January 22, 2020

The Controller of Patents

The Patents Office
Intellectual property office Building,
Plot No, 32, Sector -14,
Dwarka, New Delhi – 110075
Phone: 011-28034304

Re: Representation u/s 25(1) of the Patents Act against Indian Patent Application No.
In201917033542 filed on August 20, 2019
Applicant: DOW GLOBAL TECHNOLOGIES LLC

Dear Sir,

We submit herewith a Representation/Pre-grant Opposition under Section 25(1) of the Patents

Act, 2005 alongwith Form 7A.

We crave leave of the Controller to submit additional documents or evidence or if necessary to

support any of the averments in the representation as may be necessitated in the proceeding.

The Controller is requested to take the documents on record and proceed further in the matter
and keep the petitioner advised of each and every step taken in the matter.

Lastly, we request the Controller to grant us an opportunity of being heard before the above
representation is finally decided.

Thanking you,

Sonal
(OPPONENT)

Encl: Form 7A
Opposition
List of documents
 FORM 7A
THE PATENTS ACT,
1970 (39 OF 1970)
AND
THE PATENTS RULES, 2003
REPRESENTATION FOR OPPOSITION TO GRANT OF PATENT
[See Rule 55]
I, Sonal, hereby give representation by way of opposition to the grant of patent
in respect of application No: IN201917033542 filed on August 20, 2019 made
by DOW GLOBAL TECHNOLOGIES LLC on the grounds:

i. Section 25(1)(b): That the invention so far as claimed in any claim of the
complete specification has been published before the priority date of the
claim;
ii. Section 25(1)(e): That the invention so far as claimed in any claim of the
complete specification is obvious and clearly does not involve any inventive
step, having regard to the matter published as mentioned in clause (b) or
having regard to what was used in India before the priority date of the
applicants claim;
iii. Section 25(1)(f): That the subject of any claim of the complete specification is
not an invention within the meaning of this Act, or is not patentable under this
Act;
iv. Section 25(1)(g): That the complete specification does not sufficiently and
clearly describe the invention or the method by which it is to be performed.

(Detailed grounds are set out in the Opposition)

Our address for service in India is:

Sonal
A130, Kendriya Vihar, Sector 56,
Gurgaon, Haryana, 122011
Email: sonalsri2990@[Link]
Contact: +91 9953275218

Dated, this 22nd day of January, 2020

Sonal
(OPPONENT)
To
The Controller of Patents,
The Patent Office, New Delhi
 BEFORE THE OFFICE OF THE CONTROLLER OF PATENTS, DELHI

IN THE MATTER OF:

The Patents Act, 1970 as amended by the Patents (Amendment) Act 2005, and The
Patents Rules, 2003, as amended by The Patents (Amendment) Rules, 2016

AND

IN THE MATTER OF:

An opposition by way of representation under Section 25(1) of The Patents Act, 1970,
as amended by the Patents (Amendment) Act, 2005 read with Rule 55 of The Patents
Rules, 2003, as amended by The Patents (Amendment) Rules, 2016 to the Indian
Patent Application No. 201917033542 filed on August 20, 2019
AND

IN THE MATTER OF:

Sonal
A130, Kendriya Vihar, Sector 56,
Gurgaon, Haryana, 122011 … Petitioner /Opponent

Versus

DOW GLOBAL TECHNOLOGIES LLC

2040 Dow Center Midland,
MI 48674 … Applicant

STATEMENT OF CASE OF OPPONENT

The Opponent herein submits as under:

1. The petitioner/opponent has learnt through publication in Patent Office that the

Respondent/Applicant has filed Indian Application No. IN201917033542, currently

pending before the Patent Office. The said application has been filed in respect of an

invention titled “CABLE JACKETS WITH CAPILLARY STRUCTURES”. The

1
 specification and claims as filed on 20.08.2019 and currently on record are annexed

herewith as ANNEXURE D-1 and reproduced herein below for ready reference:

1. A coated conductor comprising:

a conductor; and

a coating on the conductor, the coating comprising

(i) an annular wall composed of a polymeric material, the annular wall surrounding

at least a portion of the conductor;

(ii) a plurality of channels extending along a length of an outer surface of the annular

wall; and

(iii) a slip material located in the channels, the slip material forming a capillary

structure in the channels, and the capillary structures protruding radially outward from the

annular wall.

2. The coated conductor of claim 1 wherein each capillary structure is adhered to a

channel.

3. The coated conductor of any of claims 1-2 wherein the annular wall and the slip

material are co-extruded.

4. The coated conductor of any of claims 1-3 wherein the channels extend in a pattern

along the length of the outer surface of the annular wall, the pattern selected from a parallel

pattern, a helical pattern, a sinusoidal pattern, or combinations thereof.

2
 5. The coated conductor of any of claims 1-4 wherein each capillary structure has a

cross-sectional shape selected from the group consisting of an ellipse and a polygon.

6. The coated conductor of any of claims 1-5 wherein the coating comprises from 2 to

8 channels.

7. The coated conductor of any of claims 1-6 wherein each capillary structure has a

volume, and from 5% to 50% of the volume of each capillary structure protrudes radially

outward from the annular wall.

8. The coated conductor of any of claims 1-7 wherein the slip material is selected

from the group consisting of a silicone, a fatty acid amide, a plasticizer, an organic amine, a

dibasic ester, a stearate, a sulfate, a fatty acid, a mineral oil, a vegetable oil, fluorinated

organic resins, and combinations thereof.

9. The coated conductor of any of claims 1-8 wherein the slip material comprises a

silicone.

10. The coated conductor of any of claims 8-9 wherein the slip material further

comprises an ethylene-based polymer.

11. The coated conductor of any of claims 1-10 wherein the polymeric material is

selected from the group consisting of ethylene-based polymer, a propylene-based polymer,

polyvinyl chloride (PVC), and combinations thereof.

3
 12. The coated conductor of any of claims 1-11 wherein the conductor is selected

from the group consisting of an optical fiber, a carbon wire, a metal wire, and combinations

thereof.

13. The coated conductor of any of claims 1-12 wherein each capillary structure has

a volume, and from 5% to 50% of the volume of each capillary structure protrudes radially

outward from the annular wall; and

the conductor comprises an optical fiber;

the polymeric material comprises a medium density polyethylene (MDPE); and the

slip material comprises a silicone and a low density polyethylene (LDPE).

14. The coated conductor of any of claims 1-13 disposed in a conduit.

15. The coated conductor of claim 14 wherein at least one of the capillary structures

is in direct contact with an inner surface of the conduit.

BRIEF DESCRIPTION OF THE IMPUGNED APPLICATION

2. The application titled “CABLE JACKETS WITH CAPILLARY STRUCTURES” has

been filed by the Applicant wherein the Applicant claims coating for conductor

comprising annular wall, plurality of outward facing channels on annular wall and slip

materials in channel.

3. The Opponent, based on materials available and general knowledge, reasonably

believes that the invention claimed is in public domain. Accordingly, the impugned

4
 patent application no. IN201917033542 filed on August 20, 2019 is opposed on the

following amongst other grounds:

LIST OF EXHIBITS/ ANNEXURES AS RELIED UPON

Annexure No. D-1: Printout of specification and claims as filed on 20.08.2019 and
currently on record.

Annexure No. D-2: US20070280611;

Annexure No. D-3: US7637298;

GROUND I

Section 25(1)(b): That the invention so far as claimed in any claim of the complete
specification has been published before the priority date of the claim;
i) in any specification filed in pursuance of an application for a patent made in

India on or after the 1st day of January, 1912, or

ii) in India or elsewhere, in any other document:

Provided that the ground specified in sub-clause (ii) shall not be available where such

publication does not constitute an anticipation of the invention by virtue of sub-section (2) or

sub-section (3) of section 29;

The subject matter of the application is not new and has been published in several

publications and documents covering the subject matter in question.

The Act, vide Sec 25(1) read with Sec 13, provides that in case of the applications claiming

subject matter already disclosed previously in another specification or other document, no

patent can be granted for that application.

5
The subject matter of the application IN201917033542 already stands disclosed in

US20070280611 (hereinafter referred to as “US’611” and annexed herewith as Annexure D-

2). The subject matter of the application and claims are anticipated by said publications as

described here below.

Annexure US20070280611 relates to grooved jacket for undersea cables wherein the jacket

surrounds plurality of conductors. The surface of jacket that faces away from the conductors

is provided with plurality of grooves wherein the groves are filled with a material

Thus, Annexure “US’611” fully and completely anticipates the invention as claimed in the

present application.

Therefore it is evident that application No. IN201917033542 is anticipated by the

above discussed annexures and should be rejected.

GROUND II

Section 25(1)(e) that the invention so far as claimed in any claim of the complete
specification is obvious and clearly does not involve any inventive step, having regard to
the matter published as mentioned in clause (b) or having regard to what was used in India
before the priority date of the applicants claim;

As mention heretofore, the subject matter of Indian Patent application IN201917033542 is

obvious to a person skilled in the art, and therefore the application should not be granted. It is

submitted that the invention as claimed is obvious in view of US7637298 (hereinafter

referred to as “US’298” and annexed herewith as Annexure D-3).

6
Annexure US7637298 relates to a self-sealing cable comprising plurality of conductors. The

conductors are surrounded by an inner layer. The inner layer is provided with plurality of

outward protruding ribs that make cavities on the outer surface. The cavity is filled with

material. According to annexure, “Preferred material 10 comprises a polymer which can be

readily pumped at temperatures at least as low as 25° C. Preferably, the polymer will be a low

molecular weight polymer such as low molecular weight isomer. Other materials, or

combinations of materials, with or without such polymers, having such characteristics may

also be useful in the present invention. A polymer which has been found to be particularly

suitable is polyisobutene.”

Hence, the invention is obvious to a person skilled in the art and ought to be rejected on this

ground.

GROUND III

Section 25(1)(f) that the subject of any claim of the complete specification is not an
invention within the meaning of this Act, or is not patentable under this Act;

Invention as defined under section 2(1)(j) of the Act as “Invention means a new product or

process involving an inventive step and capable of industrial application”.

The application IN201917033542 lacks novelty and inventive step in view of documents

cited above and therefore, it is not an invention. Considering the fact, no patent should be

granted to an application which lacks novelty and inventive step and is already a part of

known art.

Further, the subject matter of the application IN201917033542 is a mere arrangement of the

different parts very much known in the art and is generic in nature and thus does not

constitute a patentable subject matter under the Act that is defined under section 3(f) of the

7
Patents Act 1970 as “the mere arrangement or rearrangement or duplication of known

devices each functioning independently of one another in a known way”.

The application IN201917033542 ambiguously discloses the constructional features of the

conductor coating and hence lacks industrial applicability. Considering the fact, no patent

should be granted to an application which lacks industrial application.

Therefore, no patent should be granted to the subject application, as it is not patentable under

the Act.

GROUND IV

Section 25(1)(g) that the complete specification does not sufficiently and clearly describe
the invention or the method by which it is to be performed;

It is submitted that the invention is not sufficiently and properly described and the method by

which it is to be performed is also not properly illustrated. The claims are vague and

ambiguous.

Claim 1 of the application mentions coating of a conductor comprising annular wall, plurality

of channels on outer surface of annular wall and slip materials located in the channel. The

claim further mentions that the annular wall surrounds atleast portion of the conductors.

However, the specifications ambiguously disclose the portion that is surrounded by the

annular wall. Further, the criterion of selection of the portion is arbitrarily disclosed in the

specifications of the application.

Further, the number of channels and the length of each channel is left to the imagination of

person ordinarily skilled in art.

8
Further, the pattern in which the channels are located is ambiguously disclosed in the

specifications of the application. Also, extent till which the capillary structures are extending

outwards is ambiguously and arbitrarily disclosed in the specifications of the application.

RELIEFS SOUGHT AND PERSONAL HEARING

In light of the above grounds and evidence, it is therefore humbly prayed that:

1. That the present opposition be allowed;

2. The Patent Application IN201917033542 dated 20/08/2019 be rejected and no

patent be granted on the basis thereof;

3. That other relief(s) as the Controller may deem appropriate;

4. That the Learned Tribunal be pleased to pass any other order as deemed fit and

proper;

5. It is requested that the Opponents may kindly be granted a hearing before the disposal

of the representation.

Our address for service in India is:

Sonal
A130, Kendriya Vihar, Sector 56,
Gurgaon, Haryana, 122011
Email: sonalsri2990@[Link]
Contact: +91 9953275218

Dated this 22nd day of January, 2020

Sonal
(OPPONENT)

9
ANNEXURE NO D-1
(12)Indian Patent Application
______________________________________________________________

(21) Application Number: 201917033542

(22) Filing Date: 20/08/2019 (43) Publication Date: 04/10/2019

(71) Applicant(s): DOW GLOBAL TECHNOLOGIES LLC

(72) Inventor(s): ESSEGHIR, Mohamed

KMIEC, Chester, J.
HUANG, Wenyi
PARSONS, Thomas, J.

(51) International Classifications: H01B 7/18 G02B 6/44

(30) Priority: 31/01/2017 US 62/452719

(86) International Application Number and Date: PCT/US2018/014052 17/01/2018

(87) International Publication Number: WO/2018/144223

(54) Title: CABLE JACKETS WITH CAPILLARY STRUCTURES

(57) Abstract: The present disclosure provides a coated conductor (10). The coated conductor (10) includes a conductor (2) and a coating (4) on the
conductor. The coating includes (i) an annular wall (6) composed of a polymeric material, the annular wall (6) surrounding at least a portion of the
conductor; (ii) a plurality of channels (8) extending along a length of an outer surface of the annular wall (6); and (iii) a slip material located in the
channels, the slip material forming a capillary structure in the channels, and the capillary structures protruding radially outward from the annular wall
(6).
WE CLAIM:

1. A coated conductor comprising:

a conductor; and
a coating on the conductor, the coating comprising
(i) an annular wall composed of a polymeric material, the
annular wall surrounding at least a portion of the conductor;
(ii) a plurality of channels extending along a length of an outer
surface of the annular wall; and
(iii) a slip material located in the channels, the slip material
forming a capillary structure in the channels, and the capillary structures
protruding radially outward from the annular wall.
2. The coated conductor of claim 1 wherein each capillary structure is
adhered to a channel.
3. The coated conductor of any of claims 1–2 wherein the annular wall and
the slip material are co-extruded.
4. The coated conductor of any of claims 1–3 wherein the channels extend
in a pattern along the length of the outer surface of the annular wall, the pattern
selected from a parallel pattern, a helical pattern, a sinusoidal pattern, or
combinations thereof.
5. The coated conductor of any of claims 1–4 wherein each capillary
structure has a cross-sectional shape selected from the group consisting of an
ellipse and a polygon.
6. The coated conductor of any of claims 1–5 wherein the coating comprises
from 2 to 8 channels.
7. The coated conductor of any of claims 1–6 wherein each capillary
structure has a volume, and from 5% to 50% of the volume of each capillary
structure protrudes radially outward from the annular wall.
8. The coated conductor of any of claims 1–7 wherein the slip material is
selected from the group consisting of a silicone, a fatty acid amide, a plasticizer,
an organic amine, a dibasic ester, a stearate, a sulfate, a fatty acid, a mineral oil,
a vegetable oil, fluorinated organic resins, and combinations thereof.
9. The coated conductor of any of claims 1–8 wherein the slip material
comprises a silicone.

26
10. The coated conductor of any of claims 8–9 wherein the slip material
further comprises an ethylene-based polymer.
11. The coated conductor of any of claims 1–10 wherein the polymeric
material is selected from the group consisting of ethylene-based polymer, a
propylene-based polymer, polyvinyl chloride (PVC), and combinations thereof.
12. The coated conductor of any of claims 1–11 wherein the conductor is
selected from the group consisting of an optical fiber, a carbon wire, a metal
wire, and combinations thereof.
13. The coated conductor of any of claims 1–12 wherein each capillary
structure has a volume, and from 5% to 50% of the volume of each capillary
structure protrudes radially outward from the annular wall; and
the conductor comprises an optical fiber;
the polymeric material comprises a medium density polyethylene
(MDPE); and
the slip material comprises a silicone and a low density polyethylene
(LDPE).
14. The coated conductor of any of claims 1–13 disposed in a conduit.
15. The coated conductor of claim 14 wherein at least one of the capillary
structures is in direct contact with an inner surface of the conduit.

Dated this 20th day of August, 2019

Signature:
Name: AMIT ASWAL
(IN/PA No.-2185)
of anovIP
AGENT FOR THE APPLICANTS

27
APPLICANTS: DOW GLOBAL TECHNOLOGIES LLC TOTAL NO. OF SHEETS: 04
APPLICATION NO.: _____________________ SHEET NO.: 01 of 04

AMIT ASWAL
(IN/PA No.-2185)
of anovIP
AGENT FOR THE APPLICANTS
APPLICANTS: DOW GLOBAL TECHNOLOGIES LLC TOTAL NO. OF SHEETS: 04
APPLICATION NO.: _____________________ SHEET NO.: 02 of 04

AMIT ASWAL
(IN/PA No.-2185)
of anovIP
AGENT FOR THE APPLICANTS
APPLICANTS: DOW GLOBAL TECHNOLOGIES LLC TOTAL NO. OF SHEETS: 04
APPLICATION NO.: _____________________ SHEET NO.: 03 of 04

AMIT ASWAL
(IN/PA No.-2185)
of anovIP
AGENT FOR THE APPLICANTS
APPLICANTS: DOW GLOBAL TECHNOLOGIES LLC TOTAL NO. OF SHEETS: 04
APPLICATION NO.: _____________________ SHEET NO.: 04 of 04

AMIT ASWAL
(IN/PA No.-2185)
of anovIP
AGENT FOR THE APPLICANTS
ANNEXURE NO D-2
 III III a IIOI DID IIO IIOUSlID20070280611A1
1101 0II uui 1101 lul 0II olio II DI IIi
,) United States
^

(12) Patent Application Publication (10) Pub. No.: US z

Dyer et al. (43) Pub. Date: Dec. 6,

(54) GROOVED JACKET FOR UNDERSEA Related U.S. Application Data

CABLE AND METHOD FOR
MANUFACTURING THE SAME (60) Provisional application No. 60/790,799, filed on Apr.
11, 2006.
(75) Inventors: Dennis P. Dyer, Pleasant Garden, NC
(US); Dean C. Wilson, Greensboro, NC Publication Classification
(US); Tatum Boulware, Elon, NC
(US); Michael B. Tilley, Kernersville, (51) Int. Cl.
NC (US) G02B 6/44 (2006.01)
H02G 3/04 (2006.01)
Correspondence Address: (52) U.S. Cl . .............................................. 385/104; 174/97
STEPTOE & JOHNSON LLP (57) ABSTRACT
1330 CONNECTICUT AVENUE, N.W.
WASHINGTON, DC 20036 (US) A cable and system for manufacturing the same is provided.
The cable includes a core communications medium and an
outer jacket surrounding the core communications medium.
(73) Assignee: General Dynamics Advanced, Fairfax, A plurality of grooves are in the outer surface of the outer
VA (US) jacket. Each of the grooves has a recess and an opening to
access the recess, the recess having a larger width than the
(21) Appl. No 11/783,714 opening. Each of the plurality of conductors is exposed to
the external environment and can be reached directly from
(22) Filed: Apr. 11, 2007 the external environment.

got

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Patent Application Publication Dec. 6, 2007 Sheet 3 of 8 US 2007/0280611 Al

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/O SECTION A-A
SCALE. 211
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(VIEW is NO 1 CLLAR TO AXIS of DIMENSIONED GROOVE)

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SECTION A - A
SCALEI 2/i
ROTATED IOS.39' CW
(VIEW IS PERPENDICULAR TO AXIS OF DIMENSIONED GROOVE)

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Patent Application Publication Dec. 6, 2007 Sheet 8 of 8 US 2007/0280611 Al

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NOTE 3

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US 2007/0280611 Al Dec. 6, 2007

GROOVED JACKET FOR UNDERSEA CABLE AND tially circular cross section. The core communications
METHOD FOR MANUFACTURING THE SAME medium may be an unarmored fiber optic cable, either with
or without its outer jacket.
BACKGROUND OF THE INVENTION
[0009] According to still another embodiment of the
[0001] 1. Field of the Invention invention, a communications cable is provided. The cable
includes a core communications medium and an outer jacket
[0002] The present invention relates to undersea cables. surrounding the core communications medium. The outer
More specifically, the present invention relates to undersea jacket at least partially including an extrusion grade, abra-
cables with a helical grooved outer jacket that can support sion resistant polyether-based thermoplastic polyurethane
multiple conductors. with a durometer of between and including 74 to 85 Shore
A. A plurality of helical grooves are in the outer surface of
[0003] 2. Discussion of Background Information
the outer jacket. Each of the grooves has a recess and an
[0004] Commercially available undersea cables typically opening to access the recess, the recess having a substan-
include a core cable, a protective cover around the cable, and tially circular cross section and a diameter larger than the
a series of conductors (metal or fiber-optic) embedded in the opening. A communications cable is laid in each of the
cover that carry signals separate from the main core cable. grooves, each cable having a diameter less than or equal to
One must cut into the protective cover to access these the diameter of the recess, but greater than a width of the
conductors, which places the underlying main core cable at opening.
risk of damage. Conductors can typically be placed near the
[0010] The above embodiment may have various features.
surface of the protective cover to minimize the cut depth
The outer jacket may include an extrusion grade, abrasion
needed to access the conductors, which minimizes potential
resistant polyether-based thermoplastic polyurethane with a
damage to the underlying main core cable. However, the
durometer of between and including 74 to 85 Shore A. The
reduction in thickness of the overlapping protective cover
outer jacket may include a lubricant mixed with polyure-
results in a corresponding loss of protection for the conduc-
thane. The plurality of,grooves may each have a substan-
tors.
tially circular cross section. The core communications
medium may be an unarmored fiber optic cable, either with
SUMMARY OF THE INVENTION or without its outer jacket. Each of the plurality of commu-
[0005] According to an embodiment of the invention, a nications cables may be exposed to the external environment
cable is provided. The cable includes a core communications and can be accessed directly from the external environment.
medium and an outer jacket surrounding the core commu- [0011] According to yet another embodiment of the inven-
nications medium. A plurality of grooves are in the outer tion, a method for manufacturing a communications cable is
surface of the outer jacket. Each of the grooves has a recess provided. The steps include applying adhesive to a cable,
and an opening to access the recess, the recess having a preheating the cable and applied adhesive, passing the cable
larger width than the opening. Each of the plurality of with adhesive through a die, the die being configured to form
conductors is exposed to the external environment and can an outer jacket with grooves therein over the cable, rotating
be reached directly from the external environment. the die during the passing, extruding a compound around the
[0006] The above embodiment may have various features. cable with adhesive during the rotating, cooling the com-
The outer jacket may include an extrusion grade, abrasion pound, cable and adhesive to form a cable with an outer
resistant polyether-based thermoplastic polyurethane with a jacket having grooves, and laying individual communication
durometer of between and including 74 to 85 Shore A; the cables in the grooves.
outer jacket may include a lubricant mixed with polyure- [0012] The above embodiment may have various features.
thane. The plurality of grooves may each have a substan- There may be an additional step of forming the compound
tially circular cross section. The core communications by mixing a lubricant with an extrusion grade, abrasion
medium may be an unarmored fiber optic cable, either with resistant polyether-based thermoplastic polyurethane with a
or without its outer jacket. durometer of between and including 74 to 85 Shore A. There
may be an additional step of winding the cable over a spool,
[0007] According to another embodiment of the invention,
which may precede or follow the step of laying.
a communications cable is provided. The cable includes a
core communications medium and an outer jacket surround- [0013] According to yet another embodiment of the inven-
ing the core communications medium. A plurality of helical tion, a method for manufacturing a communications cable is
grooves are in the outer surface of the outer jacket. Each of provided. The method includes removing an outer layer of a
the grooves has a recess and an opening to access the recess, cable, preheating the cable, passing the cable through a die,
the recess having a larger width than the opening. A com- the die being configured to form an outer jacket with grooves
munications cable is laid in each of the grooves. Each therein over the cable, rotating the die during the passing,
communications cable has a diameter less than or equal to a extruding a compound around the cable during the rotating,
width of the recess, but greater than a width of the opening. cooling the compound and cable to form a cable with an
outer jacket having grooves, and laying individual commu-
[0008] The above embodiment may have various features. nication cables in the grooves.
The outer jacket may include an extrusion grade, abrasion
resistant polyether-based thermoplastic polyurethane with a [0014] The above embodiment may have various features.
durometer of between and including 74 to 85 Shore A; the There may be an additional step of forming the compound
outer jacket may include a lubricant mixed with polyure- by mixing a lubricant with an extrusion grade, abrasion
thane. The plurality of grooves may each have a substan- resistant polyether-based thermoplastic polyurethane with a
US 2007/0280611 Al Dec. 6, 2007
2

durometer of between and including 74 to 85 Shore A. There 108 separates and joins cable 104 and jacket 102. FIG. 4
may be an additional step of winding the cable over a spool, shows individual conductors 110 placed in each of grooves
which may precede or follow the step of laying. 106. The embodiments herein show eight grooves 106, but
any number may be used.
BRIEF DESCRIPTION OF THE DRAWINGS [0027] Jacket 102 includes projections 112 that define
[0015] The present invention is further described in the each of the individual grooves 106. The groves are substan-
detailed description which follows, in reference to the noted tially circular in shape with an opening. 114 facing outward,
plurality of drawings by way of non-limiting examples of although other non-circular shapes could be used. Opening
certain embodiments of the present invention, in which like 114 is preferably smaller than the diameter of conductors
numerals represent like elements throughout the several 110 so that conductors 110 will not fall out (absent inten-
views of the drawings, and wherein: tional efforts to remove them), but wide enough such that
conductors 110 can be popped into grooves 106 under the
[0016] FIG. 1 illustrates a perspective view of a cable application of suitable external pressure. The inwardly fac-
according to an embodiment of the invention; ing edges of projections 112 adjacent opening 114 and the
[0017] FIG. 2 illustrates a side view of the outer jacket of apex of projections 112 are preferably rounded to ease in
the embodiment of FIG. 1 over a single pitch of the helicoid cable insertion.
on the outer jacket; [0028] Jacket 102 provides protection for both core cable
[0018] FIG. 3 illustrates a cross section taken along line 104 and conductors 110. However, a technician can access
A-A in FIG. 2; individual conductors 110 simply by popping them right out
of the groove 106. There is no need to cut into protective
[0019] FIG. 4 illustrates the cross section of FIG. 3 with jacket 102, and thus no corresponding risk of damaging core
reference circles; cable 104.
[0020] FIG. 5 illustrates a perspective view of a cable [0029] The dimensions of embodiment 100 are highly
according to another embodiment of the invention; dependent upon the nature of cable 104 and conductors 110.
[0021] FIG. 6 illustrates a side view of the outer jacket of An unarmored commercial cable 104 typically has a diam-
the embodiment of FIG. 5 over single pitch of the helicoid eter of 0.882 inches, and commercially available conductors
on the outer jacket; 110 typically have a diameter of 0.260 inches. For cables and
conductors of such dimensions, then embodiment 100 may
[0022] FIG. 7 illustrates a cross section taken along line have the following parameters:
A-A in FIG. 6; and
[0030] Adhesive 108 is preferably approximately 0.03
[0023] FIG. 8 illustrates an additional cross section view inches thick, ±0.0075 inches. Since adhesive 108 surrounds
taken along line A-A in FIG. 6. cable 104, the diameter of cable 104 and adhesive 108 is
preferably approximately 0.935±0.015 inches.
DETAILED DESCRIPTION OF EXEMPLARY
EMBODIMENTS [0031] The distance between the outer diameter of adhe-
sive 108 and the inner diameter of grooves 106 is preferably
[0024] The particulars shown herein are by way of 0.195 inches, ±0.0375 inches.
example and for purposes of illustrative discussion of the
embodiments of the present invention only and are presented [0032] The centers of each of conductors 110 preferably
in the cause of providing what is believed to be the most define a circle having a diameter of approximately 1.43
useful and readily understood description of the principles inches.
and conceptual aspects of the present invention. In this [0033] The outer diameter of jacket 102 is preferably
regard, no attempt is made to show structural details of the 1.95-2.10 inches.
present invention in more detail than is necessary for the
fundamental understanding of the present invention, the [0034] The diameter of the circular portion of groove 106
description taken with the drawings making apparent to is preferably 0.270-0.330 inches.
those skilled in the art how the several forms of the present [0035] The width of opening 114 is preferably 0.170-0.330
invention may be embodied in practice. inches.
[0025] Referring to FIG. 1, an embodiment 100 includes [0036] The edges of projections 112 adjacent opening 114
an outer jacket 102 concentrically about a core cable 104. preferably have a radius of curvature of 0.050 inches.
Cable 104 is preferably any commercially available unar-
mored cable used in undersea operations, although any [0037] The outermost edges of projections 112 preferably
commercially available cable could be used. Jacket 102 is have a radius of curvature of 0.030 inches.
preferably an extruded polyurethane structure which holds [0038] The length of a single turn (360° revolution) of one
and protects cable 104 substantially coaxially therewith. of grooves 106 is preferably 16-17.5 inches.
Referring now also to FIG. 2, jacket 102 includes several
equally spaced helical grooves 106 around its outer periph- [0039] The minimum bend radius for embodiment 100 is
ery. The grooves form a so-called "left hand lay," which preferably approximately 40 inches if the cable tension is
matches the lay of commercial undersea cables. less than 2000 lbs, and preferably approximately 60 inches
if the cable tension is greater than or equal to 2000 lbs.
[0026] FIG. 3 shows a cross section of the embodiment
100 taken across line A-A in FIG. 2, which exposes the core [0040] Jacket 102 is preferably made primarily from an
cable 104 and the surrounding jacket 102. An adhesive layer extrusion grade, abrasion resistant polyether-based thermo-
US 2007/0280611 Al Dec. 6, 2007

plastic polyurethane with a durometer of between (and which have been used herein are words of description and
including) 74 to 85 Shore A. Below 74 would be sufficiently illustration, rather than words of limitation. Changes may be
soft that it may not hold conductors 110 in place, whereas made, within the purview of the appended claims, as pres-
above 85 would be sufficiently hard that projections 112 ently stated and as amended, without departing from the
would not bend under pressure to enlarge opening 114 to scope and spirit of the present invention in its aspects.
allow insertion of conductors 110. Elastolan 1175AIOW is Although the present invention has been described herein
suitable for this purpose, although other compounds may be with reference to particular means, materials and embodi-
used. ments, the present invention is not intended to be limited to
the particulars disclosed herein; rather, the present invention
[0041] The jacket 102 compound includes polyurethane
extends to all functionally equivalent structures, methods
having the characteristics noted above and approximately
and uses, such as are within the scope of the appended
0.10%±0.05% lubricant. The lubricant will reduce the coef-
claims.
ficient of sliding friction of the polyurethane during extru-
sion. Americhem 44192 is suitable for this purpose, although What is claimed is:
other compounds may be used. 1. A cable, comprising:
[0042] The manufacturing process is as follows. Cable a core communications medium;
104 is first fed into a system which applies adhesive 108 in
an appropriate thickness. The cable 104 with adhesive 108 an outer jacket surrounding the core communications
is then preheated to approximately 330-370 degrees F., medium; and
particularly 350 degrees F., before being fed to a rotating die a plurality of grooves in the outer surface of the outer
(not shown). The die has a cross section that substantially jacket, each of said grooves having a recess and an
mirrors that shown in FIG. 3, modified as necessary to opening to access said recess, said recess having a
account for post-extrusion changes such as shrinkage. The larger width than said opening;
polyurethane compound is extruded around cable 104 as it
passes through the rotating die. Rotation of the die creates wherein said each of said plurality of conductors is
the helical exterior shape of jacket 102. Preferably approxi- exposed to the external environment and can be
mately 1 foot of cable is extruded per minute. Jacket 102 is reached directly from the external environment.
then cooled (under ambient temperature, fans, or other 2. The cable of claim 1, wherein the outer jacket com-
cooling systems) for approximately 1 hour before the fin- prises an extrusion grade, abrasion resistant polyether-based
ished product is wound on a spool. thermoplastic polyurethane with a durometer of between and
including 74 to 85 Shore A.
[0043] Individual conductors 110 are preferably added at
3. The cable of claim 1, wherein the outer jacket com-
a later date, although they could also be added before the
prises a lubricant mixed with polyurethane.
cable is wound; in either case, portions of conductors 110 are
4. The cable of claim 1, wherein said plurality of grooves
aligned with grooves 106 and subject to inward radial
each has a substantially circular cross section.
pressure to force the conductors 110 through opening 114
into grooves 106. This process repeats along with length of 5. The cable of claim 1, wherein said core communica-
the cable. tions medium is an unarmored fiber optic cable.
6. The cable of claim 1, wherein said core communication
[0044] A perspective view of another embodiment 500 of medium is an unarmored fiber optic cable with its outer
the invention is shown in FIG. 5. A cable 504 is preferably coating removed.
a commercially available armored cable with its "tar and 7. The cable of claim 1, further comprising a layer of
jute" (its outer nylon coating) removed, but other cables may adhesive between said core communications medium said
be used. Since the polyurethane compound will easily bond outer jacket.
with cable 504, no adhesive layer is necessary. Ajacket 502 8. A communications cable, comprising:
is identical to jacket 102 discussed above.
a core communications medium;
[0045] The dimensions of embodiment 500 are highly
dependent upon the nature of cable 504 and conductors 110. an outer jacket surrounding the core communications
An armored commercial cable 504 typically has a diameter medium;
of 0.933 inches, and commercially available conductors 110 a plurality of helical grooves in the outer surface of the
typically have a diameter of 0.260 inches. Since the diameter outer jacket, each of said grooves having a recess and
of cable 504 is substantially equal to the diameter of cable an opening to access said recess, said recess having a
104 plus adhesive 108, then the dimensions of jacket 102 larger width than said opening; and
discussed above are equally applicable to jacket 502.
a communications cable laid in each of said grooves, each
[0046] The manufacture of embodiment 500 is similar to cable having a diameter less than or equal to a width of
embodiment 100. The steps of applying adhesive and heat- said recess, but greater than a width of said opening.
ing are replaced with a step of removing the "tar and jute"
9. The cable of claim 9, wherein the outer jacket com-
outer coating of cable 504. The remainder of the manufac-
prises an extrusion grade, abrasion resistant polyether-based
turing process is the same.
thermoplastic polyurethane with a durometer of between and
[0047] It is noted that the foregoing examples have been including 74 to 85 Shore A.
provided merely for the purpose of explanation and are in no 10. The cable of claim 9, wherein the outer jacket com-
way to be construed as limiting of the present invention. prises a lubricant mixed with said polyurethane.
While the present invention has been described with refer- 11. The cable of claim 8, wherein said plurality of grooves
ence to certain embodiments, it is understood that the words each has a substantially circular cross section.
US 2007/0280611 Al Dec. 6, 2007
0

12. The cable of claim 8, wherein said core communica- rotating said die during said passing;
tions medium is an unarmored fiber optic cable.
extruding a compound around the cable with adhesive
13. The cable of claim 8, wherein said core communica-
during said rotating;
tion medium is an unarmored fiber optic cable with its outer
coating removed. cooling said compound, cable and adhesive to form a
14. The cable of claim 8, further comprising a layer of cable with an outer jacket having grooves; and
adhesive between said core communications medium said
laying individual communication cables in said grooves.
outer jacket.
22. The method of claim 21, further comprising forming
15. A communications cable, comprising:
said compound by mixing a lubricant with an extrusion
a core communications medium; grade, abrasion resistant polyether-based thermoplastic
polyurethane with a durometer of between and including 74
an outer jacket surrounding the core communications
to 85 Shore A.
medium, said outer jacket at least partially including an
23. The method of claim 21, further comprising winding
extrusion grade, abrasion resistant polyether-based
said cable over a spool.
thermoplastic polyurethane with a durometer of
24. The method of claim 21, wherein said winding pre-
between and including 74 to 85 Shore A;
cedes said laying.
a plurality of helical grooves in the outer surface of the 25. The method of claim 21, wherein said laying precedes
outer jacket, each of said grooves having a recess and said winding.
an opening to access said recess, said recess having a 26. A method for manufacturing a communications cable,
substantially circular cross section and a diameter comprising:
larger than said opening;
removing an outer layer of a cable;
a communications cable laid in each of said grooves, each
preheating the cable;
cable having a diameter less than or equal to said
diameter of said recess, but greater than a width of said passing the cable through a die, the die being configured
opening. to form an outer jacket with grooves therein over said
16. The cable of claim 15, wherein said each of said cable;
plurality of communications cables are exposed to the
external environment and can be accessed directly from the rotating said die during said passing;
external environment. extruding a compound around the cable during said
17. The cable of claim 16, wherein the outer jacket rotating;
comprises a lubricant mixed with said polyurethane.
18. The cable of claim 15, wherein said core communi- cooling said compound and cable to form a cable with an
cations medium is an unarmored fiber optic cable. outer jacket having grooves; and
19. The cable of claim 15, wherein said core communi- laying individual communication cables in said grooves.
cations medium is an unarmored fiber optic cable with its 27. The method of claim 26, further comprising forming
outer coating removed. said compound by mixing a lubricant with an extrusion
20. The cable of claim 15, further comprising a layer of grade, abrasion resistant polyether-based thermoplastic
adhesive between said core communications medium said polyurethane with a durometer of between and including 74
outer jacket. to 85 Shore A.
21. A method for manufacturing a communications cable, 28. The method of claim 26, further comprising winding
comprising: said cable over a spool.
applying adhesive to a cable; 29. The method of claim 26, wherein said winding pre-
cedes said laying.
preheating the cable and applied adhesive;
30. The method of claim 26, wherein said laying precedes
passing said cable with adhesive through a die, the die said winding.
being configured to form an outer jacket with grooves
therein over said cable;
ANNEXURE NO D-3
 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 l Ol
US007637298B2
lli

(12) United States Patent (10) Patent No.: US 7,637,298 B2

Spruell (45) Date of Patent: *Dec. 29, 2009

(54) MULTI-LAYER EXTRUSION HEAD FOR (58) Field of Classification Search ................. 156/500,
SELF-SEALING CABLE 156/51, 52, 55, 56; 174/120 R; 425/113,
425/114, 131.1
(75) Inventor: Stephen Lee Spruell, Carrollton, GA See application file for complete search history.
(US) (56) References Cited
(73) Assignee: Southwire Company, Carrollton, GA U.S. PATENT DOCUMENTS
(US) 2,583,025 A 1/1952 Swift et al.

(*) Notice: Subject to any disclaimer, the term of this (Continued)

patent is extended or adjusted under 35
FOREIGN PATENT DOCUMENTS
U.S.C. 154(b) by 0 days.
CA 2439367 At 3/2004
This patent is subject to a terminal dis- (Continued)
claimer.
OTHER PUBLICATIONS
(21) Appl. No.: 12/036,121
Canadian Office Action dated Sep. 25, 2006 cited in Canadian Appli-
cation No. 2,332,005.
(22) Filed: Feb. 22, 2008
(Continued)
(65) Prior Publication Data
Primary Examiner Jeff H Aftergut
US 2008/0286399 Al Nov. 20, 2008 (74) Attorney, Agent, or Firm Merchant & Gould

Related U.S. Application Data (57) ABSTRACT

(63) Continuation of application No. 11/083,454, filed on An extrusion head may be provided. The extrusion head may
Mar. 18, 2005, now Pat. No. 7,367,373, and a continu- include an inner flow path, an outer flow path, and at least one
ation-in-part of application No. 10/364,808, filed on sealant flow path. The inner flow path may be configured to
Feb. 11, 2003, now abandoned, which is a continua- direct a flow of an inner layer around a conductor. The outer
tion-in-part of application No. 09/851,475, filed on flow path may be configured to direct a flow of an outer layer
May 8, 2001, now Pat. No. 6,573,456, which is a around the inner layer. The at least one sealant flow path may
continuation-in-part of application No. 09/730,661, extend to a connecting point with the inner flow path and the
filed on Dec. 6, 2000, now abandoned. outer flow path. The at least one sealant flow path may be
(60) Provisional application No. 60/557,526, filed on Mar. configured to direct a sealant to fill at least one sealant channel
30, 2004. region between the inner layer and the outer layer. The con-
nection point may be configured to cause the flow of the inner
(51) Int. Cl. layer and the flow of the outer layer to join before the sealant
H01B 7/00 (2006.01) fills the at least one sealant channel region.
(52) U.S. Cl. ........................... 156/500; 156/51; 156/52;
156/55; 156/56; 425/113; 425/114; 425/131.1 22 Claims, 14 Drawing Sheets
 US 7,637,298 B2
Page 2

U.S. PATENT DOCUMENTS EP 0 271 296 A2 6/1988

EP 0 940 819 Al 9/1999
2,583,026 A 1/1952 Swift EP 0 947 999 A2 10/1999
2,885,737 A 5/1959 Whalen et al . ............. 264/45.9 EP 1081720 Al 3/2001
3,229,012 A * 1/1966 Garner .................. 264/171.17 FR 2 384 336 10/1978
3,502,752 A * 3/1970 Brown ................... 264/171.17 FR 2 566 955 1/1986
3,607,487 A 9/1971 Biskeborn et al. GB 2 099 829 A 12/1982
3,775,548 A 11/1973 Zinser, Jr. et al. ......... 174/23 C SE CH-608419 A 1/1979
3,823,255 A 7/1974 La Gase et al. WO WO 01/52272 Al 7/2001
3,843,568 A 10/1974 Woodland et al. WO WO-02/091396 A2 11/2002
3,889,455 A 6/1975 Portinari et al.
3,943,271 A 3/1976 Bander et al. OTHER PUBLICATIONS
4,095,039 A 6/1978 Thompson ................... 174/23 PCT International Search Report dated Aug. 7, 2002 cited in Inter-
4,095,404 A 6/1978 Babayan national Application No. PCT/US02/10723.
4,105,485 A 8/1978 Portinari etal. PCT International Search Report dated Apr. 24, 2000 cited in Inter-
4,129,466 A 12/1978 Portinari etal. national Application No. PCT/US00/00703.
4,130,450 A 12/1978 Bander et al. Canadian Office Action dated Jul. 19, 2005 cited in Canadian Appli-
4,273,597 A 6/1981 Garner et al. cation No. 2,439,367.
4,360,704 A 11/1982 Madry Mexican Office Action dated Mar. 16, 2006 cited in Mexican Patent
4,435,613 A 3/1984 Gaubert Application No. PA/a/2003/007921.
4,563,540 A 1/1986 Bohannon, Jr. et al. Canadian Office Action dated Sep. 21, 2006 cited in Canadian Appli-
4,631,229 A 12/1986 Martens cation No. 2,446,724.
4,659,424 A 4/1987 Baxter et al ................... 156/51 Mexican Office Action dated Apr. 6, 2006 cited in Mexican Patent
4,703,132 A 10/1987 Marciano-Agostinelli Application No. PA/a/2003/010177.
et al . ........................ 174/23 C Mexican Office Action dated Jun. 24, 2005 cited in Mexican Patent
4,725,121 A 2/1988 Priaroggia .................. 385/113 Application No. PA/a/2000/008990.
4,832,443 A 5/1989 Cameron et al. U.S. Office Action dated Dec. 3, 2001 cited in U.S. Appl. No.
4,840,996 A 6/1989 Wild et al . .................. 525/193 09/730,661.
5,010,209 A 4/1991 Marciano-Agostinelli U.S. Final Office Action dated Jun. 5, 2002 cited in U.S. Appl. No.
et al . ........................ 174/23 C 09/730,661.
5,049,593 A 9/1991 Marciano-Agostinelli U.S. Office Action dated Jul. 1, 2004 cited in U.S. Appl. No.
et al . .......................... 523/173 10/235,024.
5,221,781 A 6/1993 Aida et al. U.S. Office Action dated Dec. 20, 2004 cited in U.S. Appl. No.
5,455,881 A 10/1995 Bosisio et al . .............. 385/100 10/364,808.
5,512,625 A 4/1996 Butterbach et al. U.S. Final Office Action dated Aug. 8, 2005 cited in U.S. Appl. No.
5,580,265 A 12/1996 Koblitz et al. 10/264,808.
5,898,044 A 4/1999 Nooren U.S. Office Action dated Mar. 14, 2006 cited in U.S. Appl. No.
5,902,849 A 5/1999 Heucher et al. 10/264,808.
5,920,032 A 7/1999 Aeschbacher et al. U.S. Final Office Action dated Jul. 25, 2006 cited in U.S. Appl. No.
5,922,155 A 7/1999 Clouetetal. 10/264,808.
5,990,419 A 11/1999 Bogese, II U.S. Office Action dated Jan. 24, 2000 cited in U.S. Appl. No.
6,184,473 B1 2/2001 Reece et al. 09/228,482.
6,258,885 B1 7/2001 Heucher et al. U.S. Final Office Action dated Aug. 2, 2000 cited in U.S. Appl. No.
6,353,177 B1 3/2002 Young ......................... 174/42 09/228,482.
6,359,231 B2 3/2002 Reece et al. U.S. Office Action dated Jul. 5, 2001 cited in U.S. Appl. No.
6,391,447 B1 5/2002 Kornfeldt et al. 09/756,533.
6,534,715 B1 3/2003 Maunder et al. U.S. Final Office Action dated Feb. 26, 2009 cited in U.S. Appl. No.
6,573,456 B2 6/2003 Spruell et al. ........... 174/110 R 11/295,048.
6,664,476 B2 12/2003 Belli et al. U.S. Office Action dated Sep. 7, 2007 cited in U.S. Appl. No.
6,914,193 B2 7/2005 Ware et al ............... 174/110 R 11/083,454.
7,204,896 B2 4/2007 Maunder et al . .............. 156/51 European Communication & Supplemental European Search Report
7,367,373 B2 5/2008 Spruell ....................... 156/500 dated Apr. 9, 2008 cited in EP Application No. 02 72 6705.3-1231
2 00 1/00 09 19 8 Al 7/2001 Belli et al . .............. 174/110 R PCT/U50210723.
2002/0108773 Al 8/2002 Ware et al ............... 174/120 R U.S. Office Action dated Sep. 8, 2008 cited in U.S. Appl. No.
2002/0108774 Al 8/2002 Belli et al . .............. 174/120 R 11/295,048.
2003/0062188 Al 4/2003 Ware et al. Pour Point definition from [Link], undated.
2003/0168245 Al 9/2003 Spruell et al. ........... 174/120 R Complaint filed Mar. 10, 2009 by Plaintiff, Southwire Company
2005/0161248 Al 7/2005 Ware et al. against Defendant, Prysmian Power Cables and Systems U.S.A.,
2006/0090925 Al 5/2006 Spruell et al. ........... 174/120 R LLC; Infringement of U.S. Patent No. 7,367,373, (8 pages).
U.S. Office Action dated Sep. 18, 2009 cited in U.S. Appl. No.
FOREIGN PATENT DOCUMENTS 11/295,048.
CA 2446724 3/2009 "Single Conductor 600V Secondary UD SureSeal," Southwire Com-
pany, 2003, 2 pgs.
DE 2 115 844 10/1972
DE 28 07 767 8/1979 * cited by examiner
U.S. Patent Dec. 29, 2009 Sheet 1 of 14 US 7,637,298 B2

N
U.S. Patent Dec. 29, 2009 Sheet 2 of 14 US 7,637,298 B2

$1

...
U.S. Patent Dec. 29, 2009 Sheet 3 of 14 US 7,637,298 B2

FA

L
0)
u

N
 SLOT, 30 DEG. ANGLE, 150 MILS
CONDUCTOR - --•° WIDE AT CABLE SURFACE, 60 MILS
WIDE AT CONDUCTOR SURFACE

Figure 4
U.S. Patent Dec. 29, 2009 Sheet 5 of 14 US 7,637,298 B2

Damage Key: --------- slot damage

Samples 1-4 Control
Samples 5-12 Self-Sealing

FIG. 5
 PROJECT #00122
LEAKAGE CURRENT{ + 1LLIAMPERES)

d1
8

DAYS
Figure 6, Cable Sample Leakage Current Measurements
 PROJECT #00122
CONDUCTOR RESISTANCE ([Link])
1000

950

900
81-C
850
t S2-C
800
-4-33-C
750

700 -x- $4-C

650 -0- 85-SS

600 -o-S6-SS

550 -x- S7-SS

500 -x- SS•SS

450 -a- Ss-SS 0

400 - - 810-SS .
350 -- 811•SS
300 ----512-SS
250
f i
200

DAYS

Figure 7: Cable Sample Conductor Resistance Measurements

 TEMPERATURE PROFILE
125.0
120.0
115.0
110.0
105.0
100.0
195.0
m
90.(
m 85.0
80.0
75,(
G 70.(
m 65.(
am 60,(
55.0
G)
50.(
h 45.(
40.0
35.0
30.(
25.(
20.0
15.0

DAYS
I---S1-C —4— S2-C —e— S3-C —x— S4-C --S5-SS —o—S6-SS --S7-SS —x— 58-SS --- S9-SS — -- S1a-SS —:—S11-$S --•— S12-S5
CABLE SAMPLE TEMPERATURE MEASUREMENTS
Figure 8
U.S. Patent Dec. 29, 2009 Sheet 9 of 14 US 7,637,298 B2

Figure 9

Figure 10
U.S. Patent Dec. 29, 2009 Sheet 10 of 14 US 7,637,298 B2

4 ~
J %+~vs T i ? ..I( L ~~+ ••

j r

~ ' }I^ •(y /'

..;4 LL- }'.1,

Sample 8 (Self Sealing) No visible corrosion after 91 days in test

Figure 11
U.S. Patent Dec. 29, 2009 Sheet 11 of 14 US 7,637,298 B2
U.S. Patent Dec. 29, 2009 Sheet 12 of 14 US 7,637,298 B2
U.S. Patent Dec. 29, 2009 Sheet 13 of 14 US 7,637,298 B2

FIG. 14
U.S. Patent Dec. 29, 2009 Sheet 14 of 14 US 7,637,298 B2

it

(2-

FIG. 15
 US 7,637,298 B2
1 2
MULTI-LAYER EXTRUSION HEAD FOR All the reasons for 600 V failures are unknown, but several
SELF-SEALING CABLE have been postulated by cable users. These cables seem to
experience a high degree of infant mortality, followed by
CROSS-REFERENCE TO RELATED failures occurring over decades. The infant mortalities are
APPLICATION 5 usually directly related to damage caused by adjacent utili-
ties, damage inflicted by landscaping and planting, or damage
This application is a continuation of U.S. application Ser. to the cable prior to or during installation. The failures occur-
No. 11/083,454 filed Mar. 18, 2005, now U.S. Pat. No. 7,367, ring years later are harder to explain. There have been postu-
373, which claims priority from Provisional Application No. lations of lightning damage, manufacturing defects, or insu-
60/557,526 filed Mar. 30, 2004, and is a continuation-in-part io lation degradation over the life of the installation.
of application Ser. No. 10/364,808 filed Feb. 11, 2003, now In order to better understand the insulation characteristics,
abandoned, which is a continuation-in-part of application Ser. studies of the AC breakdown, and DC impulse breakdown
No. 09/851,475 filed May 8, 2001, now U.S. Pat. No. 6,573, were conducted. AC breakdown studies on several different
456, which is a continuation-in-part of application Ser. No. cables showed a high safety margin of performance. Each of
09/730,661 filed Dec. 6, 2000, now abandoned, and relates to 15 these cables had a 0.080 inch wall thickness. Tests were
copending application Ser. No. 11/295,048 filed Dec. 6, 2005, conducted in water filled conduits. The AC breakdown
all of which are relied on and incorporated by reference. strength of all of these cables was consistently above 20 kV,
far in excess of the operating stress.
BACKGROUND
Impulse breakdown studies have also been performed on
20
several 600 V cable constructions having different insulation
Insulated solid and stranded electrical cables are well
formulations. The impulse breakdown level of these cables
known in the art. Generally stranded cables include a central
was approximately 150 kV. This exceeds the BIL require-
stranded conductor with a protecting insulation jacket dis-
ments of a 15 kV cable system and should well exceed the
posed around the conductor.
impulses on 600 V secondary cables during operation.
The most frequent cause of failure of directly buried alu- 25
minum secondary cables is a cut or puncture in the insulation The above margins of electrical performance were mea-
inflicted during or after installation. This leads to alternating sured on new cables. They are far above what is needed to
current corrosion of the aluminum and finally to an open operate on a 600 V system since most of these cables operate
circuit. When a conductor is exposed to wet soil, upon dam- at 120 V to ground. One of the tests during compound and
age, leakage current may flow, and cause localized electro- 30
product development is a long term insulation resistance test
chemical conversion of aluminum to hydrated aluminum performed in water at the rated operating temperature of the
oxide and eventually to an open circuit of the conductor. insulation. For crosslinked polyethylene cables the water
In the U.S., thousands of such instances occur annually and temperature is 90° C. The insulation resistance must demon-
the repair (location, excavation, repair, and replacement) can strate stability and be above minimum values for a minimum
be very costly. As a result of the failures and in response to this 35 of twelve weeks. If there is instability indicated, the test is
problem, a tougher insulation system was introduced and continued indefinitely. Relative permittivity is measured at 80
became an industry standard. The tougher cable is described v/mil and must meet specific values. Increase in capacitance
as "ruggedized," and generally consists of two layers: an and dissipation factor are also measured in 90° C. water over
inner layer of low density weight polyethylene and an outer a 14 day period. Insulation compounds used in present day
layer of high density polyethylene. This design is more resis- 40
cables easily meet these requirements.
tant to mechanical damage than one pass low density poly- Manufacturing defects in cable insulation are found during
ethylene, but still can result in exposure of the aluminum production by either of two methods. During the extrusion
conductor if sufficient impact is involved. process, the cable is sent through a spark tester, where 28 kV
Investigations show that AC electrolysis current can DC, or 17 kV AC, is applied to the insulation surface. Any
approach half-wave rectification when the current density is 45 manufacturing defect resulting in a hole in the insulation will
high. This accounts for the rapid loss of aluminum metal initiate a discharge, which is detected by the spark tester.
frequently experienced in the field. A caustic solution (pH Most manufacturers use this method. Another test that is also
10-12) develops at the aluminum surface and dissolves the often employed is a full reel water immersion test. In this test
protective oxide film. 21 kV DC, or 7 kV AC is applied to the cable after immersion
The mechanism of aluminum cable failure is the formation 50 for 1 hour or 6 hours, depending on whether the cable is a
of hydrous aluminum oxide. As the aluminum oxide solids plexed assembly or single conductor, respectively. The actual
buildup, the insulation in the vicinity of the puncture is forced voltages used for these tests are dependent on the wall thick-
to swell and splits open, making larger areas of the aluminum ness. The above values are for an 0.080 inch wall.
conductor surface available for electrolysis, thus increasing The above testing has demonstrated electrical performance
the leakage current and accelerating the corrosion process. 55 that is stable and far surpasses the requirements of the instal-
Rapid loss of aluminum by AC electrolysis continues until lation for 600 V cable. This does not explain a sudden cable
ultimately the cable is open-circuited. A caustic environment failure after many years of operation. Such sudden failure can
is created at the aluminum, electrolyte interface, which dis- be explained by a better understanding of the failure mecha-
solves the protective oxide film. nism. Aluminum corrosion in the presence of an alternating
The ruggedized or abuse resistant type insulation was sup- 60 leakage current is a combination of two different mecha-
posed to protect the cable from physical abuse. While it nisms. Aluminum is normally afforded a great deal of corro-
helped this problem, it did not eliminate 600 V cable failures. sion protection by a relatively thin barrier layer of aluminum
Utilities have recently reported varying numbers of 600 V oxide, and a more permeable bulk layer of oxide. However,
aluminum underground distribution cable failure rates scat- flaws or cracks exist in these layers which provides a spot for
tered between 70 and 7000 per year. Failures are evidenced by 65 the corrosion reaction to begin. The metal in contact with
an open circuit condition accompanied by severe corrosion of water undergoes an anodic (positive ions moving into solu-
the aluminum conductor. tion) and a cathodic cycle, sixty times per second.
 US 7,637,298 B2
3 4
During the anodic half cycle of leakage current, aluminum tares, this compound, becomes fluid and viscous and can be
ions leave the metallic surface through these flaws and com- applied as the conductor is being formed. The individual
bine with hydroxyl ions in the water surrounding the cable. wires used to form the conductor are fed into an extrusion die
This reaction results in pitting of the metal and the formation where the moisture blocking compound is extruded onto and
of aluminum hydroxide, the whitish powder evident in cor- 5 around each individual wire and, as the wires are stranded into
roded cables. Another important reaction also occurs. The the conductor, the interstitial space is filled with the j elly-like
hydroxyl ions are attracted to the metal surface during this material. Upon cooling, the filler becomes very stable and
half cycle, which increases the pH, causing a caustic deterio- immobile and does not flow out of the interstitial spaces of the
ration of the oxide layer, further exposing more aluminum. stranded conductor. Once the filling compound is applied
During the cathodic half cycle another reaction occurs. io within the interstitial spaces of the stranded conductor, it
Hydrogen ions are driven to the aluminum surface. Instead of tends to remain in place. The problems encountered in apply-
neutralizing the caustic hydroxyl concentration, the hydrogen ing such a filling substance revolve around precise metering
ions combine and form hydrogen gas, which leaves the cable. of the material into the interstitial spaces as the stranded
The hydrogen depletion has the effect of further concentrat- conductor is being formed. If too much material is extruded
ing the caustic hydroxyl ions, thus furthering the deterioration 15 into the conductor, the outer insulation will not fit properly. If
of the surface oxide. No pitting occurs during this half cycle too little material is applied, the interstitial spaces will not be
since the aluminum ion is attracted to the metal. A caustic filled and therefore will allow moisture to flow within the
solution develops, hydrogen evolves, aluminum pitting takes conductor.
place, and aluminum hydroxide forms during this reaction. Another drawback to this method of applying a moisture
A critical current density is necessary to sustain the corro- 20 blocking material is that an extrusion head and an extrusion
sion reaction. Below this current density corrosion will be pump for applying the material is required for every indi-
very slight, or almost imperceptible. Once the current density vidual layer of wires used to form the conductor. The prob-
is high enough, the reaction can be swift. The necessary lems described above regarding the regulation of the volume
current density is below 1 mA/in2. The current density of a of material applied through an extrusion head are multiplied
damaged 600 V cable is influenced by the voltage, leakage 25 every time an additional extrusion pump and extrusion head is
resistance, and the area of exposed metal. Variables affecting required within the conductor manufacturing system. Prior
this can include dampness of the soil, chemistry of the soil, art efforts to manufacture an acceptable moisture blocked
degree of damage, etc. conductor revolved around methods for uniform application
of the moisture blocking material to the conductor, but did not
DESCRIPTION OF THE RELATED ART 30 solve the problems created by handling and installation dam-
age.
The toughest cables on the market today will not always Applications of moisture blocking material to the spacing
stand up to the rigors of handling, installation, and operation. of concentric lay conductors is known within the industry.
And exposed aluminum will eventually deteriorate. The solu- This can be found in U.S. Pat. Nos. 3,607,487; 3,889,455;
tion, then, is to find a way to economically prevent the cor- 3s 4,105,485; 4,129,466; 4,435,613; 4,563,540; and 4,273,597.
rosion process.
U.S. Pat. No. 4,273,597 shows a method of strand filling
Attempts have been made to prevent the ingress of mois-
the interstitial spacing of a conductor with a powder. This is
ture by introducing a sealant between the strands of the con-
accomplished by passing the strands through a fluidized pow-
ductor and between the conductor and the insulation. SeeU.S.
der bed, where the interstitial spacing is filled with the pow-
Pat. Nos. 3,943,271 and 4,130,450. However, it has been 40
der. The stranded conductor then exits the opposite end of the
found that the mere introduction of a sealant into such spaces
bed where an insulating layer is applied which prevents the
is not entirely satisfactory. Attempts to prevent moisture from
powder from vacating the interstitial spacing of the conduc-
reaching the conductor, such as using water swellable mate-
tor.
rial, have not met with technical and/or economic success.
For example, voids may be formed in the sealant during the 45 U.S. Pat. No. 4,563,540 describes a conductor which is
application thereof or may be formed if the cable is acciden- constructed by flooding a waterproofing material among the
tally punctured. Any such spaces or voids form locations for individual conductors which make up the core of the stranded
the ingress of moisture which can lead to corrosion of the conductor. This flooded core is then wrapped with a plurality
conductor and conventional sealants used in the cables cannot of different layers of shielding material which prevents the
eliminate such voids. 50
influx of moisture into the stranded conductor.
A prior art attempt to minimize the flow of moisture or U.S. Pat. No. 4,435,613 describes a conductor constructed
water within the interstitial spaces of a stranded conductor of a plurality of layers of insulating material with the core (or
came in the form of compacted or compressed stranded con- conducting portion) of the conductor being filled with an
ductors. The stranded conductor itself was radially crushed in insulating layer of polyethylene. This polyethylene layer is
order to reduce the diameter of the conductor and to fill the 55 contained by other rubber and plastic and epoxy compounds
interstitial spacing with metal from the individual wires them- which produce a conductor having a waterproof construction.
selves. The drawback to this method is that even though some U.S. Pat. No. 4,129,466 deals with a method for the appli-
deformation ofthe individual wires does take place, and some cation of the filling medium which is applied to a stranded
of the interstitial spacing is filled, there is still the possibility conductor. This method comprises a chamber into which are
of cable insulation damage through which moisture can enter 60 passed individual wires that will be used to form the stranded
the cable and contact the conductor. conductor. These wires have a filling medium applied to them
Another attempt at correcting moisture flowing within in the chamber. After the application of this filling medium,
interstitial space consisted of filling the interstitial space with the conductor is passed through a chilling chamber where the
a foreign substance which physically prevented the flow of filling medium is cooled and allowed to solidify within the
the moisture or water within the conductor structure. These 65 interstitial spaces. This method requires that the chamber
substances typically comprised some type of jelly base and a containing the filling medium and the stranded conductor be
polyethylene filler material. At slightly elevated tempera- both heated and pressurized. The heat applied to the chamber
 US 7,637,298 B2
1 6
reduces the viscosity ofthe filling material, while the pressure BRIEF DESCRIPTION OF THE DRAWINGS
assures introduction of the material into the interstitial spaces
of the stranded conductor. The objects and advantages of the invention will be appar-
U.S. Pat. No. 4,105,485 deals with the apparatus utilized in ent from the following detailed description of the preferred
the '466 method patent previously discussed. 5 embodiments thereof in conjunction with the accompanying
U.S. Pat. No. 3,889,455 discloses a method and apparatus drawings in which:
for filling the interstitial spacing of the stranded conductor in FIG. 1 is a cut-away, perspective view of a cable of the
a high temperature flooding tank. The individual wires are fed invention showing a stranded conductor, the finned inner
into a tank containing the filling material, the material having layer surrounding the conductor, the insulation, and the area
been heated to allow it to become less viscous. The individual 10 between the fins containing the material which provides the
wires are stranded and closed within the confines of the flood- self-sealing effect;
ing tank and the finished conductor is withdrawn from the FIG. 2 is an end view of the embodiment ofthe cable shown
opposite end of the flooding tank where it is passed through a in FIG. 1; and
cooling means. The disadvantages experienced here involve FIG. 3 is a cut-away side view of the cable shown in FIG.
the practice of stranding the conductor beneath the surface of 15 1.
an elevated temperature moisture block pool. No access, FIG. 4 is a diagrammatic representation showing insulation
either visual or mechanical, to the conductor manufacturing damage.
process is practical. FIG. 5 depicts the soil-filled box used to determine current
leakage in a damaged cable.
U.S. Pat. No. 3,607,487 describes a method whereby indi-
FIG. 6 is a graph of sample leakage current measurements.
vidual strands of wire are fed into a flooding tank which is
FIG. 7 is a graph of conductor resistance measurements.
supplied with heated filling material by a pump and an injec-
FIG. 8 is a graph of sample temperature measurements.
tion means. The stranded conductor is withdrawn through the
FIG. 9 is a comparison of samples of the invention and a
opposite end of the flooding tank, wiped in a wiping die,
control after 91 days in the test.
wrapped in a core wrapper and then passed through a binder
FIG. 10 is a close-up of the control sample after 91 days in
where it is bound. The bound, wrapped core is then passed 25
the test.
through a cooler which sets the filling material. The above
FIG. 11 is a close-up of the test sample of the present
described process is repeated through another flooding tank,
invention after 91 days in the test.
another cooler, another binding machine, another flooding
FIG. 12 is a cut-away side view of the multilayer flow
tank, another extruder, another cooling trough, and is even-
30 extrusion head of the present invention; showing the flow of
tually withdrawn from the end of the manufacturing line as a
inner and outer layer polymers through the head.
product having a plurality of layers of moisture blocking
FIG. 13 is a cut-away side view of the multilayer flow
compound which protects the conductor core. The disadvan-
extrusion head of the present invention; showing the flow of
tages here comprise a complex manufacturing line whereby
sealant material through the head.
moisture blocking material is applied at many different loca-
FIG. 14 is a cut away perspective of a portion of the mul-
tions, each having to be meticulously monitored and con-
tilayer flow extrusion head of FIGS. 12 and 13, and
trolled in order for a proper conductor construction to be
FIG. 15 is an end view of an embodiment of the cable ofthe
obtained.
present invention.
It can be readily seen from the above referenced methods
and apparatuses that moisture blocked conductors are known 40 DETAILED DESCRIPTION OF THE INVENTION
and it can also be recognized that there are major problems
concerning the elimination of moisture contacting the con- The present invention relates to improvements in insulated
ductor as a result of handling and installation of a cable. solid and stranded cables. An electrical cable and a method
for manufacturing the electrical cable are provided in which a
BRIEF SUMMARY OF THE INVENTION 45 plurality of insulated conductors have an inner protective
layer extruded thereabout, and outwardly extending ribs, or
An extrusion head may be provided. The extrusion head an exterior ribbed or finned surface, which includes a plural-
may include an inner flow path, an outer flow path, and at least ity of longitudinally extending ribs or fins between which
one sealant flow path. The inner flow path may be configured exist a plurality of voids. An outer insulation layer may be
to direct a flow of an inner layer around a conductor. The outer 50 formed in the same operation as the inner layer or ribs or in a
flow path may be configured to direct a flow of an outer layer subsequent operation. In a two-pass manufacturing process
around the inner layer. The at least one sealant flow path may for the present cable, the first pass involves extruding the
extend to a connecting point with the inner flow path and the inner finned layer onto the conductor. The inner layer can be
outer flow path. The at least one sealant flow path may be polyethylene, pvc, or another suitable plastic material. The
configured to direct a sealant to fill at least one sealant channel 55 inner layer can be cross-linked while it is being applied or
region between the inner layer and the outer layer. The con- batch cross-linked after it is applied. The secondpass involves
nection point may be configured to cause the flow of the inner using a hot melt pumping system to apply the sealant layer.
layer and the flow of the outer layer to join before the sealant This system advantageously consists of a Nordson model 550
fills the at least one sealant channel region. drum melter which delivers sealant to a CH-440 head through
It is to be understood that both the foregoing general 60 which the cable passes. Other methods of pumping sealant,
description and the following detailed description are applying sealant, and sizing the sealant layer can be used
examples and explanatory only, and should not be considered depending on process or product requirements. The sealant
to restrict the invention's scope, as described and claimed. can be applied over a wide range of temperatures. Good
Further, features and/or variations may be provided in addi- results are obtained by applying the sealant at about 175
tion to those set forth herein. For example, embodiments of 65 degrees Fahrenheit. The outer encapsulating layer is then
the invention may be directed to various feature combinations applied after the sealant layer, downstream from the sealant
and sub-combinations described in the detailed description. head. The outer layer can be polyethylene, pvc or another
 US 7,637,298 B2
7 8
suitable plastic material. The outer layer can be cross-linked and/or cracks and prevent contact between the conductor
while it is being applied or afterwards in a batch process. and moisture which could cause cable failure; and
In a single pass manufacturing process, the conductor is fed (d) The material does not absorb moisture or swell upon
into a head that consists of 3 zones. The inner finned layer is contact with moisture.
applied in the first zone. In the second zone the sealant layer 5 In the preferred embodiment of the present invention, the
is applied. The outer encapsulating layer is applied in the third material used to at least partly fill voids 16 is a compound of
zone. This process requires close control of the sealant tem- a low molecular weight isomer or a low molecular weight
perature. The sealant must be applied cold enough to be able copolymer of an isomer. Preferably, the material is poly-
to remove enough heat to help set the finned layer. This avoids isobutene. Advantageously there is little or no air present
damage to the fins when the outer encapsulating layer is 10 between voids 16 and insulation jacket 13.
applied in the third zone. The sealant must not be applied too The material of the present invention may optionally con-
cold or it will prevent even distribution of the sealant in the tain filler material, but is essentially free of any solvents or
fins or cause fin damage. The optimal sealant application oils.
temperature is from about 80 to about 150 degrees Fahren- The cable 11 described in connection with FIG. 1 can be
heit. 15
used without further layers encircling the insulation j acket 13.
In one embodiment of the invention, during manufacture of Also, in other embodiments of the present invention
the self-sealing cable, a material which provides the cable described herein, the conductor and layers of insulation can
with puncture, crack, and void self-sealing properties is be the same as those described in connection with FIG. 1.
included between the ribs or fins and the outer insulation. The
The cable 11 illustrated in FIG. 2 is an end view of the cable
voids are at least partly filled by the material which will flow 20
illustrated in FIG. 1.
into any void, puncture, or crack formed in the insulation, thus
preventing migration of moisture. The self-sealing material is FIG. 3 is a cut-away side view of cable 11 shown in FIG. 1
applied in the voids between the ribs or fins and the outer and illustrates voids 16 and ribs or fins 15.
insulation, therefore the self-sealing material does not contact The ratio for the height of fins 15 to the width of voids 16
the conductor. 25 can vary. Advantageously, the height to width ratio ranges
Although the principles of the present invention are appli- from about 0.25 to about 2.00. Preferably the height to width
cable to different types of electric cables, the invention will be ratio ranges from about 0.5 to about 1.00. The fins do not have
described in connection with a known cable structure, such as to be equally spaced but it is generally desirable to equally
a 600 volt cable, which normally comprises, as a minimum: space the fins to achieve equal distribution of the medium that
(1) A central conductor of stranded wires of a good con- 30 is in the channel regions, voids 16, and improve cable con-
ductivity metal such as copper, aluminum, copper alloys centricity. The number of fins can range from a minimum of
or aluminum alloys; and 2 up to any practical number that is needed based on the size
of the cable, structural needs of the cable, the material being
(2) A layer of insulation around the stranded conductors
used in the voids, the delivery rate needed if applicable for the
which has been extruded thereover.
material, or the physical size of the material being delivered.
FIG. 1 shows a cable 11 comprising a conductor 12 of 35 The base thickness upon which the fins rest should not be less
stranded wires of copper or aluminum or alloys thereof. An than about 50 percent of the width of the fins. The base
inner layer 14 encircles cable 11. A plurality of longitudinally thickness can vary based on thickness requirements of indus-
extending fins or ribs 15 are formed between which extend a try specifications, structural needs of the cable, or other spe-
plurality of voids 16. A layer 10 of material which provides
40 cific cable needs.
the self-sealing effect is applied in and at least partly fills
The retaining mechanism between the outer encapsulating
voids 16 between ribs 15, inner layer 14, and an outer insu-
jacket or insulation and the fins can be a polymeric bond
lationjacket 13. Insulation jacket 13 is of known material and
between the outer extruded layer 13 and the fins 15, or may be
is preferably an extruded polymeric material.
purely frictional. The frictional mechanism is due to the com-
Preferred material 10 comprises a polymer which can be 45 pressive forces, surface area, and frictional coefficient
readily pumped at temperatures at least as low as 25° C. between the two layers. A material can be added during pro-
Preferably, the polymer will be a low molecular weight poly- cessing that increases the frictional coefficient between the
mer such as low molecular weight isomer. Other materials, or two layers. If a polymeric bond is desired, it should constitute
combinations of materials, with or without such polymers, bonding of at least 50% of the exposed surface area of fins 15,
having such characteristics may also be useful in the present
50 i.e., the upper portion of the fins that contact the interior
invention. A polymer which has been found to be particularly surface of the outer extended layer 13. Another retaining
suitable is polyisobutene. mechanism is similar to a shaft and a key, i.e., the upper
The preferred polymer of the present invention has very portion of the fin is embedded into the outer encapsulating
little or no significant ShoreA hardness. A test of determining layer which helps prevent rotation of the inner layer or other
whether or not the polymer has acceptable properties is the 55 movement. Advantageously the fin is embedded to a depth of
Penetrometer Test incorporated in ASTM D5 Penetration of at least about 0.001 inch into the interior of the outer insula-
Bituminous Materials. The 100 grams needle penetration tion layer, preferably from about 0.002 inch to about 0.005
value at 25° C. should be greater than about 100 tenths of a inch. The embodiment can be varied by controlling different
millimeter. variables of the process. It is also possible to have combina-
The material used to provide the self-sealing effect to the 60 tions of polymeric, frictional, and embedded fin-retaining
electric cable of the present invention has the following prop- mechanisms between the two layers. Fins 15 may be attached
erties: to inner layer 14, outer layer 13, or both.
(a) The material is substantially insoluble in water; Materials that can be delivered in the channels in addition
(b) The material is a dielectric, i.e., it is non-conductive and to sealing materials are fiber optics, heat transfer fluids to
is not a semi-conductor; 65 enhance cable heat transfer properties, other desirable mate-
(c) The material causes the cable to be self-sealing, i.e., it rials that would provide a beneficial cable property or use the
will flow, at ambient temperature, into insulation voids cable as a messenger to connect a beginning and/or end point.
 US 7,637,298 B2
10
The most desirable materials for use as the inner layer 14, by controlling material flow as needed as the material flow is
fins 15, and outer encapsulating layer 13 are plastics that can channeled through extrusion head 1200.
be either thermoset or thermoplastic. Known plastic materials Consistent with embodiments of the invention, the plural-
can be used in order to achieve desired cable properties. ity of layers (e.g. inner layer 14 and jacket 13) may be con-
The colors of the inner layer 14, fins 15, and outer layer 13 5 nected above and below the sealant (e.g. sealant 10) to pro-
materials can be the same or they may differ. Different colors vide a mechanical coupling back to conductor 12 to, for
may be used to allow easier identification of the product in the example, limit shrink-back of the insulation system. Connect-
field or for other desirable cable properties. The fins or ribs ing these layers (e.g. inner layer 14 and jacket 13) with axially
may be straight, may spiral, may oscillate about the axis of the extruded fins may provide improved concentricity for cable
cable, or may form different patterns depending on the 10 11 and channeling of the sealant flow, which may improve
desired cable characteristics and efficiency and flowability of sealing capabilities. As shown in FIG. 12, section A-A illus-
the sealing material used. trates flow paths for extrusion head 1200 for manufacturing,
It is to be understood that additional embodiments may for example, cable 11. This section shows inner channels (i.e.
include additional layers of protective material between the flow paths) 1205 configured to provide a first material to
conductor and the insulation jacket, including an additional 15 form, for example, inner layer 14. In addition, this section
water barrier of a polymer sheet or film, in which case it is not shows outer channels (i.e. flow paths) 1210 configured to
essential that the jacket tightly enclose the layers there within provide a second material to form, for example, jacket 13. As
or enter into the spaces between the wires and protective shown in FIG. 12, extrusion head 1200 may include a con-
materials, i.e., the interior size of the jacket can be essentially nection point 1215 where the first material and the second
equal to the exterior size of the elongated elements so that 20 material come together before being applied to conductor 12.
compression of the elongated elements, and hence, indenta- Inner channels 1205 and outer channels 1210 may deliver the
tion of the layers there within including the insulation, is same or different type materials.
prevented. FIG. 13 is a cut-away side view of extrusion head 1200
The cable of the present invention is of particular advan- illustrating a flow of sealant material (e.g. to form sealant 10)
tage in that not only does the material fill the space between 25 through sealant channels 1305 in extrusion head 1200. As
the inner layer and the insulation as the cable is manufactured, shown in FIG. 13, section B-B shows where the sealant flow
but after the cable is placed in service the material will flow is present between the inner layer (e.g. inner layer 14) and the
into any cuts or punctures formed as a result of damage during outer layer (e.g. jacket 13). Only the sealant flow path is
handling and installation of the cable or its use in service. The shaded in this cross sectional view. FIG. 13 shows an embodi-
stresses placed on the conductor and the insulation during 30 ment of extrusion head 1200 with six regions filled with
handling and installation of the cable, such as bending, sealant and six connection points absent of sealant. Extrusion
stretching, reeling and unreeling, striking with digging and head 1200 may be configured to produce one or more fins
installation equipment can form cuts or punctures in the insu- (e.g. ribs 15) with one or more sealant filled regions (e.g.
lation and between the insulation and the conductor. Such voids 16 from FIG. 2 or channel regions 16 from FIG. 15) for
cuts or punctures can also be formed after the cable has been 35 cable 11. Consistent with embodiments of the invention,
placed in service as a result of damage from adjacent utilities, extrusion head 1200 may have regions in its flow paths that
homer owners, or lightening strikes. prevent sealant flow (e.g. corresponding to sealant 10) to
The cable of the present invention can provide acceptable allow joining of the outer layer (e.g. jacket 13) and inner layer
service even after the insulation has been cut or punctured, (e.g. inner layer 14.) Moreover, extrusion head 1200 may
exposing the conductor. In order to determine the efficiency 40 have regions in the flow path that allow sealant flow between
of using a self-sealing material defects were made in the the inner layer (e.g. inner layer 14) and the outer layer (e.g.
insulation layer of two 600 V cable samples. On one of the jacket 13). FIG. 14 is a cut away perspective of a portion of
cable samples, a layer of polyisobutene polymer was applied multilayer flow extrusion head 1200.
before application of the outer insulation layer of the cable.
FIG. 15 is an end view of cable 11 consistent with embodi-
The other cable sample did not have the polyisobutene layer. 45
ments of the invention. The cable of FIG. 15 is similar to the
Both cable samples were placed inside separate 1 liter glass
cable of FIG. 2, but FIG. 15 shows channel regions 16 (e.g.
beakers containing tap water. Each cable sample was ener-
voids 16 from FIG. 2) between inner layer 14 and jacket 13
gized at 11 OV to ground with AC current. The sample which
may have curved or radius corners instead of the angled
did not have the polyisobutene layer exhibited severe corro-
corners that are shown in FIG. 2. In FIG. 2, the angles of the
sion overnight. The sample containing the polyisobutene 50
corners of each channel region 16 may be the same or may be
layer exhibited no corrosion after being energized and sub-
different. Likewise curved corners 17 of each channel region
merged for 4 weeks in tap water in the glass beaker.
16 shown in FIG. 15 may have the same or different radius.
FIG. 12 is a cut-away side view of a multilayer flow extru-
sion head 1200 showing the flow of, for example, polymeric
material through extrusion head 1200. Extrusion head 1200 55
EXAMPLE 1
may be used to make cable 11 as described above. For
example, extrusion head 1200 may allow a combined multi- This test was designed to evaluate the performance of the
layer insulation system to be applied to conductor 12 or cable present invention's self sealing, 600 V underground cable.
11 without, for example, applying each layer of cable 11 The test program was patterned after a previously developed
individually. Consistent with embodiments of the invention, 60 procedure to evaluate self-sealing or self-repairing cable
cable 11 may comprise a plurality of layers (e.g. inner layer designs.
14 and jacket 13) that make up an insulating system with a To conduct the test damaged cables were placed in a spe-
sealant material (e.g. sealant 10) between the plurality of cially mixed, moist soil. The cables were then energized with
layers. Layers below (e.g. inner layer 14) and above (e.g. 120 V ac to ground. Measurements made included changes in
jacket 13) the sealant (e.g. sealant 10) maybe attached to each 65 leakage current to earth and cable conductor resistance. The
other, for example, by one or more axial extruded fins (e.g. temperature of each cable near the damage point was also
ribs 15.) The one or more axial extruded fins may be produced monitored.
 US 7,637,298 B2
11 12
Four control sample replicates and eight self-sealing ends were cut off of the self-sealing samples so they were the
sample replicates were evaluated. All four control samples same length as the control samples. The test layout is shown
failed the test relatively early in the test program. All eight in FIG. 5.
self-sealing samples performed well, with no significant After the installation was complete, the soil was covered
increase in conductor resistance and low leakage current val- 5 with polyethylene to minimize the evaporation of water from
ues throughout the 60-day test period. the soil. 120 V ac was applied continuously to all sample
Conventional and self-sealing 600 volt underground cable conductors. The soil was grounded via the copper ground mat
with a 2/0 AWG combination unilay aluminum conductor lining the tank. The data collection was as follows:
were tested in 10-foot lengths.
The soil used in the test was a mixture of Ottawa Sand, 10 1) Measurements (Measured initially, then daily for first 5
Wyo. Bentonite and fertilizer. The combination of the three workdays, then on Monday, Wednesday and Friday of each
materials provides a sandy-silt type soil, which is very con- week thereafter.)
ductive. The sand serves as the basic soil structure while the a) Conductor resistance, each sample individually
silt provides small particles that can work their way into the Biddle DLRO, CQ #1010 (Expected accuracy: ±3% of
damaged areas of the cable. The silt also helps to keep water 15 reading)
evenly dispersed throughout the soil. The fertilizer enhances b) Leakage to ground @ 120V, each sample individually—
the conductivity of the soil and may enhance corrosion as Fluke 87, CN 4007 (Expected accuracy: ±3% of read-
well. The goal was to achieve a soil electrical resistivity of ing)
<50 ohmmeters. c) Sample surface temperature Yokaggawa DC100, CN
Tap water was used to achieve a moisture content near 20 4015 (Expected accuracy: ±2 Deg. C.)
saturation. This combination of soil materials provides a
2) The test ran for 91 days. When significant degradation
worst case condition for the ac corrosion of the aluminum
occurred on a sample, it was disconnected from the voltage
conductor in 600V underground cables and is also repeatable
source. Significant degradation is defined as:
from lab to lab. The soil mixture was:
25 a) Several days with leakage current greater than 1 amp on
100 lbs. Ottawa Sand an individual sample
3.33 lbs. Bentonite b) Conductor resistance on an individual sample 10 times
greater than starting resistance
23.33 lbs. Tap Water
3) Final soil electrical resistivity and moisture content was
1.26 lbs. of Peters 20-20-20 Plant Fertilizer (mixed with the 30 measured when the test was completed.
water before added to the sand and clay ingredients)
4) All measurements were recorded and resistance, leakage
The amount of water added achieved near saturation condi- and temperature data were plotted using an Excel spread-
tions. The wet density was approximately 127 lbs./ft. sheet.
The aging box was made of wood and lined with polyeth- 35 During the first 26 days of the test the conductor resistance
ylene to hold moisture. The approximate inside dimensions and the leakage current into the soil increased significantly on
were 6.5 feet long by 1.3 feet wide by 1 foot high. A wide, all four control samples. They were each removed from the
copper tape ground electrode covered the bottom and sides of test (disconnected from the test voltage) as the conductor
the box on top of the polyethylene. A wire connected this resistance exceeded 1,000 micro-ohms. The conductor resis-
electrode to ground. 40 tance and the leakage current to the soil for the eight self-
After moist soil was packed in the bottom of the box sealing samples did not change significantly during the test.
(approximately 6 inches), four control samples and eight The soil electrical resistivity was measured at the end of the
self-sealing samples were installed, approximately six inches test by placing a sample of the soil in a 17-inch long, 2-inch
apart. The two sample sets were: inside diameter PVC tube. It was packed to the same density
Samples 1-4: conventional 600 V UD wire (control samples) 45 used in the test tank. Two-inch diameter copper plate elec-
all with slot damage at the center of the sample trodes were pressed against the soil on each end of the tube.
Samples 5-12: self-sealing cable all with slot damage near 120 volts ac was applied across the electrodes and the result-
the center of the sample ing current was measured. The current and voltage were used
Immediately before the samples were placed in the box, to calculate the sample resistance, which was then converted
they were damaged down to the conductor. One damage 50 to resistivity.
condition was used. It consisted of a slot cut into the insula- Moisture content and density were measured at the begin-
tion down to the conductor, perpendicular to the cable axis. A ning and end of the test. To make the measurement, a soil
razor knife and an angle guide was used to control the slot sample was taken using a 1/3o cubic foot metal shelby tube.
size. The size and shape of the damage location is shown in The sample was then oven dried to calculate moisture and
FIG. 4. The damage locations were staggered so they were not 55 density. The measured weights were used to calculate mois-
adjacent to each other. ture content.
The 10-foot long self-sealing samples were first damaged
Soil resistivity, moisture and density measurements are
in the middle. After 5 minutes, they were placed in the box
summarized in Table 1.
with the damage facing up. They were then covered with soil.
The control samples were initially 2.5-foot long. They 60
TABLE 1
were also damaged in the middle, then installed in the box.
There was no waiting period before they were covered with Time of Electrical Resistivity Moisture Content Wet Density
soil. Measurement (ohm-meters) (% by weight) (lbs . ft3)
As each sample was installed, a type T thermocouple with Initial 4.3 near saturation 126
a welded bead was attached to the cable surface, approxi- 65 Initial 5.1 15.8 126
mately one inch from the damage location. Once all samples
were installed, the soil was compacted. After 24 hours, the
 US 7,637,298 B2
13 14
The insulation resistance, conductor resistance and sample
temperature measurements made during the test are shown in
FIGS. 6-8. The samples are identified as 51, S2, S3, etc. The
Sample 2 - Duct Seal (Prior Art)
first four are control, the remaining eight are self-sealing. In
addition, C=Contro1, SS=Self-Sealing. 5 Shrinkback at Total
Weeks ofAging Shrinkback at Top Bottom Shrinkback (in)
During periods of relatively high leakage current on the
control samples the temperature of these samples was also Initial .2205 .2555 0.4760
1 3.1345 2.7980 5.9325
relatively high. Photos of the samples under test are shown in 2 3.7155 2.7255 6.4410
FIGS. 9, 10 and 11. From the photos it is obvious that the to 3 4.7570 2.0195 6.7765
4 5.1600 1.5315 6.6915
control samples experienced significant corrosion while the
5 5.4965 1.2150 6.7115
self-sealing samples experienced no noticeable corrosion. 6 5.7300 1.1115 6.8415
7 5.6915 1.2420 6.9335
8 6.0065 1.0395 7.0460
EXAMPLE 2 9 6.1285 .8860 7.0145
15

A cyclic load test was run on the finned cable of the present
invention and compared with similar non-finned prior art
cables. 50 ft. samples were tested. The samples had a 50° C.
conductor temperature, and were cycled on 8 hours a day and 20 Sample 3 - Mastic Tape (Prior Art)
off 16 hours, 7 days a week. The cables were terminated with Shrinkback at Total
a mechanical connector. No duct seal, mastic tape, electrical Weeks ofAging Shrinkback at Top Bottom Shrinkback (in)
tape, or the like was used. The tops of the samples were Initial .2270 .2195 0.4465
approx. 11 ft. above the floor. The samples gradually droop to 1 3.6490 1.6500 5.2990
25
the floor. 2 3.5330 2.0550 5.5880
3 4.0990 1.6900 5.7890
4 4.3685 1.5315 5.9000
5 4.4675 1.4650 5.9325
6 4.6870 1.3660 6.0530
7 4.6605 1.3435 6.0040
Sample 1 (Invention) 30 8 4.7635 1.2190 5.9825
9 4.9370 1.0500 5.9870

Shrinkback at Total
Weeks ofAging Shrinkback at Top Bottom Shrinkback (in) Over 80% of the total shrinkback of the prior art cable
35 occurred in the first week of testing.
Initial .0000 .0000 .0000
Comparative results with the present invention show a
dramatic reduction in shrinkable after 1 week of testing. The
1 .3035 .1510 .4545
reduction is more than 92% when compared with the prior art.
Although preferred embodiments of the present invention
40 have been described and illustrated, it will be apparent to
those skilled in the art that various modifications may be
made without departing from the principles of the invention.
Sample 2 (Invention)
What is claimed is:
Shrinkback at Total 45 1. An extrusion head comprising:
Weeks ofAging Shrinkback at Top Bottom Shrinkback (in)
an inner flow path configured to direct a flow of an inner
Initial .0000 .0000 .0000
layer around a conductor;
1 .1385 .1880 .3265 an outer flow path configured to direct a flow of an outer
layer around the inner layer; and
50
at least one sealant flow path disposed between the inner
flow path and the outer flow path and extending to a
connection point with the inner flow path and the outer
Sample 1 - Bare (Prior Art)
flow path, the at least one sealant flow path configured to
55 direct a sealant to fill at least one sealant channel region
Shrinkback at Total between the inner layer and the outer layer, wherein the
Weeks ofAging Shrinkback at Top Bottom Shrinkback (in) connection point is configured to cause the flow of the
Initial .8450 .2220 1.0670 inner layer and the flow of the outer layer to join before
1 4.6375 1.2010 5.8385 the sealant fills the at least one sealant channel region.
2 5.5390 .8220 6.3610 2. The extrusion head of claim 1, wherein the inner layer
60
3 5.9350 .6735 6.6085
4 6.1110 .6150 6.7260
comprises a first material and the outer layer comprises a
5 5.9065 .5850 6.4915 second material, wherein the first material and the second
6 6.3725 .6020 6.9745 material are chemically different.
7 6.2960 .7320 7.0280
8 6.4500 .5340 6.9840
3. The extrusion head of claim 1, wherein the inner layer
9 6.6855 .4350 7.1205 65 comprises a first material and the outer layer comprises a
second material, wherein the first material and the second
material are chemically the same.
 US 7,637,298 B2
15 16
4. The extrusion head of claim 1, wherein the extrusion 17. The extrusion head of claim 16, wherein the at least one
head is configured to produce an equal number of inner layers fin comprises one of the following configurations: straight,
and outer layers surrounding the conductor. spiral, and oscillating about an axis of the conductor.
5. The extrusion head of claim 1, comprising at least two 18. The extrusion head of claim 11, wherein the extrusion
sealant flow paths equally spaced about the extrusion head. 5 head is configured to create a first coupling between the first
6. The extrusion head of claim 1, comprising at least two material and the second material and to create a second cou-
sealant flow paths disproportionately spaced about the extru- pling between the first material and the conductor, the first
sion head. coupling and the second coupling configured to cause, per
7. The extrusion head of claim 1, wherein the extrusion about 50 feet of the self sealing cable, less than about 0.2 inch
head is configured to block flow of the sealant to allow the 10 shrinkback of the first material and the second material.
inner layer and the outer layer to join. 19. The extrusion head of claim 18, wherein the first cou-
8. The extrusion head of claim 1, wherein the extrusion pling and the second coupling independently are a frictional
head is configured to form at least one fin where the inner bond, a mechanical bond, a polymeric bond, or a combination
layer and the outer layer join. thereof.
9. The extrusion head of claim 8, wherein the at least one fin 15 20. The extrusion head of claim 11, wherein the extrusion
comprises one of the following configurations: straight, spi- head is configured to create a first coupling between the first
ral, and oscillating about an axis of the conductor. material and the second material and to create a second cou-
10. The extrusion head of claim 1, wherein the connection pling between the first material and the conductor, the first
point is configured to cause the flow of the inner layer and the coupling and the second coupling configured to cause, per
flow of the outer layer to join before the flow of the inner layer 20 about 50 feet of the self-sealing cable, initially less than about
contacts the conductor. 0.2 inch shrinkback of the first material and the second mate-
11. An extrusion head for producing a self-sealing cable rial subsequent to accomplishing a complete circular cut of
including a conductor, the extrusion head comprising a hous- the self sealing cable and after aging the self sealing cable for
ing having an elongate bore therethrough to receive the con- at least one week.
ductor, the housing defining: 25 21. The extrusion head of claim 20, wherein the first cou-
an inner flow path configured to direct a flow of a first pling and the second coupling independently are a frictional
material onto the conductor in the bore; bond, a mechanical bond, a polymeric bond, or a combination
an outer flow path configured to direct a flow of a second thereof.
material onto the first material; and
22. An extrusion head comprising:
at least one sealant flow path disposed between the inner 30
flow path and the outer flow path configured to direct a an inner flow path configured to direct a flow of an inner
sealant to fill at least one sealant channel region between layer around a conductor;
the first material and the second material, the extrusion an outer flow path configured to direct a flow of an outer
head being configured to cause the first material and the layer around the inner layer; and
second material to join and to create at least one fin 35 at least one sealant flow path disposed between the inner
before the sealant fills the at least one sealant channel flow path and the outer flow path and extending to a
region between the first material and the second mate- connection point with the inner flow path and the outer
rial. flow path, the at least one sealant flow path configured to
12. The extrusion head of claim 11, wherein the first mate- direct a sealant to fill at least one sealant channel region
rial and the second material are chemically different. 40 between the inner layer and the outer layer, wherein the
13. The extrusion head of claim 11, wherein the first mate- connection point is configured to cause the flow of the
rial and the second material are chemically the same. inner layer and the flow of the outer layer to join before
14. The extrusion head of claim 11, comprising at least two the sealant fills the at least one sealant channel region,
sealant flow paths equally spaced about the extrusion head. wherein the extrusion head is configured to block flow of
15. The extrusion head of claim 11, comprising at least two 45 the sealant to allow the inner layer and the outer layer to
sealant flow paths disproportionately spaced about the extru- join, and wherein the extrusion head is configured to
sion head. form at least one fin where the inner layer and the outer
16. The extrusion head of claim 11, wherein the extrusion layer join.
head is configured to block flow of the sealant to allow the first
material and the second material to join.