Methods of and apparatus for applying a waterproofing material to a cable core wrap

A method of making a bonded sheath cable, said method comprising the steps of:

• advancing a core comprising at least one conductor;
• coating an outer and an inner surface of a strip of plastic material with a first waterproofing material;
• controlling the quantity and the distribution of the first waterproofing material which is disposed on each major surface of the strip;
• wrapping the strip of plastic material about the core to form a longitudinal overlapped seam;
• wrapping a first corrugated metallic tape about the strip of plastic material to form an inner shield, the quantity and distribution of waterproofing material on the strip being sufficient to seal the seam of the plastic strip and to prevent substantially the formation of any voids between the plastic strip and the inner shield;
• applying a second waterproofing material to the outer surface of the inner shield;
• wrapping a second corrugated metallic tape having a surface thereof coated with an adhesive material about the first metallic tape to form an outer shield having a longitudinal overlapped seam and having the adhesive material facing outwardly;
• introducing sufficient sealant material into the vicinity of the longitudinal edge portions of the second metallic tape as they are being overlapped to cause the sealant material to seal the overlapped seam of the outer shield and to fill any cavities between the outer shield and the inner shield in the vicinity of the overlapped seam of the outer shield;
• and
• extruding a plastic material about the outer shield to form a jacket and to cause the adhesive material on the outer surface of the shield to bond the jacket thereto.

An apparatus for enclosing a cable core with a strip of plastic material having a waterproofing material applied to at least one major surface thereof, said apparatus including:

• means for advancing a cable core along a path of travel;
• means for advancing a strip of plastic material along a path juxtaposed to the path of travel of the core;
• means for causing a waterproofing material to be applied to at least one major surface of the strip of plastic material;
• metering means for controlling the quantity and the distribution of the waterproofng material that remains on the one major surface of the strip as the strip is advanced past the metering means, said metering means including means disposed transversely across the one major surface of the advancing strip and adjustable means for holding at least a portion of the advancing strip out of engagement with said metering means;
• and
• forming means for wrapping the strip about the advancing core to form a longitudinal seam with the quantity and distribution of the waterproofing material remaining on the one major surface being sufficient to become disposed in the seam.

An apparatus for making a bonded sheath, filled cable, said apparatus comprising:

• means for advancing a cable core filled with a first waterproofing material;
• means for advancing a strip of plastic material;
• means for causing the plastic strip to have a controlled amount and distribution of the first waterproofing material along each major surface thereof;
• means for enclosing the core in the strip of plastic material, the waterproofing material on the strip being sufficient to seal the overlapped seam;
• means for forming a first corrugated metallic tape into an inner shield about the plastic strip, the waterproofing material on the one major surface of the plastic strip being sufficient to fill the corrugations on the inwardly facing surface of the inner shield;
• means for introducing a second waterproofing material in the vicinity of said means for forming the metallic shield for filling the outer corrugations of the inner shield;
• forming means for causing a second metallic tape having a surface thereof coated with an adhesive material to be wrapped about the inner shield to form an outer shield having a longitudinal overlapped seam and having the adhesive material facing outwardly;
• means for introducing a sealant material into the vicinity of the longitudinal edge portions of the second tape as they are being overlapped to cause the sealant material to seal said overlapped seam of the outer shield and to cause the sealant material to flow circumferentially of said core to fill any cavities between said outer shield;
• and
• means for extruding a jacket of plastic material about said outer shield and for causing said jacket to be bonded by said adhesive material to said outer shield.