Electrical cables with non-metallic jackets and methods of fabricating the same

Abstract

An electrical cable having a plurality of conductors including a grounding conductor and at least one power-carrying conductor. The plurality of conductors disposed approximately in parallel within an outer jacket such that the electrical cable has a substantially elongated horizontal cross-section.

Claims

1. A method of fabricating an electrical cable, the electrical cable including a plurality of insulated conductors and a bare conductor disposed approximately in parallel within an outer jacket such that the electrical cable has an elongated horizontal cross-section, comprising: parallelizing the insulated conductors and the bare conductor with a first guide plate; wrapping the bare conductor with a filler sheath; surrounding the parallelized insulated conductors and the filler-wrapped bare conductor with binding; and extruding the outer jacket over the parallelized insulated and filler-wrapped bare conductors such that the electrical cable has the elongated horizontal cross-section.

2. The method of claim 1, wherein the binding is a twine binding.

3. The method of claim 2, wherein surrounding the parallelized insulated conductors and the filler-wrapped bare conductor with binding comprises: passing the parallelized insulated conductors and the filler-wrapped bare conductor through a binder twine application stage for helically winding the binder twine around the parallelized insulated conductors and the filler-wrapped bare conductor.

4. The method of claim 1 further comprising: passing the binding-wrapped parallelized insulated conductors and the filler-wrapped bare conductors through a filler folder to wrap the parallelized insulated conductors and the filler-wrapped bare conductor with filler.

5. The method of claim 4, wherein the filler folder is a paper folder.

6. The method of claim 4, wherein extruding a jacket around the filler-wrapped parallelized insulated conductors and the filler-wrapped bare conductor comprises: passing the filler-wrapped parallelized insulated conductors and the filler-wrapped bare conductor through a parallel retainer; passing an assembly exiting the parallel retainer through a parallel-type extrusion tip; and passing an assembly exiting the parallel-type extrusion tip through an extrusion die.

7. A method of fabricating an electrical cable, the electrical cable including a plurality of insulated conductors and a bare conductor disposed approximately in parallel within an outer jacket such that the electrical cable has an elongated horizontal cross-section, comprising: parallelizing the insulated conductors and the bare conductor with a first guide plate; wrapping the bare conductor with a filler sheath; surrounding the parallelized insulated conductors and the filler-wrapped bare conductor with a filler; and extruding the outer jacket over the parallelized insulated and filler-wrapped bare conductors such that the electrical cable has the elongated horizontal cross-section.

8. The method of claim 7 further comprising: passing the parallelized insulated conductors and the filler-wrapped bare conductor through a filler folder to wrap the parallelized insulated conductors and the filler-wrapped bare conductor with filler.

9. The method of claim 8, wherein the filler folder is a paper folder.

10. The method of claim 8, wherein extruding a jacket around the filler-wrapped parallelized insulated conductors and the filler-wrapped bare conductor comprises: passing the filler-wrapped parallelized insulated conductors and the filler-wrapped bare conductor through a parallel retainer; passing an assembly exiting the parallel retainer through a parallel-type extrusion tip; and passing an assembly exiting the parallel-type extrusion tip through an extrusion die.

11. A method of fabricating an NM-type electrical cable: parallelizing at least three insulated conductors and a bare conductor; wrapping the bare conductor with a filler; wrapping the parallelized insulated conductors and the filler-wrapped bare conductor with filler to produce a filler-wrapped assembly; and forming jacket around the filler-wrapped assembly to produce a generally elongated horizontal cross-section with the at least three insulated conductors and the filler-wrapped bare conductor.

12. The method of claim 11, wherein the filler is paper.

13. The method of claim 11 wherein parallelizing the three insulated conductors and the bare conductor comprises passing the at least three insulated conductors and the bare conductor through a first guide plate.

14. The method of claim 11 wherein wrapping the bare conductor with a filler comprises wrapping the bare conductor with paper.

15. The method of claim 11 further comprises passing the at least three insulated conductors and the filler-wrapped bare conductor through a second guide plate.

16. The method of claim 11, wherein wrapping the parallelized insulated conductors and the filler-wrapped bare conductor with filler comprises wrapping the parallelized insulated conductors and the filler-wrapped bare conductors with paper.

17. The method of claim 11, wherein forming jacket around the filler-wrapped assembly comprises extruding plastic around the filler-wrapped assembly.

18. The method of claim 11 further comprising wrapping binding cord around the parallelized insulated conductors and the filler-wrapped bare conductor prior to wrapping the parallelized insulated conductors and the filler-wrapped bare conductor with filler.

19. The method of claim 11, wherein the at least three insulated conductors and the filler-wrapped bare conductor are disposed generally in parallel without bundling or cabling.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is cross-sectional diagram of a prior art electrical cable with a non-metallic sheath and cabled inner conductors;

(3) FIGS. 2A and 2B are cross-sectional diagrams of prior art electrical cables with non-metallic sheaths and bundled inner conductors, respectively with and without binding cord;

(4) FIGS. 3A and 3B are cross-sectional diagrams of representative non-

(5) metallic sheathed cables embodying the principles of the present invention, respectively with and without binding cord;

(6) FIG. 4A is a diagram illustrating a representative process according to the principles of the present invention for fabricating the electrical cable of FIG. 3A;

(7) FIG. 4B is a diagram illustrating a representative process according to the principles of the present invention for fabricating the electrical cable of FIG. 3B; and

(8) FIG. 5 is a diagram of an exemplary guide plate suitable or use in the processes shown in FIGS. 4A and 4B.

DETAILED DESCRIPTION OF THE INVENTION

(9) The principles of the present invention and their advantages are best understood by referring to the illustrated embodiment depicted in FIGS. 1-5 of the drawings, in which like numbers designate like parts.

(10) FIG. 1 is a diagram of a cross-section of a conventional finished three (3) conductor with ground NM or NM-8 type electrical cable 100 having a round construction with cabled inner conductors. In cable 100, three (3) insulated conductors 101a, 101b, and 101c, preferably of copper, are each constructed with an insulation layer 102, preferably of polyvinyl chloride (PVC) resin and sheathed with a conductor jacket 103, preferably of nylon.

(11) Ground conductor 104 is wrapped in a filler-type sheath 105, preferably paper, as is the entire internal construction. Surrounding insulated conductors 101a, 101b, and 101c, ground conductor 104, and fillers 105 is a non-metallic jacket 106. All four interior conductors (i.e. insulated conductors 101a, 101b, and 101c, and ground conductor 104) have been cabled, which gives a round shape to the profile of cable 100.

(12) FIG. 2A depicts a cross-section of a conventional finished three (3) conductor with ground NM or NM-8 type electrical cable 200a in which the inner conductors have been bundled in a quasi-rounded, diamond, or square stacked formation, with a binder cord.

(13) In cable 200a, three (3) insulated conductors 201a, 201b, and 201c, preferably of copper, are constructed with an insulation layer, preferably of polyvinyl chloride (PVC) resin 202 and sheathed with a conductor jacket 203, preferably of nylon. Ground conductor 204 is wrapped in a filler-type sheath 205, preferably paper, as is the entire bundle of insulated conductors 201a, 201b, and 201c and ground conductor 204. Surrounding insulated conductors 201a, 201b, and 201c, ground conductor 204 and fillers 205 is non-metallic jacket 206. All four (4) interior conductors (e.g. insulated conductors 201a, 201b, and 201c, and ground conductor 204) in cable 200a are held together by a binding cord 207, which gives cable 200a a more or less rounded profile.

(14) FIG. 2B illustrates an alternate conventional bundled cable 200b, which is similar to cable 200a discussed above, except that bundled cable 200b does not utilize a binder cord.

(15) A first illustrative embodiment of the principles of the present invention is electrical cable 300a shown in the cross-sectional diagram of FIG. 3A. Generally, electrical cable 300a comprises a finished three (3) conductor with ground NM or NM-8 type electrical cable with a parallel construction in which the inner conductors are all held approximately parallel to each other with a binder cord before the execution of paper barriers and the overall jacket. The overall horizontal cross-section of cable 300a is elongated, providing two (2) generally flat major sidewalls and two (2) generally rounded lateral edges.

(16) Specifically, cable 300a includes three (3) insulated conductors 301a, 301b, and 301c, preferably of copper, each constructed with an insulation layer 302, preferably of polyvinyl chloride (PVC) resin and sheathed with a conductor jacket 303 preferably of nylon. The ground conductor 304 is wrapped in a filler-type sheath 305, preferably paper, as is the entire construction prior to the final jacket. Surrounding the insulated conductors 301a, 301b, and 301c, ground conductor 304, and fillers 305 is non-metallic jacket 306, preferably of PCV resin. All four (4) conductors (i.e. insulated conductors 301a, 301b, and 301c and ground conductor 304) have been laid approximately parallel to each other and wrapped in a binding cord 307, which gives an oval, parallel profile to electrical cable 300a.

(17) FIG. 3B illustrates a second exemplary electrical cable 300b embodying the present inventive principles. Electrical cable 300b is a finished three (3) conductor with ground NM or NM-8 type electrical cable with a parallel construction similar to electrical cable 300a, with the exception that the inner conductors (i.e. insulated conductors 301a, 301b, and 301c, and ground conductor 304) have all been placed parallel to each other without a binder cord before the execution of paper barriers 305 and overall jacket 306.

(18) An illustrative fabricating system 400a, according to the principles of the present invention and suitable for fabricating electrical cable 300a of FIG. 3A, is shown in FIG. 4A. (The process of fabricating electrical cable 300a is not, however, limited to fabricating system 400a; alternate fabrication systems and methods may be used, as appropriate.)

(19) Fabricating system 400a includes supply stations or pay-offs 401a, 401b, and 401c supplying insulated conductors 301a, 301b, and 301b, and supply station or pay-off 402 supplying bare ground wire 304. All conductors pass through various primary stages of alignment by way of conventional conduits, capstans, or pulleys (not shown) before passing through a guide plate 403. Guide plate 403 gives a more exacting alignment of all the conductors 301a, 301b, 301c, and 304, especially such that bare ground conductor 304 alone passes through first paper folder 404, which surrounds ground conductor 304 with paper (filler) 305. An additional paper separator apparatus 405 underneath prevents the ground wire paper from becoming entangled with the moving conductors.

(20) After the ground wire 304 has been wrapped in paper, all four conductors 301a, 301b, 301c, and 304 pass through a guide plate 406 before passing through the center of the cone of binder twine apparatus 407, which helically wraps binder twine 307 around insulated conductors 301a, 301b, 301c, and paper covered bare ground wire 304, along the entire length of the construction.

(21) After receiving the binder twine, all conductors 301a, 301b, 301c, and 304 pass through a binder-twine and paper separator apparatus 408 before passing through guide plate 409. All conductors 301a, 301b, 301c, and 304 then pass through a second paper folder 410, which allows for paper sheath 305 to be applied and completely surround the entire construction. The entire paper-covered construction passes through a parallel-type retainer 411 and parallel-type extrusion tip 412 and die 413 at the extruder head, which forms the external jacket 306. A typical embossing wheel, laser printer, cooling trough, and take-up (not shown) complete the process.

(22) FIG. 4B illustrates a second fabrication system 400b, suitable for manufacturing electrical cable 300b, which does not utilize binding twine. Fabrication system 400b is similar to fabrication system 400b, with the exception that binder twine apparatus 407 and paper separator apparatus 408 are no longer required (alternate techniques may be used, as appropriate, to construct cable 300b).

(23) FIG. 5 is a diagram of an exemplary guide plate 500 suitable for use in the processes shown in FIGS. 4A and 48 as any or all of guide plate 403, guide plate 406, and guide plate 409. Guide plate 500 includes generally flat metal plate or bracket 501 supporting a removable guide die 502. Guide die 502 includes three (3) slots 503a-501b for guiding insulated conductors provided by payoffs 401a-401c and a slot 504 for guiding the bare grounding conductor provided by payoff 402. (In the illustrated embodiment slots 503a-503c overlap to form a single aperture, although this is not a requirement for alternate embodiments.) Guide die 502 directs the insulated and bare conductors generally in parallel such that the ultimate cable 300a/300b can be formed without twisting or cabling.

(24) The embodiments of the principles of the present invention realize substantial advantages over the prior art. Among other things, since cabling is not performed on the inner conductors, the manufacturing process is streamlined, thereby increasing efficiency and reducing costs relative to conventional cabled conductor fabrication techniques. Furthermore, in contrast to conventional bundled electrical cables, the present principles provide for more aesthetically uniform electrical cables, which reduces the possibility that non-defective cables will be mistakenly perceived as defective. Functionally, horizontally elongated electrical cables according to the inventive principles are easier to pull over or through building structures, such as joints, and the substantially flat major sidewalls essentially allow for the stacking of multiple cables by the end user.

(25) Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed might be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

(26) It is therefore contemplated that the claims will cover any such modifications or embodiments that fall within the true scope of the invention.