US3763554A - Wire insulation formed from pleated sheet material and method of manufacture - Google Patents

Wire insulation formed from pleated sheet material and method of manufacture Download PDF

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Publication number
US3763554A
US3763554A US00208126A US3763554DA US3763554A US 3763554 A US3763554 A US 3763554A US 00208126 A US00208126 A US 00208126A US 3763554D A US3763554D A US 3763554DA US 3763554 A US3763554 A US 3763554A
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US
United States
Prior art keywords
wire
sheet
advancing
envelope
pleat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00208126A
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English (en)
Inventor
J Early
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AT&T Corp
Original Assignee
Bell Telephone Laboratories Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bell Telephone Laboratories Inc filed Critical Bell Telephone Laboratories Inc
Application granted granted Critical
Publication of US3763554A publication Critical patent/US3763554A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49123—Co-axial cable
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
    • Y10T29/5136—Separate tool stations for selective or successive operation on work
    • Y10T29/5137—Separate tool stations for selective or successive operation on work including assembling or disassembling station
    • Y10T29/5138—Separate tool stations for selective or successive operation on work including assembling or disassembling station and means to machine work part to fit cooperating work part
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53126—Means to place sheath on running-length core

Definitions

  • ABSTRACT This disclosure describes process and apparatus for continuous insulating of wires in which sheet material drawn from a roll is pleated and the wires are introduced into the pleats. The pleat envelopes are severed and each assembly of wire and pleat is closed and polished.
  • the sheet material is preselected for specific dielectric and structural characteristics.
  • the sheets may also be precoated with adhesive,
  • the process is capable of high speed operation and produces a highly reliable product without creating air or water pollutants.
  • FIG. 5 11 Claims, 10 Drawing Figures PATENTED 7 1975 SHEET 2 OF 4 WEB LENGTH DIRECTION
  • This invention relates to the insulating of wires, particularly small gauge wires; and especially concerns the insulating of telephone conductors.
  • Wood pulp is hydroscopic and wet-swelling, and therefore in use provides a barrier to longitudinal flow of water that may penetrate the cable sheath. Further, pulp insulation when wet, so drastically alters the transmission characteristics of the pair in the wet region that it is relatively simple to detect the problem promptly, and to locate the water-logged portion-and hence the cable fault-by voltage breakdown tests. In contrast, plastic insulation when wet affects transmission properties only very slowly and does not swell into a water-blocking medium.
  • the common sulfate wood-pulp insulation process has well recognized inherent process control problems relating to uniformity of insulation and coating weight, and moisture content of dried insulation. wastage caused by defectively manufactured insulated conductor is significant despite quality control efforts and skilled process operators. Besides, unlike plastic insulation, the dielectric properties of wood pulp cause severe signal attenuation at frequencies of about 1 MHz and beyond. Because of this drawback, the high bit rate needs of video telephony and many other proposed subscriber services tend to preclude use of conventional pulp insulation, however attractive its wetswelling properties may be.
  • the invention contemplates a payout device for feeding a web of material in tandem with the advancing wires.
  • the wires are continuously enveloped in this material by folding the material into parallel pleats running the long direction of the web, continuously gathering the pleats, and continuously inserting conductors into the pleat interstices.
  • the pleats are cut apart, smoothed and, if necessary, wetted. Thereafter, the pleats are passed through polishing heads to wrap the tabs around the conductor as is done in conventional sulfate wood-pulp insulation polishing.
  • One feature of the invention is the use of any insulative sheet material as a starting point in a wire insulating line which need not be changed equipment-wise when the sheet material is changed.
  • a further feature of the invention is use of precolor coded sheet material to supply conductor color coding.
  • a further feature of the inventive process is the step of pleating an advancing sheet to create slots or envelopes to receive advancing wires, and then severing the sheets to provide one envelope per wire.
  • FIGS. 2-7 are schematic diagrams illustrating in stages the structures used to produce the inventive result
  • FIGS. 8 and 9 are a schematic flow diagram and a schematic block process diagram respectively further illustrating the invention.
  • FIG. 10 is a color code version.
  • FIG. 11 shows apparatus for practicing the invention.
  • a flat sheet of insulating material 1 from a source such as roll 2 mounted on chassis 3 is advanced in the direction of arrow 4 by means not shown.
  • sheet 1 is scored at spaced intervals by the scoring wheels 5 mounted on shaft 6.
  • the advancing sheet 4 enters a folding die 7, which places a wide-angled pleat pattern across the entire sheet face, by cooperation of the die 7 with mating surfaces therebeneath, not shown.
  • sheet-cutting knives 8 slice the advancing sheet at the top of each pleat fold to produce a series of advancing bottom-pleated strips 9.
  • Wires such as the substantially round wire 10 de picted in FIIG. 7 from reels Til are led into the envelope of each pleated strip 9.
  • the wires 10 are advanced in the direction of arrow 45 and at the same rate as the pleated strips 9.
  • the pleated strips 9 and wires 10 are fed through the folding and wire spacing die 12, where each wire is positioned, for example, about midway within the pleat envelope, that is, into a central region of the envelope.
  • Each pleat envelope on exiting from die 12 is formed as a well-defined V-shape.
  • each pleated strip 9 and its respective wire 10 are fed through a fold flattening roller 13 and thence to a conventional wrapping and polishing head 14.
  • a wetting spray from sprayer 15 may be applied to the strip 9 before it enters the roller 13. Wetting at this point with a solution such as soap and water serves the purpose of softening the paper and making it selfadherent on drying.
  • each insulative wire which now has the shape depicted in FIGS. 6 and 7is dried in furnace l7 and stored on a takeup reel 18 shown in FIG. 8.
  • the wires 10 are precoated with an adhesive such as polyvinyl alcohol-acetate or an acrylic latex to cause the pleat envelope to adhere to the wire and thus stabilize the configuration.
  • the adhesive can be activated by the liquid applied by the wetting sprayer 15.
  • the adhesive can be solvent activated, pressure activated, or heat activated; or can be applied to the paper raw material if desired.
  • the invention in its broadest aspect contemplates the forming of a pleated sheet structure such as shown in FIG. 2, introduction of wire into the pleat envelopes either before or after cutting, then cutting of the sheet into advancing pleated strips as in FIG. 4, closing of each pleat as shown in FIG. 5, and polishing or otherwise dressing the closed pleat to produce the structure shown in FIGS. 6 and 7.
  • the entire process is illustrated further in the schematic apparatus diagram of FIG. 8 and a flow chart of FIG. 9.
  • any preformed insulation web assures a uniform insulation covering on each wire, thus substantially reducing the wastage in manufacture.
  • materials other than paper may be used. These include nonwoven fabrics, synthetic paper, preformed webs, fabrics of various types, film, or foil. Many material candidates from this wide assortment have been known to possess interesting conductor insulation properties, but for want of a viable application process have not found much use.
  • 0.002- inch-thick paper approximately 15 pounds per 3,000 square foot basis weight, is used to produce 60 parallel separate conductors insulated with approximately a 0.006-inch-thick paper insulation creating a 0.020-inch diameter conductor.
  • the insulation as applied in the inventive process can be arbitrarily strong, tough and abrasion resistant since the insulation is preselected on the basis of whatever properties are desired and during the process the material does not undergo any changes.
  • wires 10 are stationed in the troth of the pleats as shown in FIG. 3. Rather, it may be desirable to station them within the roof of pleats as is illustrated by the wired 10a in FIG. 2.
  • FIG. 10 shows an example of a preprinted sheet 1 with regions A-E defined between scoring lines made by the scoring wheel. Each of the regions is preprinted with color pursuant to some preselected color code scheme. Obviously one color, or a variety of colors may be preprinted on sheet 1.
  • Method of making insulated conductors comprising the steps of:
  • Method pursuant to claim 2 comprising the further step of scoring said advancing sheet, along the lines later to be severed, while said sheet is still flat.
  • Process for insulating a wire comprising:
  • said internal region is a central region substantially midway between the pleat and the edges of said open side.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electric Cables (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)
  • Paper (AREA)
  • Laminated Bodies (AREA)
  • Insulating Bodies (AREA)
  • Insulated Conductors (AREA)
US00208126A 1971-12-15 1971-12-15 Wire insulation formed from pleated sheet material and method of manufacture Expired - Lifetime US3763554A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US20812671A 1971-12-15 1971-12-15

Publications (1)

Publication Number Publication Date
US3763554A true US3763554A (en) 1973-10-09

Family

ID=22773277

Family Applications (1)

Application Number Title Priority Date Filing Date
US00208126A Expired - Lifetime US3763554A (en) 1971-12-15 1971-12-15 Wire insulation formed from pleated sheet material and method of manufacture

Country Status (9)

Country Link
US (1) US3763554A (nl)
JP (1) JPS527995B2 (nl)
AU (1) AU476544B2 (nl)
CA (1) CA982334A (nl)
DE (1) DE2261079C3 (nl)
ES (1) ES409989A1 (nl)
FR (1) FR2165951B1 (nl)
GB (1) GB1412446A (nl)
NL (1) NL158638B (nl)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3969169A (en) * 1973-05-21 1976-07-13 Phelps Dodge Industries, Inc. Method of making paper-insulated electrical conductor
US4043851A (en) * 1975-12-23 1977-08-23 Southwire Company Method and apparatus for continuous production of NM cable
US4218285A (en) * 1978-10-16 1980-08-19 Western Electric Company, Inc. Methods of pulp-insulating a conductor
US4281617A (en) * 1979-12-19 1981-08-04 Western Electric Company, Inc. Apparatus for coating conductors
US5477507A (en) * 1985-11-15 1995-12-19 Hughes Aircraft Company Ribbon splicing method and apparatus
US20040069525A1 (en) * 2002-06-21 2004-04-15 Carl Freudenberg Kg Flexible flat cable

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3286017A (en) * 1964-03-03 1966-11-15 Ralph R Batcher Multiple conductor cable and method of making it
US3530018A (en) * 1965-11-23 1970-09-22 Int Standard Electric Corp Method of manufacturing an insulated electrical conductor
US3654027A (en) * 1969-09-24 1972-04-04 Pre Stress Concrete Apparatus for manufacturing a sheathed cable for use in post-tensioning concrete structures

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3286017A (en) * 1964-03-03 1966-11-15 Ralph R Batcher Multiple conductor cable and method of making it
US3530018A (en) * 1965-11-23 1970-09-22 Int Standard Electric Corp Method of manufacturing an insulated electrical conductor
US3654027A (en) * 1969-09-24 1972-04-04 Pre Stress Concrete Apparatus for manufacturing a sheathed cable for use in post-tensioning concrete structures

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3969169A (en) * 1973-05-21 1976-07-13 Phelps Dodge Industries, Inc. Method of making paper-insulated electrical conductor
US4043851A (en) * 1975-12-23 1977-08-23 Southwire Company Method and apparatus for continuous production of NM cable
US4218285A (en) * 1978-10-16 1980-08-19 Western Electric Company, Inc. Methods of pulp-insulating a conductor
US4281617A (en) * 1979-12-19 1981-08-04 Western Electric Company, Inc. Apparatus for coating conductors
US5477507A (en) * 1985-11-15 1995-12-19 Hughes Aircraft Company Ribbon splicing method and apparatus
US20040069525A1 (en) * 2002-06-21 2004-04-15 Carl Freudenberg Kg Flexible flat cable
US6965082B2 (en) * 2002-06-21 2005-11-15 Carl Freudenberg Kg Flexible flat cable

Also Published As

Publication number Publication date
GB1412446A (en) 1975-11-05
JPS4865469A (nl) 1973-09-08
DE2261079C3 (de) 1974-09-12
NL158638B (nl) 1978-11-15
DE2261079B2 (de) 1974-02-14
JPS527995B2 (nl) 1977-03-05
FR2165951A1 (nl) 1973-08-10
CA982334A (en) 1976-01-27
AU4992572A (en) 1974-06-13
FR2165951B1 (nl) 1977-02-04
DE2261079A1 (de) 1973-06-20
NL7216791A (nl) 1973-06-19
ES409989A1 (es) 1976-01-01
AU476544B2 (en) 1976-09-30

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