ARRANGEMENT AND METHOD FOR MAKING A FLUID-TIGHT CABLE

Abstract: An arrangement for making a fluid-tight cable, as well as a method and a cable obtained thereby, includes a tubular injection device (21) through which passes a cable core (9) wrapped in a permeable tape. The device which has an adjustable chamber (W) disposed around the cable core is able to perform a reciprocating movement. During the forward stroke the device travels with the cable and a water blocking material is injected into the cable core to fill the interstices between the conductors thereof. During the backward stroke when the device returns to its initial position the injection is stopped and the material present in the chamber is smeared out over the tape.

Description: Arrangement and method for making a fluid-tiqht cable and cable obtained thereby The invention relates to an arrangement for making a fluidtight, e.g. water-tight, cable containing a cable core with a plurality of conductors by filling interstices between said conductors with a fluid blocking, e.g. water blocking, material to prevent fluid, e.g. water, penetration, said arrangement including means to displace an injection device to inject said material into said cable core. Such an arrangement is known from the article "Compartementalized Longitudinal Waterproof Cables", by D.J. Dekker, J. Bruining and G.A.C. Schuring, published on pages 254 to 267 of the "Proceedings of the 28th International Wire and Cable Symposium" held in Cherry Eill on Nov. 13, 14, 15, 1979. In this paper a comparative study is made of materials and methods to render electric cables water-tight in longitudinal direction. It is known that water may penetrate through a locally damaged cable sheath and then propagate further longitudinally through the cable core between the conductors thereof. This can adversely affect the electrical properties of the cable. This longitudinal water infiltration can be stopped by filling the interstices between the wires of the cable core either completely or at regular intervals with water blocking material. In the last case regularly spaced discrete water blocking elements are produced. On page 26 of the above mentioned article is shown an injection machine for a polyurethane compound. A cable core on which a polyethylene sheath is to be extruded is led over a V-grooved wheel having four injection devices or moulds which are one meter apart. The wheel is being driven by the cable itself which moves at the extrusion speed of the polyethylene extruder. In each mould a complete injection takes place while the cable is in contact with the wheel. Before each injection the mould is opened, the cable is positioned therein and the mould is closed whereafter the injection of the polyurethane compound takes place at a high injection pressure. In this way a cable core is produced having discontinuous injected water blocking elements which are one meter apart from each other. The wheel used in this known machine implies a change of direction for the cable, if one assumes it contacts the wheel over half its circumference, and therefore the necessary space to accomodate the two parallel cable parts as well as the provision of four injection moulds. It is a first object of the invention to use only one displaceable injection mould. The invention is characterized in that said means produces substantially no relative movement between said cable core and said injection device during a first part of an injection cycle but allows such a relative movement during the second part of said cycle. The invention is further characterized in that said means impart to said injection device a reciprocating movement, said injection of said blocking material occurring during one of the two stokes of said reciprocating movement. In this way, there is no longer any link between the displacement of the injection unit and that of the cable. Not only is a single injection mould used with this reciprocating movement but the relative displacement between the mould and the cable during the return stroke can produce an advantageous smearing action as outlined below. The invention also relates to an arrangement for making a fluid-tight, e.g. water-tight, cable containing a cable ¯ core with a plurality of conductors by filling interstices between said conductors with a fluid blocking, e.g. water blocking material to prevent fluid, e.g. water, penetration, said arrangement including an injection device to inject said material into said cable core, said device comprising a cable inlet opening, a cable outlet opening and a fluid blocking material injection opening giving access to a compression chamber disposed around said cable core. Such an arrangement is known f.i. from the Dutch patent application 7308203 mentioning an injection device having an inlet opening, an outlet opening and an injection opening to inject a viscous, e.g. a paraffin like material with a volatile solvent in the core of a cable passing through the inlet and outlet openings of the device. In the German patent application 2 112 674 a device is shown with a compression chamber having tube like elements fixed threon at the entrance and exit sides. These elements are each provided with cooling chambers to cool the fluid injected into the cable core and to prevent it to escape out of the tube like elements under the influence of the injection pressure. These earlier publications do not disclose any means enabling the process to be adapted to different types of cables and it is a further object of the invention to use the same arrangement and with the same efficiency on cables of various characteristics and cross sections. The invention is also characterized in that means are provided to adjust the dimensions of said chamber. The invention is further characterized in that said means are inserts placed inside said injection device directly around said cable and on each side of said injection opening. In this way, using two nylon tubes for the two inserts around the cable on each side of the injection opening one obtains a symmetrically adjustable chamber catering for different sizes of water blocks by sliding the tubes in or out. By using tubes of different- internal diameters, one can, also adapt the chamber to different cable cross sections. Moreover, when using such inserts with the reciprocating action for the injection device, the position chosen for the tubes will also determine the quantity of filling material remaining in the chamber after the forward stoke and to be smeared out over the cable during the return stroke. A supplementary sheath is formed in this manner between the cable core and the succeeding extruded sheath, e.g. polyethylene sheath. This decreases the capacitive earth coupling with the outer layer of the wires of the cable core in the case the cable has an earthed aluminium polyethylene moisture barrier which is folded around the inner polyethylene sheath. Also, a lubricating effect is obtained during the movement in the opposite direction. It should be noted that on page 258 of the above mentioned article a polyurethane injection unit for cables is shown schematically. The filling material is an expanding soft foam provided on a non woven polyester tape immediately before a metal sheath is applied. The material penetrates through the tape when expanding. This injection unit includes no moving injection device smearing out the material during its return movement. Polyurethane compounds suitable for fluid stops in electrical cables or for rehabilitating waterlogged telecommunicationcables have already been disclosed, e.g. US patent 3 248 472 using a mixture of a polyurethane prepolymer prepared by reacting a polyol with a polyisocyanate or US patent 4 176 239 using a butadiene homopolymer to prepare an isocyanate terminated prepolymer. However, a distinct polyurethane composition preferred for the realisation of the water blocks in accordance with the present invention is the subject -of the British patent application of even date filediIby Standard Telephones and Cables Limited. The above mentioned and other objects and features of the invention will become more apparent and the invention itself will be best understood by referring to the following description of an embodiment taken in conjunction with the accompanying drawings in which Fig. 1 is a schematic representation of part of a cable extrusion line including a water blocking injection unit comprising a water blocking injection arrangement 2 used to inject water blocking material into a cable in order to provide the latter with water blocking elements according to the invention; Fig. 2 is a front view of the water blocking injection arrangement 2 with an injection device 21 forming part of the injection unit of Fig. 1; Fig. 3 is a side view of the injection arrangement of Fig. 2; Fig. 4 is a side view of the injection device 21; ; Fig. 5 is a longitudinal cross section along line AA of the injection device shown in side view in Fig. 4; Fig. 6 shows different positions of the injection device 21 during and after the injection of the water blocking material and synchronizing pulses SI used to synchronize the operations of the injection unit; Fig. 7 is a part of a pneumatic control system used to control the operations of the injection arrangement; Fig. 8 is another part of the pneumatic control system used to control the injection of water blocking material; Fig. 9 is a longitudinal cross section of a cable provided with water blocking elements realized by means of the injection arrangement; Fig. 10 is an enlarged part of a transverse cross section along line AA of Fig. 9. Before describing the arrangement and device shown in the - figures it is reminded that a cable including a plurality of insulated electric conductors or optical fibres for instance may be rendered immune to longitudinal water penetration by injecting water blocking material into the cable core either in a continuous or discrete way. In the last case regularly spaced water blocking elements acting as water stops are produced. In what follows water blocking elements will be called water stops for short. A way to obtain such water stops is to fill the free spaces between the insulated conductors and those between the conductors near the inner sheath and this sheath with water blocking material. Such water stops are realized by means of the water blocking injection unit to be described below and which forms part of the extrusion line shown on Fig. 1. The water blocking injection unit includes an injection arrangement 2 to be described later, a liquid metering system 5 to dose different ingredients to be mixed and to be injected into a cable core in order to form water stops and a control system 7 to control the operation of the injection arrangement 2. The liquid metering system 5 is available on the market. The system used in this embodiment is the model 100 mm variable ratio type from Liquid Control (Northants, England) and is able to mix predetermined quantities of liquid ingredients used and to supply this mixture to the injection arrangement at the required pressure. The liquid metering system mainly includes three vessels, a first one containing an uncured polyurethane co-polymer consisting of an hydroxy-terminated polybutadiene, a second one containing a diphenylmethane diisocyanate and a third one containing a 2-ethylhexane diol serving as a chain extender and water. The liquid metering. system supplies predetermined quantities of the above mentioned liquids to a rotary mixer at a required pressure. More details concerning the mixture and ingredients can be found in the British patent application previously referred to. In order to shorten the length of the conduct from the mixer to the- injection- arrangement the mixer has been mounted in the injection arrangement and is connected to the liquid dosing system via three flexible conducts shown schematically (Fig. 1) by 51. on Fig. 1 are shown the main parts of the injection arrangement. These parts are T-shaped injection device 21, a valve 27, a mixer 30 to mix the predetermined liquid quantities and a cylinder 38 with double acting piston to impart a reciprocating movement to the main parts as explained later. The control system 7 is connected to pneumatic valve 27 and cylinder 38 by means of control conducts 71 and 72 respectively. The above extrusion line further includes a pay-off reel 1 supplying a wrapped cable core 9 to the injection arrangement 2, a sheath extruder 6 to cover the injected cable with a polyethylene sheath, a cooling trough 12 to cool the extruded cable, a cable puller 8 to pull the sheated cable and a take-up reel 11. The cable core which may be for instance built up of 25 quads is held together by means of a helically wound non woven permeable polyester tape. The liquid mixture is injected into the cable through this permeable tape as explained below. This tape is known on the market as "Reemay tape" NO 2014 from Du Pont de Nemours. The polyethylene sheath extruder 6 and cable puller 8 are machines known in the art of cable extrusion techniques so that they do not need to be described. The cable puller 8 is provided with a synchronizing system supplying a synchronizing pulse to the control system 7 via electrical connection 81 for every predetermined length (e.g. 2 meters) of extruded cable in order to synchronize the injection arrangement 2 with the extruder 6. The synchronizing system simply consists of a cam system and switch mounted on drive shaft of the cable puller and a time delay circuit to produce periodic pulses of a predetermined.time interval. Upon the occurrence of such a synchronizing pulse valve 27 is opened during the predetermined time interval to allow liquid mixture or material from the mixer 30 to the injection device through which the cable passes. This device travels with the cable during the injection time interval. Then the device 21 returns to its initial position in a direction opposite to the direction of the cable movement until the occurrence of the next synchronising pulse. In this way a stop of a predetermined lenght is injected into the cable, e.g. every two meters. The detailed explanation of the movement of the injection device and of the injection mechanism which is shown in Figs. 2 and 3 will follow below. It should be noted that as mentioned before the mixture is injected through the permeable helically wound tape. After the injection of the water blocking material an inner polyethylene sheath is extruded and this partly finished cable is wound on the takeup reel. Afterwards an aluminium polyethylene laminate moisture barrier is folded around the sheathed cable (not shown) and an outer polyethylene sheath is extruded thereon (also not shown) . Subsequently, the thus obtained cable may be armoured. Referring to Figs. 2 and 3 the injection arrangement 2 shown thereon mainly includes the already mentioned injection device 21, the valve 27 and mixer 30. The injection device 21 is fixed on bar 25 by means of clamping member 23. These members tightly clamp the device 21 by means of bolts such as 24 (Fig. 3). The clamping members are adjustable mounted (not shown) on bar 25 for reasons which will become clear later. The bar 25 is welded to vertical bars 33 and 33' of an inner frame also including horizontal bars 34 and 34'. By means not shown the mixer 30 is fixed to bar 32 which is also welded to vertical bars 33 and 33' of the inner frame. This inner frame is guided by means of guiding rods 35 and 36 rigidly connecting uprights 36 and 37' of a fixed outer frame including these uprights and guiding rods 35 and 36. The uprights of the outer frame are rigidly fixed to the floor. Fig. 3 shows a side view of the arrangement 2 with the vertical bar 33 of the inner frame and the upright 37 of the outer frame removed. A reciprocating movement is imparted to the inner frame by means of a double acting piston 40 of cylinder 38 fixed to the upright 37' of the outer frame by means of nut 39. The air pressure moving the reciprocating piston is admitted via the flowcontrol valves 41 and 42 connected to the control system 7 via flexible conducts 72. The system used is that schematically shown on Fig. 7. The valve 43 which forms part of the control system 7 is controlled by the synchronizing pulses as explained later. The cylinder with reciprocating piston, valve 43 and flow control valves 41 and 42 are standard piece parts available on the market. The valve 43 has 5 ports A B C D E and 2 positions. In its rest position the ports A and B, D and E are interconnected (connections drawn in full lines). In the actuated state ports A and D, B and C are interconnected (connections drawn in dashed lines). The flow control valves each include a parallel connection of a restrictor to regulate the air flow and a non return valve allowing the air only to flow from the valve 43 to the cylinder 38. The above mentioned three ingredients are each fed va a different flexible conduct 51 to the mixer 30 and the mixture is supplied to the injection device via conducts 29 and 26 and pneumatically operated valve 27 (Fig. 2). Conduct 26 is connected to injection tube 214 (Fig. 4) of injection device 21 by means of coupling 26'. Valve 27 is an on-off valve operated by a double acting piston 40' of a cylinder 38' mounted on the valve. The pneumatic system used is 'schematically shown on Fig. 8. The cylinder with double acting piston, is itself connected ( via conducts 71) to a 5 port, two positions valve 43' similar to valve 43. This valve forms part of the control system and is connected to the cylinder 38' in a way similar to that shown on Fig. 7 except for the flow control valves which are not used. Referring to Figs. 4 and 5 the injection device shown thereon includes nylon tubes 216 and 217 adjustable within a housing 210 so as to delimit a chamber 222 with adjustable width W. The adjustable tubes 216 and 217 are provided with longitudinal grooves 216' and 217' wherein the top ends of the screws 211 and 212 are located respectively. These screws are used to fix the adjustable tubes in the housing. The housing 210 is further provided with an injection tube 214 having a threaded end 215 to screw on the coupling 26' (Fig. 2). To prevent mixed liquid from penetrating between the contact surfaces of the housing and the tubes 216 and 217 the latter are provided with circular-grooves 218 and 221 wherein sealing rings 219 and 220 are located respectively. The operation of the injection arrangement will now be explained, reference being made to Figs. 2, 3, 4, 5, 6, 7 and 8. In the rest position ports A and B, D and E of valve 43 (Fig. 7) and ports A' and B', D' and E' of valve 43' (Fig. 8) are interconnected. Consequently, when pressurized air is admitted both pistons 40 and 40' move to the left. The latter piston closes valve 27; Since the return valve of flow control valve 42 allows the air to flow from valve 43 to cylinder 38 piston 40 moves to the left in a controlled way since the air in the left cylinder part is exhausted via the restrictor of valve 41, the non return valve of this flow control valve being blocked. Piston 40 moves the inner frame with the injection device 21, mixer 30 and valve 27 to the left until it reaches its rest position which is indicated as P1 in Fig. 6. A cable core is now pulled through the injection device and the extruder but before starting the water blocking operation and subsequent extrusion a few preparatory operations such as core tube centering for instance have to be carried out. To prevent blocking material present on the outer cable core surface due to the blocking operation to contaminate and obstruct the core tube of the extrusion tool of the polyethylene extruder a core tube is used having an inner diameter which is larger than the cable core diameter and a so called tube extrusion is carried out. In order to obtain a constant polyethylene sheath thickness it is then necessary to first center the cable core with respect to the core tube and then to extrude a few meters and to check the sheeth thickness. To carry out this centering the injection device is therefore positioned correctly by means of the adjustable clamping members. At the occurrence of a synchronising pulse SI (Fig. 6) valve 43 of the pneumatic system moving the inner frame and valve 43' controlling the operation of valve 27 are actuated and remain actuated during the time interval ds (Fig. 6) Pressurized air is admitted to cylinder 38 moving the inner frame and to the cylinder 38' moving valve 27 admitting liquid mixture from the mixer. Pressurized air is admitted to cylinder 38 via interconnected ports A and D of valve 43 and the opened non return valve of flow control valve 41. The air is exhausted via the restrictor of flow control valve 42 (Fig. 7). The restrictor of flow control valve 42 is adjusted in such a way that the movement of piston 40 to the right takes place at a speed equal to that of the cable extrusion. Consequently, during the time interval ds the inner frame with the injection device moves to the right at the extrusion speed and liquid mixture is injected. into the cable core to form a water stop. As mentioned earlier. this liquid mixture is injected through the permeable non woven polyester tape wound around the wires of the cable core. At the end of time interval ds the inJection device is in position P2 (Fig. 6), valves 43 and 43' return to their rest positions so that the injection of liquid mixture is stopped and the movement of the inner frame is reversed since pressurized air is now admitted via interconnected ports A' and B' (Fig. 8) and via interconnected ports A and B and flow control valve 42 (Fig. 7). The air in the left part of cylinder 38 is exhausted via flow control valve 41 which is adjusted in such a way that the inner frame with injection device 21 returns to its rest position P3 (=P1) in a time interval necessary for the block WB1 completely formed in position P2 to travel the distance d-b (water stop in WB2), d being the distance of the water stops in the cable. At the occurrence of a following synchronisation pulse the above mentioned cycle is repeated, i.e. the injection device moves from position P3 to P4 while the injecti6n takes place and the already formed water stop WB2 moves to position WB3. In position P4 of the injection device a new complete water block WB4 is formed, the distance between two succeeding stops WB4 and WB3 being necessarily equal to d. It should be noted that during the return movement of the injection device the liquid mixture contained in the chamber 222 (Fig. 4) is smeared out over the permeable tape holding the wires of the cable core together. Therefore, the chamber must contain a volume of liquid mixture sufficiently large to be smeared out over the tape between two succeeding stops. Since on the other hand the stop length is also determined by the chamber width, the choice of this width is conditioned by these two factors, i.e. the stop length and the chamber volume. The heat of the immediately following extrusion of the inner polyethylene sheeth accelerates the foaming of and curing of the injected liquid mixture and part of the smeared mixture impregnates the tape. The remaining part forms a supplementary sheeth between the tape and the polyethylene sheeth. As mentioned in the introductory part this decreases the capacitive earth coupling with the outer layer of the wires of the cable core. Also, a lubricating effect is obtained during the return movement of the injection device, it being remarked that since the inner diameter of this device is equal to the enveloped cable core diameter it is difficult to move the cable core with respect to the device in dry condition. Referring to Fig. 9 the cable 10, e.g. a 25 quad cable, shown in a longitudinal cross section thereon is provided with water stops such as 100 made in the above described way. These stops are limited on both sides by substantially concave surfaces which are separated by a minimum distance L. This distance is called the length of the stop. As shown on Fig. 10 which is an enlarged part of a cross section along line AA of Fig. 9, the interstices 102 and 103 between the stranded wires 101 and between the wires 101 and the permeable polyester tape 104 respectively are filled with the above mentioned blocking mixture. The tape itself is impregnated as explained earlier The cable further has an inner polyethylene sheath 105 extruded over the impregnated tape, an aluminium polyethylene moisture barrier 106 folded around the inner sheath and an outer polyethylene sheath 107 extruded on the outer sheath. In a typical example a cable core containing 25 quads held together by means of an helically wound non woven polyester tape and extruded at a speed of 1080 meters per hour is provided with water stops made by means of the above described arrangement. The water stops have a length substantially equal to 10 centimeters and the distance between stops is 2 meters with an alowable tolerance of 10%. The chamber width is 4 centimeters and the liquid mixture is injected during 1 second at a pressure of 8 atmospheres. It should be remarked that instead of extruding an inner polyethylene sheath the cable core already provided with water stops and an impregnated tape as explained above could be enveloped in a second permeable tape which may then be impregnated with the above mixture and cured. Also, instead of folding the aluminium polyethylene moisture barrier directly around the sheathed cable supplementary water blocking material can be provided between the inner sheeth and the moisture barrier either in a continuous or discrete way. A way to provide such a supplementary barrier is to simply permit blocking material to drip onto the sheathed cable prior to the aluminium polyethylene moisture barrier folding operation. While the principles of the invention have been described above in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention.

Claims: Patent claims 1. Arrangement for making a fluid-tight, e.g.water-tight, cable containing a cable core with a plurality of conductors by filling interstices between said conductors with a fluid blocking, e.g. water blocking, material to prevent fluid, e.g. water, penetration, said arrangement including means to displace an injection device to inject said material into said cable core, characterized in that said means produces substantially no relative movement between said cable core and said injection device during a first part - of an injection cycle but allows such a relative movement during the second part of said cycle. 2. Arrangement according to claim 1, characterized in that said means impart to said injection device a reciprocating. movement, said injection of said blocking material occurring during one of the two strokes of said reciprocating movement, 3. Arrangement according to claim 2, characterized in that said means comprise a displaceable frame whereon said injection device (21) is mounted and pneumatic means (38) to impart to said displaceable. frame said reciprocating movement, said displaceable frame being able to slide on guiding rods (35, 36) forming part of a stationary frame (37, 37'). 4. Arrangement according to claim 3, characterized in that on said displaceable frame are mounted a mixer (30) to mix the components of said material and a valve (27) to admit said mixture to said injection device. 5. Arrangement for making a fluid-tight, e.g. water-tight, cable containing a cable core with a plurality of conductors by filling interstices between said conductors with a fluid blocking, e.g. water blocking,material to prevent fluid, e.g. water, penetration, said arrangement including an injection device to inject said material into said cable core, said device comprising a cable inlet opening, a cable outlet opening and a fluid blocking material injection opening giving access to a compression chamber disposed around said cable core, characterized in that means are provided to adjust the dimensions of said chamber. 6. Arrangement according to claim 5, characterized in that said means are inserts (216, 217) placed inside said injection device directly around said cable and on each side of said injection opening (215). 7. Arrangement according to claim 6, characterized in that said inserts are formed by tubes (216, 217) able to slide and to be adjustably fixed within a housing (210) provided with said injection opening, said adjustable tubes and said housing delimiting said adjustable chamber. 8. Arrangement according to claim 7, characterized in that part of the external surface of said tubes is designed to leave a space (216',217') between the tube and the inside wall of said chamber, fixing means (211, 212) abutting against said surface part. 9. Method for making a fluid-tight, e.g. water-tight, cable containing a cable core with a plurality of conductors including the steps of injecting fluid blocking material into said core with an injection device and in a discontinuous way in order to obtain discrete fluid blocks and of applying a number of sheaths on said cable core, characterized in that said discontinuous injection step comprises moving said injection device with said cable core during said injection and in an opposite direction when said injection-is stopped. 10. Method according to claim 9, characterized in that said fluid blocking material is smeared out over said cable core during said movement in an opposite direction. 11. Method according to claim 9, characterized in that said cable core is wrapped in at least one layer of permeable tape, said material being injected in said cable core through said permeable tape during said injection step and material is smeared out over said permeable tape during said movement in opposite direction. 12. Method according to claim 11, characterized in that part of said material impregnates said permeable tape and said injected material expands due to the heat of succeeding sheathing, e.g. polyethylene sheathing operation. 13. Method according to claim 11, characterized in that said blocking material is injected into said cable core through a first layer of said permeable tape applied directly on said core, material is smeared out over said first layer, a following layer of said tape is applied on said first tape and fluid blocking material is smeared out thereon. 14. Method according to claim 10 or 11, characterized in that said fluid water blocking material layer is applied onto a sheath, e.g. a polyethylene sheath, extruded on said cable core whereafter a moisture barrier, e.g. aluminium polyethylene, is folded around the thus sheathed core. 15. Method according to claim 14, characterized in that said fluid blocking material is allowed to drip onto said sheath before the application of said moisture barrier. 16. Arrangement or method according to claim 1, 5 or 9 respectively, characterized in that said fluid blocking material is formed from a mixture including a hydroxyterminated polybutadiene, a diphenylmethane diisocyanate and a 2-ethylhexane diol used as a chain extender and water. 17. Method according to claim 13, characterized in that it makes use of the arrangement as claimed in any of the claims 1 to 8. 18. Cable obtained by means of the arrangement or method as claimed in any of the preceding claims.

Inventors: DE CONINCK, JOHAN A.C., DEVOLDERE, JOHAN A. B. G.
Applicants: BELL TELEPHONE MANUFACTURING COMPANY NAAMLOZE VENNOOTSCHAP, INTERNATIONAL STANDARD ELECTRIC CORPORATION
Application year: 1980
Main classification: H01B13
IPC codes: H01B7, H01B13