 0.5cm hole cut in its jacket for pressure communication
with the inside of the splice case. The splice cases
were put under pressure of 70 KPa ~10 psi) and cycled
between -40 and +60C for 100 cycles at 3 cycles per
day. The splice cases were also tested in water at 105
KPa through lO0 cycles between 5 and 50C~ No leaks
8Z~
-32-
or breaks were detectable, indicating a high degree of
pressure retention. The amount of creep detected
was minimal and in some cases not detectable.
The invention is further illustrated with reference
to the accompanying drawingsl in which:
Figure 1 shows a joint between two substrates
surrounded by a liner and an unrecoverened tubular
sleeve;
Figure 2 shows a similar joint but with the sleeve
after recovery;
Figure 3 shows a cable splice partially surrounded
by a wrap-around liner and a wrap-around recoverable
sleeve;
Figure 4 shows an end of a splice case having an
auxiliary ~ember to aid pressure retention;
Figure 5 shows a liner and a sleeve bearing a
valve; and
Figure 6 shows a co~posite recoverable fabric.
Two substrates l are jointed at a joint region 2
and surrounded by a liner 3 and recoverable fabric
sleeve 4. In Figure 1 the sleeve is shown before
recovery, and in Figure 2 it is shown after recovery.
In Figure 2 an adhesive can be seen bonding the sleeve
to the substrates 1 and to the liner 3. The adhesive is
preferably supplied coated to the internal surface of
the sleeve. Where recovery is initiated by heat, the
adhesive is preferably heat-activatable so that the
single step of heating causes recovery of the sleeve and
activation of the adhesive . It is not necessary that
78~5
-33-
the adhesive covers the entire surface of the sleeve,
and in the embodiment illustrated an adhesive coating
may be provided only at the regions where the sleeve
meets the cables.
In Figure 3 the substrates 1 are shown as multi-
conductor cables, and region 2 is a sp:Lice bundle
joining the two cables. In this Figure both the liner 3
and the fabric sleeve 4 are wrap-around. The liner is
hinged at 8 and has castellated edges 9 to ensure
rigidity when closed. The sleeve is provided with
closure means 6 at its longitudinal edges which can be
held together with an elongate channel of C-shaped
cross-section. Other types of closure may be used and
in general what is preferred is a mechanical closure
for maintaining edge regions o the fabric in proximate
relationship during recovery~ The liner has crowned
ends 7 which provide transitions from its central region
to the cables 1 and which locate the liner with respect
to the cables, thereby allowing production of a hollow
pressure vessel having outlet portions only recovered
into engagement with the cables.
In Figure 4 an auxiliary member 10 is shown to aid
pressure retention within the splice case. The auxiliary
member can present , for example, a concave or re-entrant
surface to pressure within the splice case and this puts
the adhesive bonding the sleeve 4 to the cable 1 out of
peel. The auxiliary member may be a strip of material
of generally U or V cross-section that is wrapped around
the cable such that one limb engages the cable, and the
other engages the ~leeve.
A valve 11 is shown in Figure 5, by means of which
the splice case can be pressurized or monitored. The
valve is secured to the liner and sleeve by means of a
~2~7~32~i
-34-
nut 12 which engages a screw thread on the shaft of the
valve. Various washers 13 are provided to ens~re an
air tight seal. The valve, or other appendage, can be
used to locate the sleeve with respect to the liner, or
can provide a means by which the liner can be earthed.
An end of a composite recoverable fabric is shown
in Figure 6. The fabric comprises a warp 15 and a weft
16 embeded in a matrix material 17 by means of which the
fabric is rendered impervious to air. an adhesive
coating 18 is provided on one side of the fabric.
