Patent ID: 12248194

DETAILED DESCRIPTION

FIG.1andFIG.1Ashow a high strength data transmission cable20of the present disclosure including: a core1comprising thermoplastic material, and coupled to a first strength member8(see alsoFIG.2); at least one and preferably several fiber-optic conductors2helixing about the core1(see alsoFIG.3), that can be any type of useful fiber-optic conductor, although a single mode fiber-optic conductor has surprisingly been found preferable; additional thermoplastic layer3encompassing the helically disposed fiber-optic conductors between layer3and the exterior surface of core1(see alsoFIG.4); flow shield4; strength member jacket layer5; elastic adhesive layer6; and protective outer cover7.

The core1preferably is formed of thermoplastic material. However, the core1may include metallic and/or other conductors (not shown inFIG.1) and/or other elements (not shown inFIG.1) located within the core, such as a coaxial energy and/or information cable (see elements depicted by reference numerals21,22and23ofFIG.9,FIG.9A,FIG.10andFIG.11, depicting a coaxial cable internal core1); and/or such as a braided copper filament conductor and/or such as an electromagnetic shield, as taught in our prior publications referenced above. Whatever portion of the core1is not occupied by items needed for the production of and/or for the function of the high strength data transmission cable preferably is formed of thermoplastic material. Whatever construction is used for the core1, the exterior surface layer of the core1is formed of thermoplastic material and has a thickness in a range of about half a millimeter to about four millimeters, preferably about one and a half millimeters to about four millimeters, prior to any stretching steps.

Preferably, for all embodiments of the present disclosures high strength data transmission cable: core1has a circular cross section (although, less preferably, it can have an oval or quasi oval or quasi circular or elliptical cross section); and, when core1has a circular cross section, the diameter of core1preferably ranges from thirty-two times to two hundred sixty four times; and preferably from forty times to sixty-four times, the diameter of the optical pipe of a fiber-optic conductor used in forming the present disclosures high strength data transmission cable. Such embodiments have surprisingly been shown to provide for greater resolution of the data transmitted and are contrary to the known state of the art and trend in the industry as shown by exemplary example in our prior published patent applications. When core1has a cross-section which is not perfectly circular, the diameter of core1being measured as the diameter at the largest width of the cross-section, preferably has a value within the above mentioned ranges.

In a particular preferred embodiment of the present disclosures high strength data transmission cable, the core1preferably is directly coupled to the first strength member8. This can be accomplished by forming the core1about the first strength member8, such as by extruding a thermoplastic rod about a first strength member8(seeFIG.2), or, alternatively, such as by first extruding a thermoplastic rod to form core1and subsequently braiding in hollow braid fashion about the thermoplastic rod a hollow braided multifilament first strength member8such as can be accomplished using a conventional braiding machine. It is presently preferred that core1be formed about the first strength member8, as shown inFIG.1andFIG.2, and that first strength member8not contact the surface of core1. It is presently preferred to use a strength member capable of retaining its integrity at temperatures up to 120 Celsius, preferably up to 200 Celsius, and especially at temperatures up to 270 Celsius, such as an Aramid filament or such as stranded polyester filaments, for forming the first strength member8. It presently is preferred that the strength member not be formed of thermoplastic material.

However, and alternatively, in reference toFIG.9toFIG.11, that show an alternate embodiment of the high strength data transmission cable ofFIG.1andFIG.1Awhere a coaxial cable assembly has been included within core1as indicated by elements21,22and23, when it is desired to include a metallic conductor within the core1, then the first strength member8can be situated internal a braided metallic conductor21, and the combination of the braided metallic conductor21and the first strength member8then may be directly coupled to the core1, preferably by extruding a thermoplastic layer22about the combination of the braided metallic conductor21and the first strength member8so as to form a rod that defines core1; and, further, an electromagnetic shield23may be formed about the exterior of the thermoplastic layer22, such as by laying two opposing layer directions of copper filaments, where such electromagnetic shield23also may serve as a conductor and/or conductive loop, and then the thermoplastic layer forming the exterior of core1may be formed about the electromagnetic shield.

Fiber-optic conductors used in forming any high strength data transmission cable of the present disclosure preferably have a buffer layer exterior the cladding where such buffer layer is of sufficient thickness and is formed of sufficiently abrasion resistant material that it can tolerate abrasion encountered during the production process without being entirely displaced in any location from the exterior surface of the cladding, and is capable of retaining its integrity at temperatures up to 200 Celsius, and especially at temperatures up to 250 Celsius, and yet more especially at temperatures up to 270 Celsius; and, furthermore, where such buffer layer is comprised of a material that includes a blend of materials where one material of the blend is the same thermoplastic material as used in forming layers1and/or3, with a polyethylene or a nylon being preferred, where a combination of silicone with a thermoplastic material presently is preferred. An example of such a buffer layer is indicated by reference numeral45inFIG.12andFIG.13.

With reference to reference numeral19ofFIG.5, reference numeral19indicating the pitch of the fiber-optic conductors helixing about the core1: the fiber-optic conductors preferably helix about the core1with a pitch that is in a range of 160 times to 480 times; and preferably 336 times to 480 times, the diameter of the optical pipe for at least one and preferably for all fiber-optical conductors formed into the high strength data transmission cable.

With further reference toFIG.5: For any embodiment of a high strength data transmission cable of the present disclosure, the additional thermoplastic layer3preferably is formed so as to entirely cover the outermost surfaces15of the fiber-optic conductors2with a layer13of thermoplastic material having a thickness selected so that after final production of the high strength data transmission cable the fiber-optic conductors remain encased in thermoplastic, even after the combination of the core-cable10enclosed in flow shield4has, optionally but preferably, been deformed through heat stretching as taught herein so as to conform to and support the internal cavity of the strength member5(seeFIG.8).

With further reference toFIG.5: for any embodiment of a high strength data transmission cable of the present disclosure: Preferably, when situated around the core and the fiber-optic conductors helixing about the core, the additional thermoplastic layer3has a thickness measured from the exterior most edge15of a fiber-optic conductor to the surface17of layer3of core-cable10that, preferably, is at minimum four times, and can be in a range from four times to sixty-six times, the diameter of the optical pipe of that fiber-optic conductor. In other terms, for any high strength data transmission cable of the present disclosure, preferably, the thickness of that portion of additional thermoplastic layer3that is exterior the outermost edge15of the buffer layer45of a fiber-optic conductor forming the high strength data transmission cable has a thickness in a range of from four times to sixty-six times the diameter of the optical pipe of that fiber-optic.

The flow shield sheath4can be any layer that stops and/or mainly stops molten (e.g. “semi-liquid”) phases of the thermoplastic material from passing through the flow shield. Preferably, the flow shield is formed by tightly braiding polyester fibers or filaments with such a dense braid construction that molten phases of the thermoplastic contained within the additional thermoplastic layer3as well as contained within the core1are stopped and/or mainly stopped from passing through the flow shield. When it is desired to enact the optional, but less preferred embodiment of the present disclosures high strength data transmission cable, by forming the high strength data transmission cable by omitting steps of heating the cable until thermoplastic material in the core1and/or layer3reaches a molten phase, that is contrary to the state of the art and against the trend in the industry, then the flow shield can be omitted and thus the flow shield is optional but not mandatory in such embodiments, that also is contrary to the state of the art and against the trend in the industry.

The strength member jacket layer5preferably is formed of a super fiber such as HMPE, and, when the option of heat stretching the high strength data transmission cable at or near the phase change temperature of the thermoplastic is selected, preferably is formed with a twenty-four strand carrier braiding machine so as to make a twenty-four strand hollow braided strength member jacket layer5, especially for example a “2×24” strand construction and even more preferably a “3×24” strand construction, a twenty-four strand hollow braided construction for the strength member being contrary to the state of the art and against the trend in the industry which is to use a twelve strand carrier braiding machine so as to make a twelve strand hollow-braided strength member jacket layer5. When it is chosen to heat and tension stretch the high strength data transmission cable of the present disclosure, such step is done prior to installation of the elastic adhesive layer6and the outer cover7, and is done in such a way as to result in the combination of the outer layer3of core-cable10and the flow shield4enclosing core-cable10being deformed to adapt themselves to the internal cavity of the hollow braided strength member (and also cause core-cable10to adopt an undulating profile when viewed in plan view, seeFIG.7), while, most preferably, not deforming the layer of thermoplastic material that is most exterior the core1and about which the fiber-optic conductors form their helix (seeFIG.8), which can be determined by forming the exterior layer of thermoplastic material of core1of a different color than the layer3of thermoplastic material, and determining whether or not their interface is deformed as a result of the heat and tension stretching, the goal to be to remove constructional elongation and to cause compaction of the strength member without deforming the core1, that is contrary to the state of the art and against the trend in the industry exemplified by our prior patent applications where the fiber-optic conductors were pressed into core1as a result of the stretching steps and/or heat and tension stretching steps.

Elastic adhesive layer6preferably is a type of polyurethane, such as two or more component blended polyurethane, that preferably is applied while in a flowable state to the exterior surface of the strength member jacket layer just prior to formation of the protective cover7about the strength member jacket layer. As a result, the elastic adhesive layer6binds the strength member jacket layer to the protective cover.

Production Processes

The method for producing the present disclosures high strength data transmission cable includes steps of:(a). Step One: providing a flexible core1of solid material (seeFIG.2), and preferably a core1coupled to a first strength member8that is located internal and central the core1, as shown inFIG.1;FIG.1A; andFIG.2. The core1comprises flexible solid thermoplastic material, and, when it contains no other elements besides the first strength member8, preferably comprises, in addition to first strength member8, only flexible solid thermoplastic material (first strength member8itself ideally formed of a non-thermoplastic material as described supra). Core1preferably has a shape that is of a cable and/or of a rod having a circular cross section; or a shape that is an elongate object having a circular cross section viewed in a plane that is perpendicular to the longitudinal axis of core1. Importantly, whatever elements may optionally be included within core1, such as for example a metallic electrical energy conductor, core1has an exterior surface layer formed of flexible solid thermoplastic material.(b). Step Two: situating at least one and up to several fiber-optic conductors2in helixing form about the exterior of the core (seeFIG.3). This step may be accomplished by using a winding machine, such as a machine that orbits about a central point one or more bobbins and/or spools, where each spool carries a wound spooled optic fiber conductor. The flexible core1is passed in continuous feed fashion through the central axis of the winding machine, such as for example by being taken off a take-off reel and being wound upon a take-up reel, preferably with guides to keep the core1passing through the central winding point of the winding machine that is situated along the central axis of the winding machine. Care is taken to ensure that the fiber-optic conductors are unwound from the bobbins and/or spools in a direction that perpendicular or at least that is more perpendicular to the longitudinal axis of the bobbins and/or spools that it is parallel to such axis, so that not rotation is imparted to the fiber-optic conductors. The fiber-optic conductors, and thus the spools and/or bobbins, are located equidistance apart (seeFIG.3A), and the fiber-optic conductors are wound and situated on the thermoplastic surface of core1(see alsoFIG.3A). For example, if there are four fiber-optic conductors, there are four spools and/or bobbins, each situated sixty degrees apart. If there are three fiber-optic conductors then there are likewise three spools and/or bobbins, each situated one hundred twenty degrees apart. If there are two fiber-optic conductors, then there are two spools and/or bobbins, each spaced one hundred eighty degrees apart. When only one fiber-optic conductor is used to form the high strength data transmission cable of the present disclosure, then, preferably, a strand and/or filament and/or fiber that is not a fiber-optic conductor is also situated on core1in helix fashion in the same location and by the same means and machinery as would have been placed a second fiber-optic conductor if it had been used, resulting in a helixing fiber-optic conductor and a helixing strand that is not a fiber-optic conductor, that also may be a strand of thermoplastic material or of, for example, polyester. Yet more preferably, in the case when only one fiber-optic conductor is used, then two strands and/or filaments and/or fibers are situated in helix fashion about core1, where these three elements, e.g. the one fiber-optic conductor, and the two strands and/or filaments and/or fibers that are not a fiber-optic conductor, each are situated one hundred twenty degrees apart and wound about core1by the same machinery and methods used to wind about core1three fiber-optic conductors. In this case, the two strands and/or filaments and/or fibers may be a strand of thermoplastic material or of, for example, polyester.(c). Step Three: optionally, but most preferred, providing additional fixation between the core and the fiber-optic conductors that helix about the core;(d). Step Four: situating additional thermoplastic material3about the combination of core1and fiber-optic conductors2helixing about core1, so as to encase the fiber-optic conductors between the core1and the thermoplastic material3(seeFIG.4), and allowing the additional thermoplastic material3to set, thereby completely encasing the helically disposed fiber-optic conductors within a solid, flexible material formed as a rod and/or cable, thus arriving at a core-cable10(see alsoFIG.5). Polyethylene and various forms of polyethylene are suitable for the thermoplastic material of core1and layer3. This step may be accomplished by positioning downstream of the above mentioned central winding point an extrusion head that extrudes flowable thermoplastic material about the combination of: the core1and anything coupled to the core1, such as any fiber-optic conductors helixing about core1; and, any strands and/or fibers and/or filaments helixing about core1(e.g. when only one or in some cases when only two fiber-optic conductors are used), and pulling and/or otherwise passing the “cable” formed by this combination through the extrusion head while (preferably pressure) extruding thermoplastic material to form layer3, preferably selecting a temperature for the molten thermoplastic material as well as an extrusion pressure and time that both causes a softening (but not liquefaction) of the surface of thermoplastic exterior of core1while also causing sufficient pressure to force the fiber-optic conductors partially into the exterior thermoplastic surface of the exterior of core1so that they “seat” into the surface of core1, followed by permitting the thermoplastic material forming layer3to set (while continuing the feeding of core1), thus forming resultant core-cable10.

To further discuss the core-cable10:FIG.5shows a side plan view of what is the production phase of the core-cable10of the most preferred embodiment of the high strength data transmission cable in accordance with the present disclosure (e.g. the core-cable that is the result of Steps One through Four, especially mandatory steps Step One, Step Two and Step Four, and preferably including optional Step Three) and prior to enclosing the core-cable within either the flow shield or the strength member, and certainly prior to any chosen heat stretching steps) where the thermoplastic material forming core1as well as any thermoplastic material and/or elements forming core1as well as the additional thermoplastic material forming layer3of the core-cable have been omitted from the drawing figure, excepting the peripheral outline of the thermoplastic material forming layer3, so as to make visible the helix shaped fiber-optic conductors2that are completely encased in set, solid, flexible thermoplastic material. WhileFIG.5shows three fiber-optic conductors, one often is preferable, although any needed quantity may be used. Accordingly, shown inFIG.5is a core-cable10comprising a fiber-optic conductor2disposed in a helix and entirely encased in a flexible solid material.

Having discussed the core-cable10resultant of Steps One through Four, discussion resumes of subsequent production steps:(e). Step Five: optionally, and in the event that it should be desired to heat stretch the high strength data transmission cable after adding the strength member, a subsequent step is forming the flow shield4(seeFIG.6) about the core-cable10(preferably directly about the additional thermoplastic material forming layer3situated around the combination of the core1and the fiber-optic conductors2helixing about the core);(f). Step Six: forming a preferably braided strength-member jacket layer5of polymeric material about the thermoplastic material forming layer3(seeFIG.1), or, should the optional step have been made of forming a flow shield4about layer3, then the strength member jacket layer is formed about the flow shield and thus by extension all the items contained within the flow shield; while ensuring that the fiber-optic conductors remain intact, thus forming a high strength data transmission cable of the present disclosure.

A preferred construction for the strength-member jacket layer is a hollow-braided construction, preferably where there are an equal number of S and Z strands forming the hollow braid, where each main braid strand preferably, has a flattened form. Each such braid strand preferably has a width that is at minimum two times its height, especially when in the formed hollow braided strength-member jacket layer. Each such braid strand preferably also is comprised of multiple yarns. Preferably, each such braid strand comprises two yarns, where each of the yarns is not of a braided or parallel laid construction but preferably is of a twisted/laid construction, especially with a long twist and/or loose twist, according to industry standards for a loose twist for HMPE and/or other fiber chosen. Importantly and preferably, each such yarn is formed sufficiently loosely constructed, e.g. sufficiently loosely twisted/laid, that the braiding tension applied by the braiding apparatus deforms each such yarn into a flattened form, having a greater width in comparison to its height, in the final produced hollow braided strength-member jacket layer. In this way, the braid strands adopt a flattened form having an aspect ratio greater than two to one. That is to say, because there are at minimum two yarns forming each braid strand forming the strength-member jacket layer, and because each such yarn has a similar height and width as other such yarns forming the single braid strand, and because each such yarn exhibits a greater width in comparison to its height after the braiding process, the final braid strand that is formed of the at minimum two yarns must by extension have and/or define a flattened form having a greater width in comparison to its height and where its width is greater than and/or more than two times its height.

Contrary to the state of the art and against the trend in the industry, the high strength data transmission cable of the present disclosure may be used at the state it is in at Step Six above, preferably after applying a protective cover that is adhered to the strength member with an elastic adhesive layer. However, this is not preferable. Most preferably, and contrary to the state of the art and against the trend of the industry, the high strength data transmission cable formed by the methods as taught above in Steps One through Six (and lacking the adhesive layer6and outer cover7) is further processed with steps of applying to the high strength data transmission cable heat selected so as to be sufficient to, preferably, allow for deformation of the thermoplastic layer3without causing a change to the phase of the thermoplastic material comprising core1; and yet more preferably, and also contrary to the state of the art and against the trend of the industry, also without causing a change to the phase of the thermoplastic material comprising layer3and/or the high strength data transmission cable (e.g. so as to preclude said thermoplastic from changing phase from solid phase to a molten phase and/or liquid phase), combined with steps of stretching the cable a predetermined amount so as to permanently elongate and permanently compact the strength member jacket layer and the core-cable10especially so as to reducing both its diameter as well as the diameter and/or average thickness of the entire the high strength data transmission cable (lacking its adhesive layer6and outer cover7), followed by cooling the high strength data transmission cable (lacking its adhesive layer6and outer cover7) preferably while maintaining a sufficient tension on the cable so as to maintain its elongation and compaction, so that the combination of the outer portion of thermoplastic layer3combined with the flow shield4adapt a form that conforms to and supports the natural interior cavity wall surface of the hollow braided strength member, while retaining the predetermined amount of elongation and compaction so as to permanently elongate and permanently compact and permanently reduce the diameter of the cable. Contrary to the state of the art and against the trend in the industry, as exemplified by our own prior patent applications, the amount of heat, tension, and time in one preferred embodiment preferably is selected so as to cause the combination of the thermoplastic layer3and the flow shield4to deform so as to adapt to the natural shape of the interior cavity wall of the hollow braided strength member5while, most preferably: (i) not displacing the fiber-optic conductors2; (ii) precluding the fiber-optic conductors2from displacing the material of core1from its position prior to the heating and stretching steps in comparison to its position after the heating and stretching steps; and, (iii) precluding the fiber-optic conductors from becoming intertwined with core1in comparison to their position relative to core1prior to the heating and stretching steps.

The next step in the production of the high strength data transmission cable can then be covering the strength member jacket layer with the protective cover7that, preferably, is adhered to the strength member jacket layer by the elastic adhesive layer6.

So formed, the high strength data transmission cable of the present disclosure provides a much higher data signal quality and/or resolution in comparison to known high strength data transmission cables, thus permitting use of equipment presently in development but unable to be used with known high strength data transmission cables, that permits identifying fish species and distinguishing between fish sizes, thereby permitting avoiding with the fishing gear non-target fish species and juvenile and undersize fish, thus improving the health of fisheries and the marine mammals and seabirds and fishing communities that depend upon them, accomplishing goals of the present disclosure.

It is surprising and unexpected that by combining steps of, firstly: providing additional fixation between the core and the optic fibers helixing around the core, that is fixation beyond what fixation is obtained by helixing the optic fibers around the core1, with steps of, secondly, and subsequently, situating the additional thermoplastic material3so as to completely encase the helixing optic fibers2within thermoplastic material, where the thermoplastic material of the core1also forms the surface of the core1and is compatible with and forms a tight and preferably inseparable bond with the thermoplastic material used to form additional thermoplastic material layer3, and preferably is the same material as the thermoplastic material of layer3, followed by permitting the thermoplastic of layer3to set and/or cool, thus forming the core-cable10, followed by forming the polymeric strength member jacket layer, preferably of HMPE fibers around layer3(and any optional flow shield), that even without heat stretching with temperatures sufficient to cause the thermoplastic of either or both core1and layer3to reach a molten phase, that a superior signal resolution transmitting high resolution high strength data transmission cable is formed.

The key step of providing additional fixation between the core1and the fiber-optic conductors that helix about the core1can be accomplished in any suitable fashion that causes the fiber-optic conductors to resist sliding along the core1, and especially in any suitable fashion that stops the fiber-optic conductor from sliding along the core1and/or that maintains the originally formed helix form of the fiber-optic conductors so that the helix form of the fiber-optic conductors is not altered during further processing steps including but not limited to the step of situating the additional thermoplastic material3about the fiber-optic conductors and the core1so as to completely encase the fiber-optic conductors within thermoplastic material.

In other terms, the fixation between the fiber-optic conductors and the core about which they are situated is increased, so as to provide a resistance to sliding along the core and/or to alteration of the helix shape of the fiber-optic conductors that is greater than is provided by the mere fact the fiber-optic conductors are situated in helix fashion about the core. Examples include:1. situating a tacky substance such as an adhesive substance on the exterior surface of the core prior to wrapping the fiber-optic conductors about the core in helix fashion. The tacky substance could be situated by passing the core through a bath of such tacky substance that does not dry too quickly, or, by spraying or rolling or brushing such substance onto the core. The substance should be compatible with molten phases of the thermoplastic selected for the thermoplastic core and for the additional thermoplastic material forming the layer3.2. taping the fiber-optic conductors into place onto the core about which they helix, such as by binding the fiber-optic conductors into place with two-way tape.3. heating the fiber-optic conductors prior to helixing them about the core so that the combination of their temperature and the tension on the fiber-optic conductors while helixing them onto the core cause the fiber-optic conductors to displace some of the material on the surface of the core and form a depressed track such as a groove track on the surface of the core within which lie at least a portion of the width of the helixed fiber-optic conductors.4. heating the core or at least the surface of the core prior to helixing the fiber-optic conductors about the core so that the combination of the heat and the tension on the fiber-optic conductors while helixing them onto the core cause the fiber-optic conductors to displace some of the material on the surface of the core and form a depressed track such as a groove track on the surface of the core within which lie at least a portion of the width of each fiber-optic conductor.5. spraying or otherwise situating an adhesive substance onto the fiber-optic conductors prior to helixing them about the core so that the fiber-optic conductors become adhered to the core and resist moving along the length of the core.6. spraying or otherwise situating an adhesive substance onto the combination of the fiber-optic conductors and the core after helixing the fiber-optic conductors about the core so that the fiber-optic conductors become adhered to the core and resist moving along the length of the core.7. as presently preferred, the method of providing additional fixation between the core and the fiber-optic conductors helixing about the core is to pass the core that already has the fiber-optic conductors situated about it in helix form through a heating element that uses heat, such as radiant heat, at a temperature and exposure duration sufficient to cause excitement of the (preferably thermoplastic) surface of the core, followed by permitting the combination of the core and the fiber-optic conductors to reach a cooler temperature than it reached within the heating element, and especially a temperature at which the thermoplastic is in a solid phase, followed by situating the additional thermoplastic material about the combination of the core and the fiber-optic conductors helixing about the core.

After the step of providing additional fixation between the fiber-optic conductors helixing about the core and the core has been accomplished, the step of situating the additional thermoplastic material forming layer3about the combination of the core1and the fiber-optic conductors helixing about the core preferably is enacted. To accomplish this step, it has surprisingly and unexpectedly been discovered that it is preferable to use a type of extrusion known as pressure extrusion. After the additional thermoplastic material forming layer3has been situated so as to result in completely encasing the fiber-optic conductors within the thermoplastic of layer3with the thermoplastic of at least the surface of the core1, the next step is to form the flow shield about the thermoplastic layer3, followed by the subsequent production steps taught supra for forming the strength member jacket layer, the elastic adhesive layer and the protective cover.

Alternative Core Embodiments

FIG.14shows a perspective cross sectional view of an alternative core-cable110of the present disclosure taken in a plane perpendicular to the long axis of the alternative core-cable110. As shown, alternative core-cable110includes a variant of core-cable10that includes a coaxial cable111contained within core-cable10, and additionally includes several additional conductors112that are encased within a rigid material114, preferably a rigid thermoplastic material, that preferably is a same thermoplastic as that forming layer3of core-cable10. As shown, the several additional conductors112are situated external core-cable10. Most preferably, flow shield4has been formed about and sheaths core-cable10, and most preferably the several additional conductors112are situated both external core-cable10as well as external the flow shield4that sheaths core-cable10. The several additional conductors112preferably are parallel laid about core-cable10, but may be twisted.

A presently preferred method for forming alternative core-cable110includes steps of:A) providing a finished core-cable10produced as described supra and sheathed within flow shield4;B) providing several rods116where each rod comprises a conductor112encased in the rigid material114that preferably is the same thermoplastic material as forming layer3, and where each rod116itself is sheathed within a flow shield117, where the flow shield117preferably is formed of tightly braided polyester fibers and/or filaments that preferably are braided in hollow braided fashion, but also can be any layer that stops and/or mainly stops molten (e.g. “semi-liquid”) phases of the thermoplastic material from passing through the flow shield;C) situating a desired quantity of the rods116, preferably in parallel lay fashion, about the core-cable10, thereby forming alternative core-cable110; andD) situating a flow-shield4A about the core-cable110, where the flow shield4A preferably is formed of tightly braided polyester fibers and/or filaments that preferably are braided in hollow braided fashion, but also can be any layer that stops and/or mainly stops molten (e.g. “semi-liquid”) phases of the thermoplastic material from passing through the flow shield.

While the rods116may have any cross sectional shape, it presently is preferred that the rods116themselves are formed with and thus have a tapered cross sectional shape118(viewed in a plane perpendicular to the long dimension of any such rod116), such as for example a truncated wedge, so as to facilitate their position in parallel lay fashion about core-cable10.

Preferably, each conductor112is attached to a strength member (not shown) prior to being enclosed within a sheath and/or other layer of thermoplastic material, such as by being attached to a fiber and/or filament of HMPE or Aramid, such as by being formed of hollow braided copper and/or other metallic filaments about the strength member, where such strength member preferably has a higher softening point and/or degeneration temperature in comparison to the rigid material114

After the flow shield4A has been formed about the exterior of the alternative core-cable110, then the remainder of the production processes as taught above that occur after formation of the flow shield4for core-cable10are enacted in like fashion for alternative core cable110, so as to arrive at an alternative variant of the present disclosures cable that may, for example, be used as a kit rope to connect floating vessels to kites that are used to provide sail power to such vessels.

Methods for Use

With reference toFIG.11: in order to use the present disclosures high strength data transmission cable it must be connected to an interrogator or other equipment, such as the sonar, for which it is necessary to expose the fiber-optic connectors. This preferably may be accomplished by, firstly, removing portions of the cover7, adhesive layer6, strength member5and any flow shield4, so as to result in the core-cable10extending and/or protruding outward from a surface44formed by the cut edges of the cover, adhesive layer, strength member and flow shield; secondly, by heating the outer surface of layer3of the protruding portion of the core-cable ten (preferably heating its most distal end51), as can for example be accomplished by directing a stream of heated air from an air gun at a certain fiber-optic conductor visible through the preferably translucent thermoplastic layer3forming the exterior surface of core-cable10for a sufficient duration of time so as to soften the thermoplastic material directly contacting the selected certain fiber-optic conductor; followed by digging the fiber-optic conductor out of the layer3, such as may be accomplished by probing alongside it with sharp nosed pliers or tweezers, then grabbing the fiber-optic conductor at its distal end61; followed by gently tearing the selected certain fiber-optic conductor outward from the softened thermoplastic layer3of core-cable10; followed by pausing and heating the next region of thermoplastic layer3of core-cable10that is exterior the remaining encased portions of the selected certain fiber-optic conductor; followed by continuing to tear out of core-cable10the selected certain fiber-optic conductor until sufficient length of such fiber-optic conductor has been exposed and withdrawn from core-cable10to permit its being spliced to another fiber-optic conductor that couples the fiber-optic conductor forming the high strength data transmission cable to other fiber-optic conductors connecting to other equipment. When the data transmission cable also includes a coaxial cable or energy conductor, such also is extended from the core-cable10as shown inFIG.11to make it accessible for connection to other equipment.

INDUSTRIAL APPLICABILITY

The data transmission cable of the present disclosure may be used as a headline sonar cable and also may also be used to connect to and communicate with and, when a metallic power conductor21is included, provide power to sonar units located at other regions of the trawl in addition to the headline, and can for example serve as a sonar cable for sonar units mounted on the trawl's midsection, bag or belly/codend. The data transmission cable also can also be deployed from a trawler's main warp drums and serve a double purpose, e.g. as a trawler warp as well as a headline sonar cable, and thus for example communicate with a headline sonar or other device in the fishing gear through a trawler warp rather than through a dedicated headline sonar cable.

The data transmission cable of the present disclosure also is able to serve as a high strength data cable for trawler warps, and thus for example communicate with a headline sonar or other device in the fishing gear through a trawler warp rather than through a dedicated improved high-resolution power-capable crush resistant fiber cable, and also that is capable of being used as a towing warp, a deep sea winch line, a crane rope, a seismic line, a deep sea mooring line, a well bore line, an ROV tether or ROV line, a superwide for seismic surveillance, or as a load bearing data and/or energy cable, as a lead-in cable for towed seismic surveillance arrays, and/or energy cable. When used as a well bore line and/or well bore cable, it is anticipated useful to make the final outer cover of laid steel wire so as to armor the cable. However, in most other applications it is anticipated that the braided cover already disclosed supra is most useful. When used as a seismic Superwide or as a crane rope, or in any application requiring heat tolerance, including a well bore cable, it is anticipated useful that the strength member shall be formed of a hollow braided construction using a 24 strand construction, that is contrary to the state of the art and against the trend in the industry, where most useful is anticipated to be a 2×24 strand construction, or, even more preferably, a 3×24 strand construction, where each of the 24 strands is formed of an Aramid strand that is ensheathed within a HMPE or PTFE or Polyester sheath, and then those strands are braided together into the hollow braided 24 strand constructed strength member, that is preferably, at least a 2×24 strand or a 3×24 strand construction. When used in any application requiring any of heat tolerance, heat detection, elongation detection, or break detection, or detection of a region of the cable responsible for failure of any of the cable's ability to transmit data and/or energy, it is anticipated useful that the improved high-strength light-weight crush-resistant high-data-resolution power-capable fiber cable of the present disclosure comprise for its optical fibers those selected from a type capable of being used with interrogators that read and interpret Brillouin scattering and/or Raman backscattering wavelengths, and specifically with optical fibers capable of transmitting accurately interpretable Brillouin scattering wavelengths and/or Raman backscattering wavelengths, so as to permit monitoring the elongation and/or heat of the optical fibers at any region along the length of the optical. Thus, by transmitting light through the optical fibers in such a fashion that permits reading Brillouin scattering and/or Raman backscattering, and interpreting the Brillouin and/or Raman wavelengths with a suitable interrogator, the elongation and/or heat at specific locations along the optical fiber being monitored may be determined and thus the elongation of the cable may be determined at specific locations along the cable; and thus the elongation of the cable's strength member as well as its temperature may be determined at specific locations along the length of the cable; and thus the integrity of the cable's strength member is able to be determined and a determination made as to whether or not the cable is suitable for continued use in a particular application or is better retired from that application and replaced. Importantly, prior attempts at using Brillouin scattering wavelengths and/or Raman backscattering wavelengths monitor the elongation and/or heat of the optical fibers at any region along the length of the optical fibers and/or cable containing the optical fibers have failed, and none of the art has proposed the construction and method of the data cable of the present disclosure. Importantly, it has been the long held belief in the industry and the trend in the industry to minimize bending of fiber optic conductors contained within cables of any type, including but not limited to yachting cables, including when using such fiber optic conductors to monitor heat and or elongation of both the fiber optic conductors and by extension of the cables containing them. It is contrary to the state of the art and against the trend and commonly held views in the industry that a fiber optic conductor formed into a helical shape and used to form the core of a cable in the manner and construction as taught herein is capable of transmitting high resolution data signals. The fact that the present invention's cable functions this way is contrary to the widely held beliefs in the industry.

Thus, present invention also is based upon the surprising and unexpected discovery that by forming a data cable with process steps including:suspending within a flexible solid material at least one and preferably two fiber optic conductors defining a helix (or alternately defining a double helix; or, in the case of three or more fiber optic conductors defining other helix forms), so as to form a core-cable created by the combination of (i) the fiber-optic conductors defining a helix (and/or double helix or other helix); and (ii) the flexible solid material within which is suspended (and preferably completely encased) the fiber-optic conductors defining a helix, and using the core-cable as a supportive core for a (preferably braided) strength member formed of polymeric material, and, preferably where the core cable supports the natural internal cavity shape of the strength, that the temperature and the elongation of the cable may be monitored by further steps of:a) selecting fiber optic conductors capable of transmitting Brillouin scattering and/or Raman backscattering wavelengths;b) transmitting light through the optical fibers in such a fashion that permits reading Brillouin scattering and/or Raman backscattering wavelengths;c) interpreting the Brillouin and/or Raman wavelengths with a suitable interrogator so as to determine the elongation and/or heat at specific locations along the optical fiber or fibers being monitored;d) correlating the specific locations along the length of the optical fiber or fibers being monitors to specific locations along the length of the data cable containing the optical fiber or fibers; and corresponding to the specific locations along the length of the optical fiber or fibers being monitored; thus determining the elongation of the cable's strength member as well as its temperature at said specific locations along the length of the cable.

Next, in or to determine the integrity of the cable's strength member, the next step is correlating known elongation and heat values for the cables strength member with data points indicating that the strength member either is safe to use or must be replaced.

Alternatively, but less desirably, it is anticipated useful that the cable of the present disclosure comprise for its optical fibers Fiber Bragg Grating optic fibers, where there are multiple different patterns of Bragg Grating in a single fiber, corresponding to differing locations along the length of an optic fiber, and reflecting a wavelength and/or wavelengths that differ from some or all or most of the other Bragg Grating patterns at other locations along the length of the optic fiber and thus by extension along the length of the cable. To dispose a Fiber Bragg Grating optic fiber in a helix construction and suspend and/or encase such in a rigid material in a load bearing cable is contrary to the state of the art and against the trend in the industry and surprisingly allows useful monitoring of heat and elongation and strain using otherwise known methods.

Although the present disclosure has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the disclosure, various alterations, modifications and/or alternative applications of the disclosure are, no doubt, able to be understood by those ordinarily skilled in the art upon having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications or alternative applications as fall within the true spirit and scope of the disclosure.