Abstract In the manufacture of cordage (25), at least two groups (28, 29) of individually insulated, flexible conductors (21--21) which comprise a planar array (40) are moved through a core tube (71) of an extruder (27) in adjacent paths. As the groups are moved out of an exit portion of the core tube where they are spaced apart a predetermined distance and along converging paths to a die, a first plastic material is flowed about the array to enclose it and to be formed into a jacket by the die. Portions of the first plastic material flow between the groups to achieve an equilibration of pressure in the plastic material about each group, which controls the direction and magnitude of lateral movement of each group within the plane of the array, and to form a web (41) which is integral with the jacket and which may vary in thickness along its length to compensate for changes in the outside diameter of the insulated conductors. The control of the lateral movement of each group between the core tube and the die and the formation of a web results in a jacket having substantial symmetry and in cordage having the groups separated by the web which has a thickness that is substantially less than the predetermined distance. The jacket is coated with a second plastic material which has a stiffness modulus that is substantially greater than that of the first plastic material.
Telephone cordage, which includes: at least two groups of relatively flexible, individually insulated conductors which are disposed in a planar array; a plastic jacket which encloses said groups of conductors; a web of plastic material which is integral with the jacket and which separates adjacent groups of conductors, said web having a thickness which varies along the cordage to compensate for conductor size variations and to cause the distance from an outwardly facing surface of each outermost conductor in the array to be spaced a substantially constant distance from the outwardly facing surface of the jacket along the length of the cordage.
Claim 2
Dependent Claim
102 words
Telephone cordage, which includes: at least two groups of relatively flexible, individually insulated conductors which are disposed in a planar array; a plastic jacket which encloses said groups of conductors; a web of plastic material which is integral with the jacket and which separates adjacent groups of conductors, said web having a thickness which varies along the cordage to compensate for conductor size variations and to cause the distance from an outwardly facing surface of each outermost conductor in the array to be spaced a substantially constant distance from the outwardly facing surface of the jacket along the length of the cordage.
Claim 3
Dependent Claim
46 words
The telephone cordage of claim 1, wherein said telephone cordage has substantial symmetry about coordinate axes through a cross-section thereof and said cordage includes a coating that encloses said plastic jacket, said coating having a uniform thickness because of its application over a substantially symmetrical cross-section.
Claim 4
Dependent Claim
39 words
The telephone cordage of claim 1, wherein said cordage also includes a coating that encloses said plastic jacket, said coating comprising a plastic material having a stiffness modulus that is substantially greater than the stiffness modulus of said plastic
Claim 5
Dependent Claim
45 words
The telephone cordage of claim 3, wherein the stiffness modulus of the plastic jacket is in the range of about 56 to 70 kg/cm 2 and the stiffness modulus of the coating plastic material is in the range of 1757 to 2460 kg/cm 2 .