Water blocking cable tape and methods for making same

European).

Z-4733/07

EP 1 634 304 B1

Cable protection tape and methods for its production Field of the invention

The invention generally relates to non-woven waterproof tapes used for power cables, data transmission and telecommunications cables.

State of the art

Underground cabling systems including power (energy) or data transmission cables and telecommunications cables are invariably susceptible to damage and degradation due to water ingress and migration into the cable cores. Water is especially dangerous for fiber optic cable, causing long-term reduction of transmission reliability and complete interruption of transmission.

Fiber optic cables are susceptible to water damage caused, for example, by mechanical damage to the outer cable sheath or protection system, which allows water to penetrate into the central core or buffering layers containing optical fibers. Exposure of optical fibers to water causes micro-bends, in which water, nearby or surrounding optical fibers, freezes and tightens the structure of optical fibers, causing them to bend. Micro-bending destroys the optical fiber and increases signal transmission loss. Changes in ambient conditions also expose the optical fiber to moisture. Such changes cause a difference in pressure inside and outside the cable sheath, which causes moisture to diffuse through the sheath to the central core or group of buffer layers, exposing optical fibers to unwanted moisture.

Many cables have one or more types of water protection to prevent water from entering and migrating. In the prior art, water-blocking safeguards are introduced into the cables in various forms including waterproof sheaths, water-resistant sheaths inserted between the central core and the core or sheath, water-resistant yarns, water-resistant tapes and the connections mentioned above. Such water protection provides underground cables with sealing properties against water, preventing the ingress of water through cable protection systems towards a central core area, for example, containing optical fibers and preventing further damage caused by water migration along the cable axis. The prior art water protection tapes are often arranged between the central core and the protective system or outer cable sheath. For example, US Patent 6,173,100 discloses a watertight tape sandwiched between the core and the outer shell. The tape contains two or more layers of material with fibers. The fibers form a matrix for binding and retaining the polymer with special absorption properties placed on the surfaces. US Patent 5,642,452 discloses an optical fiber cable comprising a water protection system comprising a protective layer with water swellable properties, inserted between the core and the sheath. The cable also contained one or more water-resistant yarns with swelling properties that increased in volume longitudinally along the cable. The locking yarns and protective layers are coated with a compound with special absorption properties, such as poly (acrylic acid), to increase the swelling properties of the yarn and the protective layers before being introduced into the cable.

Other water protection known in the art include strength components coated with water absorbing compounds. US Patent 5,163,115 discloses a water protection element coated with a salt-tolerant, temperature-resistant polymer with special absorption properties. European publication no. EP 0 314 99 B1 discloses an element inserted between the inside of a central core containing optical fibers and a plastic cable sheath sealed with a thin layer or paste of an intumescent material or with special absorption properties, such as poly (acrylic acid) or polyacrylamide . European publication No. EP 0 827 625 B1 discloses a water-resistant composite sealed or covered with a mixture of radiation-polymerized compound 20 and a water-swellable compound.

Layered water-resistant tapes are, however, susceptible to "leakage" or loss of water-blocking compounds contained between layers of material in the cable manufacturing process. For specific applications, water-resistant tapes and materials must be sufficiently thin and flexible to use, for example, on certain cable models, such as fiber optic cable 25. These tape arrangements can limit the amount of water-absorbing compounds that can be placed between layers of material. Multilayer waterproofing tapes are often sealed or glued with binders and binders and, in some cases, water blocking compounds must be used. In contact with water, such binders and binders can reduce the swelling process of water-blocking compounds and can limit the extent to which water-resistant tapes can swell and increase their thickness, limiting the protective properties of the tapes against water.

Thus, a water-resistant tape that can overcome at least some of the limitations of multi-layer tapes is desired. In addition, a water-resistant tape is desirable to contain one or more water absorbing compounds sufficient to provide the required bulge height. A water-protective tape is also desirable to provide a significant distribution of one or more water-absorbing compounds between the layers to ensure a constant bulge height. The production of a water-resistant tape without the use of binders and / or binders is also desirable to increase the tape swelling process and bulge height. A water-resistant tape that is lightweight and highly flexible is desirable for use in certain cable models, such as optical fiber cables.

Summary of the Invention

In a general aspect, the invention provides an improved water resistant tape for use with a cable. In a further aspect, the invention provides a multi-layer water-resistant tape having two or several layers of material bonded according to a template. The template helps to counteract migration or stops the movement of one or more water-absorbing compounds spaced between layers. In a further aspect, the invention provides an improved system and method for making a water-resistant tape using ultrasonic gluing and cutting techniques that eliminate the use of binders and binders.

In one aspect, the invention provides a water resistant tape comprising a first layer of material; one or more water blocking compounds disposed on the surface of the first layer of material; and a second layer of material arranged on one or more water blocking compounds such that the water blocking compounds are arranged between the first and second layers of material in which the first layer and the second layer are ultrasonically glued to each other along a template placed transversely to the surface of at least a portion of the first the layer and the second layer so as to include and contain the movement of one or more water blocking compounds between the first and second layers.

The practice of the invention may include one or more of the following aspects. One or more water-blocking compounds are arranged with the help of the template so that one or more water-blocking compounds, in a substantially solid manner, are distributed between the first and second layers. When in contact with water, the tape swells evenly to a constant swelling height.

The practice of the invention may include one or more of the following aspects. The template contains a repeating and essentially uniform template. The repetitive and substantially uniform template contains a template of similar rhombic forms, each of which has a size of about 1.6 cm by 1.6 cm. The first layer of material comprises a nonwoven material. The second layer of material comprises a nonwoven material. The first material layer has dimensions substantially similar to those of the second material layer. The nonwoven material is selected from the group consisting of: spun15 bonded nonwoven fabric, spun-bonded / melt-blown / spun-bonded nonwoven fabric, spun-bonded / melt-blown / melt-blown nonwoven fabric / spun-bonded ", melt-blown non-woven fabric, non-woven nylon, non-woven carded fabric, plastic, polyester, polyethylene terephthalate and combinations of the above.

The nonwoven material weighs from about 10 grams per square meter (g / m2²) to approx

40 g / m².

One or more water blocking compounds contain one or more water swellable compounds. One or more water blocking compounds are selected from the group consisting of: polyacrylate, polyacrylamide, polyvinyl alcohol, polyacrylate copolymer, polyacrylamide, polyvinyl alcohol, polyacrylate and polyacrylamide copolymer, polyacrylamide copolymer and poly (vinyl alcohol) copolymer and poly (vinyl alcohol) and combinations of the above. One or more water blocking compounds are distributed in the material in an amount in the range of 10 g / m2² up to 50 g / m2².

The tape further comprises at least one layer of coating material disposed directly on the surface of one of the first and second layers and sonically adhered along the template.

In a further aspect, the invention provides a method of making a water resistant tape comprising providing a first sheet of material; dispensing one or more water blocking compounds on the surface of the first sheet of material, placing a second sheet of material on the surface of the first sheet such that one or more water blocking compounds are distributed between the first sheet and the second sheet to form a fabric; affecting at least a portion of the first sheet of fabric with ultrasonic waves; printing the template on at least part of the second sheet of fabric, the first sheet of material and the second sheet of material being glued along the template.

The implementation of the method of the invention may include one or several of the following aspects. The treatment with ultrasonic waves on at least a portion of the first surface of the fabric includes treatment with ultrasonic waves on at least a portion of the first surface of the fabric at substantially the same time as printing the template on at least a portion of the second opposing surface of the fabric. The part of the first surface of the fabric where the ultrasonic waves hit is opposite to the part of the second surface of the fabric on which the template is printed. The template is located transversely, at least on part of the width of the fabric. The template includes a repetitive and substantially homogeneous template. Parts of one or more water blocking compounds are arranged by means of a template so that one or more water blocking compounds are placed substantially solid between the first sheet of material and the second sheet of material.

Treatment by ultrasonic waves on the first surface of the ultrasonically glued fabric and contacting the second surface of the fabric with one or more cutting devices, such that the cutting devices cut the fabric across one or more strips. The action of ultrasonic waves on the first surface of the ultrasonically glued fabric includes the action of these waves on the first surface of the ultrasonically glued fabric at exactly the same time at which one or more cutting devices are in contact with the second surface of the fabric. Part of the first surface of the fabric subjected to ultrasonic waves is opposite the area of ​​the second surface of the fabric in contact with one or more cutting devices.

In a further aspect, the invention provides a system for making a water-resistant tape comprising a first transfer mechanism providing a first layer of material, a first transfer mechanism arranged and configured to transfer the first layer of material along the axis; a dispensing device arranged along the axis and configured to dispense one or more water blocking compounds on the first surface of the first layer of material when the first layer of material is moved next to the dispensing device; a second transfer mechanism arranged along the axis behind the dispensing device in the direction of the process, providing a second layer of material, which second transfer mechanism is arranged and configured to transfer the second layer of material along the axis such that the second layer of material is placed on one or more water blocking compounds, wherein the first layer and the second layer of material form a fabric with one or more water blocking compounds sandwiched between them; and an ultrasonic laminating device positioned along the axis of the line behind the second transfer mechanism in the direction of the process, which ultrasonic laminating device arranged and configured to emit ultrasonic waves that hit the first surface of the fabric and to print a pattern on the second surface of the fabric when the fabric is carried next to the ultrasonic laminating device, to glue the first layer of material to the second layer of material along the pattern.

Embodiments of the system of the invention may include one or more of the following aspects. The ultrasonic laminating device comprises a first ultrasonic horn loudspeaker configured to emit ultrasonic waves and a printing device configured to print the template. The first ultrasonic horn loudspeaker and the printing device are arranged on opposite sides of the axis and are positioned relative to each other such that the fabric is transferred between the first ultrasonic horn loudspeaker and the printing device. The first ultrasonic horn loudspeaker is configured to direct the impact of the ultrasonic waves on the first surface of the fabric at exactly the same time as the printing device prints the template on the second surface of the fabric. The printing device is a roller having a template placed on its surface.

Embodiments of the system of the invention may include one or more of the following aspects. The system further includes an ultrasonic cutting device positioned along the axis behind the ultrasonic laminating device in the direction of the process, the ultrasonic cutting device being arranged and configured to emit ultrasonic waves that hit the first layer of fabric material and cut the fabric across from the second surface fabrics and cuts fabric into many belts. The ultrasonic cutting device includes a second ultrasonic horn loudspeaker configured to emit ultrasonic waves and one or more cutting devices configured to cut the fabric. The second ultrasonic horn loudspeaker and one or more cutting devices are arranged on opposite sides of the axis and are aligned with each other such that the fabric is transferred between the second ultrasonic horn loudspeaker and one or more cutting devices. The second ultrasonic horn loudspeaker is configured to strike the first surface of the fabric at exactly the same time at which one or more cutting devices cut the second surface of the fabric and cut the fabric across multiple strips.

Embodiments of the system of the invention may further include a lifting device positioned along the axis behind the ultrasonic cutting device in the direction of the process, which is configured to wind a plurality of strips of fabric on itself.

In many aspects, the invention can provide one or more of the following benefits. The water resistant tape for use with various types of cable models may contain one or more water blocking compounds that provide cables with water absorption properties and prevent water damage and cable degradation. The waterproofing tape may be equipped with a system for use with one or more cable elements, e.g. a cable core, one or more protective coatings surrounding the cable core, a protective system, a reinforcement system having one or more reinforcing elements or rods or other protective elements used. in the cable. The one or more water blocking compounds may include one or more water absorbing compounds, such as polymers with special absorption properties.

By using ultrasonic welding techniques, a multi-layer water-resistant tape can be made without the use of binders and binders, which, for example, can reduce or mask the swelling process of the water-blocking compound placed between the layers of the tape when the compound is in contact with water. Lack of binders and binders can help increase the swelling volume of one or more water blocking compounds and can thus help increase the bulge height of the water-resistant tape. Without the use of binders and binders in the production of a water-resistant tape, the desired swelling rate of water-absorbing compounds can be achieved to provide a rapid response to water ingress into the cable.

Ultrasonic bonding techniques can be used to glue or join two or more layers of material, such as a nonwoven fabric, along a desired template so that water blocking compounds placed between the layers are contained and distributed within the template. The bonding template may be arranged and shaped so that it may contain water blocking compounds and thereby inhibit their movement and prevent migration and agglomeration of water blocking compounds between the layers of material. Such a bonding template can help achieve a substantially constant distribution of water-blocking compounds between the layers of the tape. A substantially constant distribution of water blocking compounds across the belt can lead to a substantially constant bulge height of the belt in contact with water. A substantially constant bulge height of the water-resistant tape can help create a reliable barrier in the cable that helps prevent water from entering the cable core and water migration along the cable span.

The ultrasonic bonding of the multi-layer water-resistant tape according to the template can also help counteract or at least reduce the "leakage" of water-blocking compounds sandwiched between layers during cable production. Reducing the amount of compounds escaping from the material helps to ensure that there is sufficient water blocking compound contained between the layers of the tape to ensure its proper water absorption and water blocking capacity.

Nonwoven fabrics can be used to build a multi-layer water-resistant tape that has sufficient strength to withstand cable manufacturing processes, yet light enough not to increase the weight of the cable. Nonwoven fabrics can provide a flexible, multi-layer water-resistant tape, particularly suitable for use, for example with optical fiber.

Nonwoven fabrics can contain relatively inexpensive materials for making multi-layer tape economically. Other layers of different materials having specific properties, such as heat protection properties, can be incorporated into a multi-layer water-resistant tape by ultrasonic bonding of such layers.

Ultrasonic bonding and ultrasonic cutting techniques can be used in a system and method for producing multiple tapes from a multilayer nonwoven fabric having one or more water blocking compounds sandwiched between layers. The system for conducting the process in a continuous mode and the method of application of ultrasonic welding and ultrasonic cutting techniques in one production run can produce one or several multi-layer water-resistant tapes from fabric having the desired dimensions for use in more than one application or in a cable model.

These and other advantages of the invention, as well as the invention itself, will be fully understood after reviewing the following figures, detailed description and claims.

Short description of the drawings

In order to better understand the present invention, it is presented with reference to the drawings, which are hereby incorporated by reference, and in which:

Figures 1a-1b cross-sectional images of one aspect of the water-blocking tape with respect to the essence of the invention.

Figs. 2a-2b a top view of the tape shown in Fig. 1a.

Fig. 2c a cross-sectional image of the tape shown in Figs. 2a-2b.

Fig. 3 a top view of the next aspect of the tape shown in Fig. 1a.

Figs. 4a-4b a flow chart of the method for obtaining the strip shown in Figs. 2a-2c and Fig. 3.

Fig. 5 a schematic diagram of the production line in cross section of the system and method for obtaining the strip shown in Figs. 1a-1b, Figs. 2a-2c and Fig. 3.

Detailed description of the invention

The invention provides the use of a water-resistant tape against a cable, such as a data cable, telecommunication cables or a power cable. The water-resistant tape of the invention generally includes a first layer of non-woven material laid on a second layer of non-woven material with one or more water-swellable compounds interposed between the first and second layers. The layers are glued together according to a template using ultrasonic welding techniques. The impact of ultrasonic waves is directed at the layers and the template is generally simultaneously printed on these layers to glue and connect the layer along the lines and demarcations of the template. Template gluing helps to place or distribute water-blocking components between layers. When applied to a cable or combined with one or more cable components, it provides water blocking properties. Other variants are within the scope of the invention.

Referring to Figs. 1a-1b, in a first embodiment, the present invention provides a water protection tape 10 comprising at least a first layer of material 20 arranged with at least a second layer of material 30, and at least one water blocking compound 40 contained between the first layer 20 and second layer 30. In one embodiment, a protective layer, e.g., a temperature-protective layer, material 35 can be arranged with at least one of the first layers 20 and second layers 30 of nonwoven material, as shown in Fig. 1b. The present invention, however, is not limited to the tape 10 shown in Figs. 1a-1b, but provides other configurations including additional layers to obtain the multi-layer tape 10.

In one embodiment, the first layer 20 and the second layer 30 may be constructed of a non-woven material suitable to provide strength to the belt 10, so that the belt 10 can withstand the manufacturing process. Suitable non-woven material includes a lightweight construction material or fabric that will not significantly increase the weight of the cable. A nonwoven material or fabric suitable for building the first layer 20 and the second layer 30 may include, but is not limited to, spun-bonded nonwoven fabric, e.g. spunbonded polyester nonwoven fabric, spun-bonded nonwoven fabric / melt-blown / spun-bonded "(SMS), e.g. polypropylene SMS fabric, spun-bonded / melt-blown / meltblown / spun-bonded (SMMS) non-woven fabric, e.g. melt-blown non-woven fabric, spun-bonded non-woven fabric, e.g. polyurethane spunbonded nonwoven fabric, non-woven nylon, non-woven carded fabric and combinations of the above. In other embodiments of the present invention, these materials may be preferred because they are comparably inexpensive and exhibit flexibility that allows the tape 10 to be used for optical fiber. Materials such as nonwoven polypropylene or nonwoven polyester are commercially available from BBA Nonwovens, Simpson, SC, and Kimberly Clark, Neenah, WA.

In a further embodiment, the first layer 20 and / or the second layer 30 (Fig. 1a1b) may be composed of a layer or a thin layer of plastic or polyester, such as polyethylene terephthalate (PET).

In one embodiment, the first layer 20 and the second layer 30 may be constructed, for example, of spun-bonded / meltblown / spun-bonded (SMS) polypropylene nonwoven fabric, having high tensile strength and low porosity. The first and second polypropylene non-woven SMS layers can weigh from about 10 grams per square meter to about 40 g / m2²and in particular about 16 g / m2²to economically produce tape 10. Heavier SMS polypropylene nonwovens are comparatively more expensive than lighter polypropylene nonwovens.

Referring to Figs. 2a-2b, the first and second layers of nonwoven material, 20 and 30, each of which has a width W1 and W2, which can be measured depending on the application or cable model in which the tape is used 10. As shown in Fig. 2b, in one embodiment, the first layer and the second layer, 20 and 30 have a width W1 and W2 that are substantially similar to each other. The first layer 20 (not shown) has substantially similar dimensions, e.g. height and width, to the second layer 30. The longitudinal edges 20a and 20b of the first layer 20 are substantially equal to the longitudinal edges 30a and 30b of the second layer 30. The obtained tape 10 according to the invention does not is limited by W3 width and can be configured for use in many different applications and cable models. For example, in one variation, the strip 10 may have a width W3 from about 10 mm to about 100 mm for use or in combination with one or more optical fiber components. In another embodiment, the strip 10 may have a relatively large width W3, e.g., about 200 mm, for use with a power cable.

The protective layer 35 (Fig. 1b) may be constructed of a suitable material providing protective properties such as heat protection and / or other properties of one or more cable elements in which the tape 10 is placed or with which it is joined together. Suitable material includes, but is not limited to, polyester and carbon impregnated polyester.

As shown in Figures 1a-1b, the band 10 comprises water blocking compounds 40 sandwiched between first and second layers 30. Compound 40 may include, but is not limited to, one or more swelling polymers with special absorption properties, in the prior art labeled "SAPs". SAPs include polymers having water absorption capacity up to about a thousand times their weight in the case of distilled water. When in contact with water, SAPs absorb and bind water molecules, with the result that they swell and increase their volume. When the tape 10 is connected to a cable and / or to one or more of its elements, in contact with water SAPs 40 absorbs it and swells. The swellable band 10 creates a physical barrier, helping to prevent or at least reduce the ingress of water into the cable. In the swelling process, SAP 40 increases the thickness or height of the strip 10 to "bulge height" such that the strip 10 acts as a water barrier. The strip 10 can also help prevent or at least reduce water migration along the length or span of the cable.

SAPs are commercially available in various forms, such as powders with special absorption properties, very fine particles, very fine fibers or water blocking coating components. In one embodiment, SAP 40 is a polymer with special absorption properties, suitable to provide one or more water blocking properties described earlier and may include, but is not limited to, polyacrylate, polyacrylamide, poly (vinyl alcohol), polyacrylate copolymer, polyacrylamide, poly (vinyl alcohol), copolymer of polyacrylate and polyacrylamide, copolymer of polyacrylate and poly (vinyl alcohol), copolymer of polyacrylamide and poly (vinyl alcohol) and combinations of the above. Such SAPs 40 can be obtained from many manufacturers, including Sumitomo Seika in Japan.

SAP 40 is placed on the surface of at least one of the first layers of non-woven material 20 and the second layers of non-woven material 30. As shown in Figs. 1a-1b, in one embodiment, SAP 40 can include a powder form and can be sprayed onto the first layer 20 SAP 40 is applied to the first layer 20 in the desired amount, which may partly depend on the application or cable model in which tape 10 is used. In one embodiment, SAP 40 can be applied in an amount in the range, but not limited to it, from 10 g / m2² up to 50 g / m2², in particular in an amount of about 20 g / m2². A larger amount of SAP 40 can generally provide greater water absorption properties for belt 10. In one embodiment, SAP 40 may contain a percentage of about 25% to 50% by dry weight (weight%) of the total weight of belt 10.

SAP 40 type and its quantity (g / m²) partly refers to the desired swelling ratio of the belt 10. The term "swelling ratio" as used herein refers to the range or percentage in which SAP 40 increases in volume in contact with water. A certain swelling ratio SAP 40 may be required to achieve the desired bulge height or thickness of the strip 10. In addition, a certain swelling ratio may be required to increase the height of the strip 10 in contact with water at the desired time.

For example, in one embodiment, the tape 10 may be manufactured for use in communication optical fibers and may contain at least one SAP 40 in powder form, for example Sumitomo JP 550F supplied by Sumitomo Seiki in Japan. SAP 40 is placed between the first and second layers of nonwoven material, 20 and 30, in an amount of about 20 g / m2². SAP 40 represents about 30% by weight of the total weight of the tape. The SAP 40 powder particle size is about 75 μm. In contact with water, SAP 40 swells to about 95% of its maximum volume in about 30 seconds, and increases the belt height from about 6 to 8 mm. The amount of SAP 40 helps to ensure the belt 10 absorbs water quickly and to achieve a swelling ratio that provides the right bulge height and allows the belt 10 to create a physical water barrier. The absence of binders and binders in the production of tape 10 can help increase / maximize the swelling process of SAP 40.

With reference to Figs. 2c and further references to Figs. 2a-2b, in one embodiment, the first layer of nonwoven material 20 is associated with the second layer of nonwoven material 30 according to a template that is impressed on layers 20 and 30 using a welding technique ultrasonic, well known in the art. This technique allows the first layer 20 and the second layer 30 to be glued or joined by directing ultrasonic waves to the surface of at least one of the first layer 20 and the second layer 30. As shown in Fig. 2c, in one embodiment, when SAP 40 is introduced between the first and second layers, 20 and 30, the ultrasonic waves 90 hit the first surface 50a of the second layer 30, and the template 60 imprints on the first surface 80a of the first layer 20 in at exactly the same time as ultrasonic waves 90 reach the first surface 50a. The first layer 20 and the second layer 30 are substantially simultaneously processed to bond or connect layers 20 and 30 along lines or marks of the template 60. In one embodiment, the template 60 can be impressed through the first and second layers 20 and 30. In another embodiment, the area of ​​the first surface 50a of the second layer 30 that the ultrasonic waves reach is located opposite and substantially parallel to the area of ​​the first surface 80a of the first layer 20 on which the template 60 is imprinted. As shown in Fig. 2b, in one the implementation variant template 60 may extend across the width W3 of the first and second layers, 20 and 30.

In one embodiment, template 60 may include a repeating and substantially uniform template. In another embodiment, the template 60 may include a number of similar or dissimilar forms. In a further embodiment, the template 60 may include an irregular or unique pattern. As shown in fig. 2a-2b, in one embodiment, the template 60 may include a series of similar rhombic forms arranged in a repetitive and exactly uniform pattern across the width W3 of the first and second layers 20 and 30. In one embodiment, each rhombic form may have dimensions 1 , 6 cm by 1.6 cm. Variations of the strip 10 according to the invention are not limited to any particular types of template 60. The invention provides that the template 60 may contain various forms and sizes of these forms that may be required for the application in which the band 10 is used and / or to adjust the desired amount

SAP 40.

One feature and advantage of tape 10 is the effect of deploying the binding template 60. Portions of SAP 40 are contained within the molds or configuration of template 60, which prevents SAP 40 from moving between layers 20 and 30. Template 60 helps prevent agglomeration of SAP 40 at points along tape 10, in particular, it helps to prevent SAP 40 from sticking along the edges 20a, 30a and 20b, 30b of the first and second layers, 20 and 30. In addition, template 60 facilitates and maintains the distribution of SAP 40 between layers 20 and 30 in a substantially constant manner, e.g., each form and configuration of template 60 contains approximately a similar amount of SAP 40. Basically, the fixed distribution of SAP 40 helps to achieve a bulge height or thickness of the strip 10 that is substantially constant, for example having little or no irregularity or discontinuity, which could affect the water blocking performance of the strip 10 when the SAP 40 absorbs water and swells. The substantially constant bulge height of the tape 10 helps to create a reliable and compact barrier that helps prevent or at least reduce the extent of penetration of the cable core by water and migration of water along the cable span.

In addition, template 60 is one of the factors that can help increase / maximize SAP 40 swelling speed and band bulge height

Ten. For example, if the template 60 is too tight, the volume of the separate forms or layouts of the template 60 will not adapt to the SAP 40 swelling process and will not allow SAP 40 to swell freely or to achieve a swelling rate sufficient to achieve the desired swelling ratio when in contact with water . In contrast, when the template 60 is too loose, for example, separate molds or systems are too large, SAP 40 will not be divided into designated areas and the movement of SAP 40 between layers 20 and 30 will cause SAP 40 to stick together along tape 10. In this case, the bulge height may be unstable and the band 10 may not form a substantially coherent and efficient water barrier.

Preferably, the binding template 60 further allows or at least substantially reduces the "escaping" or loss of SAP 40 from tape 10, during cable production and during braiding processes in which the tape 30 is joined together with one or more cable components or its core . The reduction of SAP 40 "escaping" helps to maintain the amount of SAP 40 for sufficient water absorption and constant bulge height.

Referring to Fig. 3, in one embodiment, the belt 10 of the invention 20 includes a first layer of nonwoven material 20 having exactly the same dimensions as, for example, width as the second layer of nonwoven material 30 (not shown), such that longitudinal edges 20a and 20b of first layer 20 are substantially equal to longitudinal edges 30a and 30b of second layer 30. Layers 20 and 30 are bonded to each other using the ultrasonic welding technique described above. Ultrasonic waves hit first surface 50a of second layer 30. Belt 70 is imprinted on first surface 80a of first layer 20 along longitudinal edges 20a, 20b and 30a, 30b of layers 20 and 30. Ultrasonic waves hit first surface 50a of second layer 30 substantially including at the same time as the belt is impressed on the first surface 80a of the first layer 20. As a result, the layers 20 and 30 are glued or joined along the impressed belts 70.

Referring to Fig. 4a, the invention provides a method 100 for making a water resistant tape 10 and includes the steps shown. The method 100 is, however, an example, it does not create a restriction and can be changed, for example by adding, removing or moving steps.

At step 105, first and second layers 20 and 30 are provided, for example, each layer 20 and 30 comprises a sheet of nonwoven material. Each layer 20 and 30 has the desired dimensions, e.g. width, such that the desired number of water-resistant strips according to the invention can be formed from the first and second layers 20 and 30 with the desired dimensions.

In step 110, at least one type of SAP 40, e.g. in powder form, is applied, e.g., by spraying onto one surface one of the first layers 20 and the second layers 30 in an amount sufficient to achieve the desired swelling rate and / or the desired swelling ratio required for the particular application or cable model in which one or more tapes 10 according to the invention will be used.

At step 115, the second layer 30 is arranged on the first layer 20 such that SAP 40 is arranged between layers 20 and 30.

At step 120, the ultrasonic sound waves, e.g. emitted by an ultrasonic horn loudspeaker, hit the first surface 50a of the second layer and the template 60, e.g., provided by a roller having a surface with the template 60 thereon, the first surface is imprinted. 80a of the first layer 20 at substantially the same time as the ultrasonic waves hit the surface 50a. Layers 20 and 30 are bonded together to connect the first layer 20 to the second layer 30 along the impressed lines of the template 60. In one embodiment, the area of ​​the second layer 30 to which ultrasonic wave impacts are directed is generally opposite and aligned in relation to area of ​​the first layer 20 impressed by template 60.

At step 125, the glued layers 20 and 30 are cut into one or more tapes according to the invention, using one or more conventional cutting devices, in which each tape 10 has the desired width.

With reference to Fig. 4b, in one embodiment, the method 100 may further include step 122 as an alternative to step 125, as described above with reference to Fig. 4a. At step 122, the glued layers 20 and 30 may be transferred next to an ultrasonic cutting device comprising an ultrasonic horn loudspeaker and one or more cutting devices for cutting layers 20 and 30 into one or more belts or bands 10 according to the invention. When layers 20 and 30 are transferred next to the ultrasonic cutting device, the ultrasonic waves emitted by the ultrasonic horn loudspeaker hit the surface of one of layers 20 and 30, and one or more cutting devices contact the opposite surface of one of layers 20 and 30. Layers 20 and 30 are cut into a plurality of belts or bands 10 when the ultrasonic waves hit the surface and one or more cutting devices are in contact with the opposite surface. In one embodiment, the ultrasonic waves hit the surface substantially simultaneously or at the same time that one or more cutting devices are in contact with the opposite surface. In one variation, the surface area of ​​one of layers 20 and 30 struck by ultrasonic waves is exactly opposite and aligned with the area of ​​the opposite surface of one of layers 20 and 30. In one embodiment, one or more cutting devices may be equally spaced to each other to cut layers 20 and 30 into one or several tapes 30 of substantially the same width. In another embodiment, layers 20 and 30 have substantially similar dimensions, e.g. width, and the longitudinal edges of the first layer 20 are substantially equal to the longitudinal edges of the second layer 30.

Referring to Fig. 5, in a further aspect, the invention provides a system 200 and method for producing a water-resistant tape 10 in a continuous process using ultrasonic welding and ultrasonic cutting techniques to produce the tape 10 of the invention. As shown in Figure 5, at least the first feed roller 201, on which the nonwoven material of the desired width is wound, provides the first layer of nonwoven material 20 to production line 205. At least a second feed roller 202, on which nonwoven material of the desired width is wound, provides a second layer of nonwoven material 30 to production line 205.

In one embodiment, the second feed roller 202 can be attached to a set of one or more loose rollers 203, which helps to transfer the second layer 30 from the roller 202 to line 205. Loose rollers 203 can be placed directly at the roller

202 to receive the second layer 30. The second feed roller 202 is attached to a set of one or more pick rollers 260 and 270, arranged downstream of the feed roller 202, in the direction of the process, to help carry the second layer 30 through line 205, for example, in a substantially horizontal position and sufficient tension. As shown in fig. 5, the first feed roller 201 is connected to a set of one or more pickup rollers 260 and 270, arranged downstream of the feed roll 201, in the direction of the process, to help carry the second first layer 20 through the line 205, for example in a substantially horizontal orientation and sufficient tension.

In one embodiment, the second feed roller 202 may further be connected to one or more secondary rollers arranged to assist in feeding the protective material layer 35 to line 205. As shown in Figure 5, the secondary roller 204 is arranged and configured so as to that it can feed a layer of protective material 35 onto one of the loose rollers 203. The loose roller 203 can then feed the second layer 30 and the protective material layer 35 to production line 205.

The system 200 and method of the invention is not limited to the arrangement and connections of feed rollers 201 and 202, loose rollers 203, auxiliary rollers 204 and lift rollers 206 and 207 as shown in Fig. 5, and provides for different roller arrangements and connections to provide first and second layers 20 and 30 to production line 205 and transfer the first and second layers 30 through line 205, as well as to feed and transfer the protective material layer 35 through production line 205.

The system 200 further includes a dispenser 210 for dispensing SAP 40. In one embodiment, the dispenser 210 is positioned downstream of the first feed roller 201 in a process direction, e.g. above production line 205, such that when the first layer 20 is conveyed along line 205 , e.g., in a substantially horizontal orientation, the dispenser 210 dispenses SAP 40 onto the surface of the first layer 20. In one embodiment, the dispenser 210 may include any device well known in the art for dispensing such material, e.g., SAP 40 in powder form, and may be configured to limit the amount of SAP 40 dispensed during spraying. In one embodiment, the dispenser 210 may include a housing 220 (not shown) in which a vacuum is created to contain and locate SAP 40 during spraying. The housing 220 may include a pressure sensor and / or indicator for detecting and displaying the pressure inside the housing 220.

When the first layer 20 is moved next to the dispenser 210, the dispenser 210 sprays SAP 40 onto the first surface 80a of the first layer 20 to obtain the desired mass, e.g. from about 10 g / cm² up to about 50 g / cm²and in particular about 20 g / cm². In one embodiment, the first layer 20 may be ionized by appropriate methods known in the art before or during dispensing SAP 40 onto the first surface 80a.

A second feed roller 202 and / or one or more loose rollers 203 help feed the second layer 30 onto the line 205, e.g., at location 225 of the production line 205, where the second layer 30 is conveyed behind the dispenser 210, in the direction of the process. In one embodiment, the secondary roller 204 feeds the protective material layer 35 onto one of the loose rollers 203, and the loose roller 203 feeds the second protective layer 30 and the protective material layer 35 onto the production line 205. The second layer 30 is conveyed along the line 205, for example, in a substantially horizontal orientation, opposite and parallel to the first layer 20. During transfer, the second layer 30 is finally laid on the first surface 80a of the first layer 20. In one embodiment, in which the loose roller 203 also feeds the protective material layer 35 to production line 205, the protective material layer 25 and the second layer 30 are substantially opposite and parallel to each other, and substantially opposite and parallel to the first layer 20. W during transfer, the protective material layer 35 and the second layer 30 are finally placed on the first surface 80a of the first layer 20.

In one embodiment, each of layers 20 and 30 has a substantially similar width to the other layers 20 and 30, such that when the second layer 30 is laid on the surface 80a of the first layer 20 while layers 20 and 30 are transferred to the production line 205 , the longitudinal edges of the first and second layers 20 and 30 are substantially aligned or equal. In one embodiment, the protective material layer 35 has a similar width to one or two layers 20 and 30, such that when the protective material layer 35 is laid on the second layer 30, when the layers 20 and 30 are transferred to production line 205, longitudinal the edges of the protective material layer 35 and the first and / or second layer 30 are substantially aligned or equal. First and second layers 20, and

30, and - optionally - a protective material layer 35, thus form a continuous fabric 300, which is transferred via system 200 to line 205.

The system 200 further includes an ultrasonic laminating device comprising an ultrasonic horn loudspeaker 230 and anvil shaft 235. Ultrasonic horn loudspeaker 230 and anvil shaft 235 are located behind dispenser 210. Ultrasonic horn loudspeaker 230 and shaft 235 are separated from production line 205 and placed on opposite sides of production line 205, so that fabric 300 is transferred to the production line between the ultrasonic tube loudspeaker 230 and roller 235. In one embodiment, the ultrasonic horn loudspeaker 230 and the roller 235 are arranged on opposite sides of the production line 205 and are arranged in a line such that the fabric 300 is conveyed at the ultrasonic horn loudspeaker 230 and at the shaft 235 at substantially the same time. In one embodiment, the ultrasonic horn loudspeaker 230 is located above production line 205 and arranged vertically with a roller 235 located below production line 205. In this variant, when the fabric 300 is transferred between the ultrasonic horn loudspeaker 230 and the anvil shaft 235, the fabric is transferred in a substantially horizontal orientation.

The invention is not limited to the setting and connection of the ultrasonic horn loudspeaker 230 and the roller 235 such as shown in Fig. 5, and provides for other settings and connections between the ultrasonic horn loudspeaker 230 and the roller 235.

The surface of the roller 235 has a template 240. The roller 235 imprints the template 240 on the second surface 80b of the first layer 20 when the roller 235 contacts the first layer 20 while it is being conveyed through the line 205. In other embodiments, the template 240 may include any template that is desirable to include and separate

SAP 40 between the first and second layers, 20 and 30. In one embodiment, the template 240 includes a repeating and substantially uniform pattern. In a further embodiment, the template 240 includes an arrangement of similar or dissimilar forms. In a further embodiment, the template 240 includes a system of substantially similar rhombic forms, each of the rhombic forms having dimensions of about 1.6 cm by 1.6 cm. In the next embodiment, the template 240 includes a unique and irregular pattern. The roller 235 may include, for example, a cylindrical roller with a circular cross-section, constructed of material suitable for stamping, such as, but not limited to, metal, e.g. steel or chromium steel.

The ultrasonic horn loudspeaker 230 may include any device well known in the art for generating ultrasonic waves. In one embodiment, the ultrasonic horn speaker 230 is a device available on the market under the name and model number Ultra Sonic Generator, 2 DPC Level 2 1200w, available from Dukane, St. Charles, IL.

As shown in Figure 5, fabric 300 is transferred on production line 205 between the ultrasonic horn loudspeaker 230 and the roller 235. The ultrasonic horn loudspeaker 230 emits ultrasonic waves such that when the fabric 300 is moved next to the loudspeaker 230, the ultrasonic waves hit first surface 300a of fabric 300, facing speaker 230. When the fabric 300 is conveyed on production line 205 and near the roller 235, the roller 235 contacts the second surface 300b of the fabric 300 opposite the first surface 300b facing the roller

235. Contact of the roller 235 with the second fabric surface 300b 300 causes the template 240 to bounce across the second fabric surface 300b 300.

In one embodiment, when the fabric 300 is transferred between the ultrasonic horn loudspeaker 230 and the roller 235, the ultrasonic waves hit the first area of ​​the first surface 300a of the fabric 300, being substantially opposite the second area of ​​the second surface 300b, so that the roller 235 contacts the her and imprints the template 240 on it. Ultrasonic waves hit the first area of ​​the first surface 300a at substantially the same time as the roller 235 contacts the second surface 300b and imprints the template 240 thereon.

. The first and second layers, 20 and 30, are thus glued along the template 240 by impact of the ultrasonic waves on the first area of ​​the first surface 300a at substantially the same time as the roller 235 imprints the template 240 on the second area of ​​the second surface 300b. The roller impresses the template 240 on the second surface 300b through the second layer 30 and through the first layer 20 when ultrasonic waves hit the first surface 300a to glue layers 20 and 30 along the template 240.

In one embodiment, layers 20 and 30 are glued along template 240 substantially across the first area and the second area of ​​the first and second surfaces, 300a and 300b, fabric 300. In one embodiment, the fabric 300 is continuously transferred in production line 205, such that the ultrasonic waves continuously hit the first surface 300a of the fabric 300, and the roller 235 continuously imprints the template 240 on the second surface 300b of the fabric 300, that the first and second layers, 20 and 30, are continuously ultrasonically glued along template 240.

The system 200 further includes an ultrasonic cutting device comprising an ultrasonic horn loudspeaker 250 and one or more cutting devices 255, for example cutting anvils. Ultrasonic horn loudspeaker 250 and cutting anvils 225 behind the ultrasonic laminating device 230 and 235, in the direction of the process. The ultrasonic horn loudspeaker 250 and cutting anvils 255 are separated from the production line 205 and arranged on opposite sides of the production line 205 such that fabric 300 is transferred on the production line 205 between the ultrasonic horn loudspeaker 250 and the cutting anvils 255. In one embodiment, the ultrasonic horn loudspeaker 250 and the cutting anvils 255 are arranged on opposite sides of the production line 205 and are arranged in a line such that the fabric 300 is moved next to the ultrasonic horn loudspeaker 250 and next to the cutting anvils 255 at substantially the same time. In one embodiment, the ultrasonic horn loudspeaker 250 is positioned above production line 205 and arranged in a vertical line with one or more cutting anvils 255 located below production line 205.

In this embodiment, when the fabric 300 is transferred between the ultrasonic horn loudspeaker 250 and the cutting anvils 255, the fabric is transferred in a substantially horizontal arrangement.

The invention is not limited to such setup and connection of the ultrasonic horn loudspeaker 250 and cutting anvils 255 as shown in Fig. 5, and provides for other settings and connections between the ultrasonic horn loudspeaker 250 and the cutting anvils 255.

The ultrasonic horn loudspeaker 250 may include any device well known in the art for generating ultrasonic waves. In one embodiment, the 250 ultrasonic horn loudspeaker is a device available on the market under the name and model number Ultra Sonic Generator, 2 DPC Level 2 1200w, available from Dukane, St. Charles, IL.

As shown in Fig. 5, fabric 300 is transferred on production line 205 between ultrasonic horn loudspeaker 250 and cutting anvils 255. When fabric 300 is transferred on production line 205 between ultrasonic horn loudspeaker 250 and cutting anvils 255, ultrasonic horn loudspeaker 250 emits waves ultrasonic in such a way that when the fabric is moved next to the horn loudspeaker

250, ultrasonic waves hit the first surface 300a of the fabric 300 facing the horn loudspeaker 250. When the fabric 300 is conveyed on production line 205 and next to the cutting anvils 255, one or more cutting anvils 255 are in contact with the second surface 300b of the fabric 300 opposite first surface 300a, facing one or more cutting anvils 255. Contact of one or more cutting anvils 255 with the second surface 300b of fabric 300 causes cutting or cutting of fabric 300.

In one embodiment, when the fabric 300 is transferred between the ultrasonic horn loudspeaker 250 and the cutting anvils 255, the ultrasonic waves hit the first area of ​​the first surface 300a of the fabric 300, being substantially opposite the second area of ​​the second surface 300b in contact with one or more cutting anvils 255. Ultrasonic waves hit the first area of ​​the first surface 300a at substantially the same time at which one or more cutting anvils 255 contact and cut or cut the second surface 300b through the second layer 30 and through the first layer 20. The fabric 300 is thereby cut into two or more strips as a result of the ultrasonic waves hitting the first area of ​​the first surface 300a at substantially the same time at which one or more cutting anvils 255 cuts the second area and the fabric 300. The number of strips to which it is cut fabric 300 depends on the number of cutting anvils 255. In one embodiment, fabric

300 is transferred continuously on production line 205 so that the ultrasonic device 250 emits ultrasonic waves that continuously hit the first surface 300a of the fabric 300, and the cutting anvils 255 continually cut or cut the fabric 300 across so that two or more belts are formed continuously.

As can be seen by those skilled in the art, the width of the first layer 20 and the second layer 30 and the number and placement of cutting anvils 255 can determine the number and width of belts or strips 10 cut from fabric 300 in a single production cycle in which fabric 300 is conveyed in a manner continuous through system 200. In one embodiment, the anvil cutters 255 may be arranged to cut strips or strips 10 of varying widths, thereby forming a series of strips 10 for more than one application or cable model.

As shown in Fig. 5, the system 200 includes lifting rollers 260 and 270 positioned downstream of the ultrasonic cutting devices 250 and 255, in the process direction, for removing belts or bands 10 from line 205 and winding the bands 10 on them.

Neptco Incorporated, USA

Proxy:

Z-4733/07

EP 1 634 304 B1