Title of Invention

CORROSION-ROTECTED COAXIAL CABLE, METHOD OF MAKING SAME AND CORROSION-INHIBITING COMPOSITION

Abstract The present invention is a corrosion-protected cable, a method of making a corrosion-inhibiting cable, and a corrosion-inhibiting composition. The corrosion-inhibiting composition includes a water-insoluble corrosion-inhibiting compound dispersed in an oil, and a stabilizer selected from the group consisting of propylene based glycol ethers, propylene based glycol ether acetates, ethylene based glycol ethers and ethylene based glycol ether acetates. The corrosion- inhibiting composition is preferably applied to the outer conductor of the coaxial cable, e.g., by wiping or by immersion, and heated to provide a corrosion- inhibiting coating that is not tacky or greasy.
Full Text CORROSION-PROTECTED COAXIAL CABLE,
METHOD OF MAKING SAME AND
CORROSION-INHIBITING COMPOSITION
Field of the Invention
The invention relates to a coaxial cable and more particularly, to
corrosion-protected trunk and distribution cable and drop cable for the
transmission of RF signals. This application is being divided out of Indian Patent
application No.IN/PCT/2002/01282.
Background of the Invention
RF signals such as cable television signals, cellular telephone
signals, and even internet and other data signals, are often transmitted through
coaxial cable to a subscriber. In particular, the RF signals are typically transmitted
over long distances using trunk and distribution cable and drop cables are used as
the final link in bringing the signals from the trunk and distribution cable to the
subscriber. Trunk and distribution cable and drop cable both generally include a
center conductor, a dielectric layer, an outer conductor and often a protective
jacket to prevent moisture from entering the cable.
One problem associated With these coaxial cables is that moisture
present in the cable can corrode the conductors thus negatively affecting the
electrical and mechanical properties of the cable. In particular, during installation
of the cable, moisture can enter the cable at the connectors. This moisture can also
travel within the cable through the dielectric layer or along interfaces in the cable,
e.g., between the dielectric layer and the outer conductor.
Several methods have been proposed to prevent moisture from
entering the cable and being transported through the cable. For example,
hydrophobic, adhesive compositions have been applied at interfaces in the cable to

prevent moisture from moving along these interfaces. Flooding or water-blocking
compositions have also been used at other locations in the cable to limit water
transport in the cable. In addition, hydrophilic, moisture-absorbent materials have
been used in cables to act as water-blocking materials. These hydrophilic materials
not only water-block the cable but also remove moisture that is present in the
cable.
Although these materials can provide adequate protection from
moisture and can limit corrosion of the conductors in the cable, these materials
have a tacky or greasy feel and thus are undesirable during the installation and
connectorization of the cable, particularly when located on the outer conductor of
the cable. As a result, these materials generally must be removed or otherwise
addressed during installation and connectorization of the cable. Therefore, there is
a need to provide a corrosion-inhibiting coating for cable that does not possess a
tacky or greasy feel and thus that does not interfere with installation and
connectorization of the cable.
Summary of the Invention
The present invention provides a corrosion-protected cable that
includes a corrosion-inhibiting coating that limits and even prevents the corrosion
of the conductors, and particularly the outer conductor, of the cable. In addition,
the present invention includes a corrosion-inhibiting composition and a method of
applying the corrosion-inhibiting composition to the outer conductor of a cable.
The corrosion-inhibiting composition when heated forms a corrosion-inhibiting
coating on the surface of the outer conductor that is not tacky or greasy and thus is
desirable in the art.
According to one embodiment of the invention, the present
invention includes a coaxial cable, comprising an elongate center conductor, a
dielectric layer surrounding the center conductor, an outer conductor surrounding
the dielectric layer, a corrosion-inhibiting coating on at least an outer portion of the
outer conductor, and preferably a polymer jacket around the outer conductor. The
center conductor is preferably formed of a material selected from the group
consisting of copper, a copper alloy, a copper-clad metal, and a copper alloy-clad

metal. The dielectric layer preferably comprises a foamed polymeric material.
The cable can further include a corrosion-inhibiting layer between the center
conductor and the dielectric layer comprising a benzotriazole compound (e.g.
BTA) and a polymeric compound (e.g. a foamed, low-density polyethylene). The
outer conductor is preferably formed of aluminum or an aluminum alloy but can be
copper or another conductive material. For example, the outer conductor can
include a bonded aluminum-polymer-aluminum laminate tape extending
longitudinally of the cable preferably having overlapping longitudinal edges and
the corrosion-inhibiting composition can be applied to an outer surface of said
laminate tape. The outer conductor can further include a plurality of braided or
helically arranged wires coated with the corrosion-inhibiting composition.
Alternatively, the outer conductor can include a longitudinally-welded sheath and
the corrosion-inhibiting composition can be applied to an outer surface of the
sheath. The corrosion-inhibiting coating comprises a corrosion-inhibiting
compound selected from the group consisting of petroleum sulfonates,
benzotriazoles, alkylbenzotriazoles, benzimidazoles, guanadino benzimidazoles,
phenyl benzimidazoles, tolyltriazoles, metcaptotriazoles, mercaptobenzotriazoles,
and salts thereof. In addition, the corrosion-inhibiting coating can include a
residual amount of an oil dispersant and/or a residual amount of a stabilizer.
In accordance with the invention, the corrosion-inhibiting
composition includes a water-insoluble corrosion-inhibiting compound dispersed
in an oil, and a stabilizer selected from the group consisting of propylene based
glycol ethers, propylene based glycol ether acetates, ethylene based glycol ethers
and ethylene based glycol ether acetates. The stabilizer is preferably selected from
the group consisting of dipropylene glycol methyl ether acetate, propylene glycol
methyl ether, dipropylene glycol methyl ether, tripropylene glycol methyl ether,
propylene glycol t-butyl ether, propylene glycol methyl ether acetate, ethylene
glycol methyl ether, ethylene glycol ethyl ether, ethylene glycol butyl ether,
diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol
butyl ether, ethylene glycol ethyl ether acetate, ethylene glycol butyl ether acetate,
diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate, and
mixtures thereof, and is more preferably a dipropylene glycol ether acetate (e.g.

dipropylene glycol methyl ether acetate). The corrosion-inhibiting compound is
selected from the group consisting of petroleum sulfonates, benzotriazoles,
alkylbenzotriazoles, benzimidazoles, guanadino benzimidazoles, phenyl
benzimidazoles, tolyltriazoles, metcaptotriazoles, mercaptobenzotriazoles, and
salts thereof, and is preferably a petroleum sulfonate salt. The petroleum sulfonate
salt is selected from the group consisting of calcium, barium, magnesium, sodium,
potassium and ammonium salts, and mixtures thereof, and is preferably a calcium
salt having an activity of greater than 0 to about 25% based on the calcium salt.
The calcium salt optionally further includes a salt selected from the group
consisting of barium and sodium salts. The oil is preferably a paraffinic oil such as
a mineral oil that preferably has a molecular weight of less than about 600. The
-corrosion-inhibiting composition preferably includes the corrosion-inhibiting
compound in an amount of from about 5 to about 40% by weight, the oil in an
amount of from about 50 to about 90% by weight, and the stabilizer in an amount
of from about 1 to about 10% by weight. More preferably, the corrosion-inhibiting
composition includes the corrosion-inhibiting compound in an amount of from
about 15 to about 30% by weight, the oil in an amount of from about 60 to about
80% by weight, and the stabilizer in an amount of from about 3 to about 8% by
weight. The corrosion -inhibiting composition preferably also has a viscosity of
from about 50 to about 450 SSU at 100°F. The corrosion-inhibiting composition
can be heated to form the corrosion-inhibiting coating of the invention that is
present on at least a portion of the outer surface of the outer conductor.
The present invention further includes a method of making a coaxial
cable, comprising the steps of advancing a center conductor along a predetermined
path of travel, applying a dielectric layer around the center conductor, applying an
outer conductor around the dielectric layer, and applying the corrosion-inhibiting
composition to the outer conductor. The cable can then be heated to produce the
corrosion-inhibiting coating, e.g., by applying a polymer melt around the outer
conductor to form a protective jacket. The outer conductor can be formed by
directing an aluminum-polymer-aluminum laminate tape around the dielectric
layer and overlapping longitudinal edges of the laminate tape to form the outer
conductor. The outer conductor can also include a plurality of wires formed into a

braid or helically arranged around the laminate tape and the corrosion-inhibiting
composition applied to the wires by wiping the wires with the corrosion-inhibiting
composition. The corrosion-inhibiting composition can also be applied to the outer
conductor by wiping the outer surface of the laminate tape with the corrosion-
inhibiting composition or immersing the cable in the corrosion-inhibiting
composition prior to forming the braid or helically arranging the wires.
Alternatively, the corrosion-inhibiting composition can be applied to the outer
conductor by wiping the outer surface of the outer conductor with the corrosion-
inhibiting composition or immersing the cable in the corrosion-inhibiting
composition after forming the braid or helically arranging the wires. The outer
conductor can also be formed by directing an ahuriinum strip around the dielectric
layer and longitudinally-welding abutting edges of the metal strip, and the
corrosion-inhibiting composition applied to the outer conductor by wiping the
outer surface of the outer conductor with the corrosion-inhibiting composition or
by immersing the cable in the corrosion-inhibiting composition.
These and other features and advantages of the present invention
will become more readily apparent to those skilled in the art upon consideration of
the following detailed description and accompanying drawings, which describe
both the preferred and alternative embodiments of the present invention.
Brief Description of the Drawings
Figure 1 is a perspective view of a coaxial cable according to one
embodiment of the invention that includes a laminate tape and a braid.
Figure 2 is a perspective view of a coaxial cable according to yet
another embodiment of the invention that includes a laminate tape and helically
arranged wires around the laminate tape.
Figure 3 is a perspective view of a coaxial cable according to
another embodiment of the invention that includes a longitudinally-welded outer
sheath.
Figure 4 is a schematic illustration of a method of making a coaxial
cable corresponding to the embodiment of the invention illustrated in Figures 1 and
2.

Figures 5A and 5B schematically illustrate a method of making a
coaxial cable corresponding to the embodiment of the invention illustrated in
Figure 3.
Detailed Description of the Preferred Embodiments
In the drawings and the following detailed description, preferred
embodiments are described in detail to enable practice of the invention. Although
the invention is described with reference to these specific preferred embodiments,
it will be understood that the invention is not limited to these preferred
embodiments. But to the contrary, the invention includes numerous alternatives,
modifications and equivalents as will become apparent from consideration of the
following detailed description and accompanying drawings. In the drawings, like
numbers refer to like elements throughout As used herein, the terms "copper" and
"aluminum" include not only the pure metals but also alloy compositions that
primarily include these metals.
Figure 1 illustrates a corrosion-protected coaxial cable 10 according
to one embodiment of the invention. The cable 10 is of the type typically used as
drop cable providing a link for the transmission of RF signals such as cable
television signals, cellular telephone signals, internet, data and the like, fiom a
trunk and distribution cable to a subscriber. In particular, the cable 10 is of the
type that preferably; has a diameter about 0.24 and 0.41 inches.
As illustrated in Figure 1, the coaxial cable 10 includes an elongate
center conductor 14 of a suitable electrically conductive material and a surrounding
dielectric layer 16. As mentioned above, the center conductor 14 of the cable 10 of
the invention is generally used in the transmission of RF signals. Preferably, the
center conductor 14 is formed of copper, copper-clad steel wire, or copper-clad
aluminum wire but other conductive wires can also be used. The center conductor
is also preferably 20 AWG Wire having a nominal diameter of about 0.032 inches
(0.81 mm).
The dielectric layer 16 can be formed of either a foamed or a solid
dielectric material. Preferably, the dielectric layer 16 is a low loss dielectric

formed of a polymeric material that is suitable for reducing attenuation and
maximizing signal propagation such as polyethylene, polypropylene or
polystyrene. Preferably, the dielectric layer is an expanded cellular foam
composition such as a foamed polyethylene, e.g., a foamed high-density
polyethylene. A solid (unfoamed) polyethylene layer can also be used in place of
the foamed polyethylene or can be applied around the foamed polyethylene. The
dielectric layer 16 is preferably continuous from the center conductor 14 to the
adjacent overlying layer.
In addition to the dielectric layer 16, the cable 10 can include a thin
polymeric layer 18. Preferably, the thin polymeric layer 18 is a corrosion-
inhibiting layer comprising a polymeric material and a corrosion-inhibiting
compound. In the preferred embodiment of the invention wherein the center
conductor 14 is copper wire or a copper-clad wire, the polymeric layer 18 is
preferably low density polyethylene in combination with a small amount of a
benzotriazole compound such as benzotriazole (BTA), benzotriazole salts (e.g.
ammonium benzotriazole), mercaptobenzotriazoles, alkylbenzotriazoles, and the
like. Preferably, the polymeric layer includes from about 0.1 to about 1.0% by
weight of BTA. BTA can be purchased, for example, from PMC Specialties under
the name COBRATEC® 99. Alternatively, the polymeric layer 18 can be an
adhesive composition such as an ethylene-acrylic acid (EAA), ethylene-vinyl
acetate (EVA), or ethylene methylacrylate (EMA) copolymer, or another suitable
adhesive.
As shown in Figure 1, an outer conductor 20 closely surrounds the
dielectric layer 16. The outer conductor 20 advantageously prevents leakage of the
signals being transmitted by the center conductor 14 and interference from outside
signals. The outer conductor 20 preferably includes a laminated shielding tape 22
that extends longitudinally along the cable 10. Preferably, the shielding tape 22 is
longitudinally applied such that the edges of the shielding tape are either in
abutting relationship or are overlapping to provide 100% shielding coverage.
More preferably, the longitudinal edges of the shielding tape 22 are overlapped.
The shielding tape 22 includes at least one conductive layer such as a thin metallic
foil layer. Preferably, the shielding tape is a bonded laminate tape including a

polymer layer 24 with metal layers 26 and 28 bonded to opposite sides of the
polymer layer. The polymer layer 24 is preferably a polyolefin (e.g.
polypropylene) or a polyester film. The metal layers 26 and 28 are preferably thin
aluminum foil layers. To prevent cracking of the aluminum in bending, the
aluminum foil layers 26 and 28 can be formed of an aluminum alloy having
generally the same tensile and elongation properties as the polymer layer 24.
The shielding tape 22 is preferably bonded to the dielectric layer 16
by a thin adhesive layer 30 (e.g., having a thickness of less than 1 mil). More
preferably, the shielding tape 22 includes an adhesive on one surface thereof such
as an ethylene-acrylic acid (EAA), ethylene-vinyl acetate (EVA), or ethylene
methylacrylate (EMA) copolymer to provide the adhesive layer 30 between the
dielectric layer 16 and the shielding tape. Alternatively, however, the adhesive
layer 30 can be provided by other suitable means to the outer surface of the
dielectric layer 16. Preferably, the shielding tape 22 is a bonded aluminum-
polypropylene-aluminum laminate tape with an EAA copolymer adhesive backing.
As shown in Figure 1, the outer conductor 20 preferably further
includes a braid 40 that surrounds the shielding tape 22 and is formed by
interlacing a first plurality of elongate aluminum wires 42 and a second plurality of
elongate aluminum wires 44. Preferably, the braid 40 uses 34 AWG aluminum
braid wires. The braid 40 preferably covers a substantial portion of the shielding
tape 22, e.g., greater than 40% of the shielding tape, and more preferably greater
than 65%, to increase the shielding of the outer conductor 20.
As an alternative to forming a braid 40, a plurality of elongate
aluminum wires 46 can be helically arranged around the underlying laminate tape
22 as shown in Figure 2. A second plurality of elongate aluminum strands (not
shown) can also surround the plurality of elongate wires 46, preferably having an
opposite helical orientation than the elongate wires 46, e.g., a counterclockwise
orientation as opposed to a clockwise orientation. Like the braid wires 42 and 44,
the elongate wires 46 are preferably AWG aluminum braid wire and preferably
cover a substantial portion of the shielding tape 22, e.g., greater than 40% of the
shielding tape, and more preferably greater than 65%, to increase the shielding of
the outer conductor 20.

As shown in Figures 1 and 2, a cable jacket 50 can optionally
surround the outer conductor 22 to further protect the cable from moisture and
other environmental effects. The jacket 50 is preferably formed of a non-
conductive, thermoplastic material such as polyethylene, polyvinyl chloride,
polyurethane and rubbers. Alternatively, low smoke insulation such as a
fluorinated polymer can be used if the cable 10 is to be installed in air plenums
requiring compliance with the requirements of UL910.
Figure 3 illustrates a corrosion-protected cable 60 according to
another embodiment of the invention. The corrosion-protected cable 60 is of the
type typically used for trunk and distribution cable for the long distance
transmission of RF signals such as cable television signals, cellular telephone
signals, internet, data and the like. The cable 60 illustrated in Figure 3 typically is
of the type typically having a diameter of between about 0.3 and about 1.5 inches.
As illustrated in Figure 3, the coaxial cable comprises a center
conductor 61 of a suitable electrically conductive material and a surrounding
dielectric layer 62. The center conductor 61 is preferably formed of copper,
copper-clad aluminum, copper-clad steel, or aluminum. In addition, as illustrated
in Figure 3, the center conductor 61 is typically a solid conductor. Nevertheless,
the center conductor 61 can also be a hollow tube and can further include a
supporting material within the tube as described in coassigned and copending U.S.
Application Serial No. 09/485,656, filed February 14, 2000. In the embodiment
illustrated in Figure 3, only a single center conductor 61 is shown, as this is the
most common arrangement for coaxial cables of the type used for transmitting RF
signals. However, it would be understood by those skilled in the art that the
present invention is also applicable to coaxial cables having more than one
conductor in the center of the cable 60.
A dielectric layer 62 surrounds the center conductor 61. The
dielectric layer 62 is a low loss dielectric formed of a suitable plastic such as
polyethylene, polypropylene or polystyrene. Preferably, to reduce the mass of the
dielectric per unit length and thus the dielectric constant, the dielectric material is
an expanded cellular foam composition, and in particular, a closed cell foam
composition is preferred because of its resistance to moisture transmission. The

dielectric layer 62 is preferably a continuous cylindrical wall of expanded foam
plastic dielectric material and is more preferably a foamed polyethylene, e.g., high-
density polyethylene. As discussed above with respect to Figures 1 and 2, in
addition to the dielectric layer 62, the cable 60 can include a thin polymeric layer
63. Preferably, the thin polymeric layer 63 is a corrosion-inhibiting layer
comprising a polymeric material and a corrosion-inhibiting compound but this
layer can alternatively be an adhesive composition.
Although the dielectric layer 62 of the invention generally consists
of a foam material having a generally uniform density, the dielectric layer 62 may
have a gradient or graduated density such that the density of the dielectric increases
radially from the center conductor 61 to the outside surface of the dielectric layer,
either in a continuous or a step-wise fashion. For example, a foam-solid laminate
dielectric can be used wherein the dielectric 62 comprises a low-density foam
dielectric layer surrounded by a solid dielectric layer. These constructions can be
used to enhance the compressive strength and bending properties of the cable and
permit reduced densities as low as 0.10 g/cc along the center conductor 61. The
lower density of the foam dielectric 62 along the center conductor 61 enhances the
velocity of RF signal propagation and reduces signal attenuation.
Closely surrounding the dielectric layer 62 is an outer conductor 64.
In the embodiment illustrated in Figure 3, the outer conductor 64 is a tubular
metallic sheath. The outer conductor 64 is preferably characterized by being
continuous, both mechanically and electrically, to allow the outer conductor 64 to
mechanically and electrically seal the cable from outside influences as well as to
prevent the leakage of RF radiation. Alternatively, the outer conductor 64 can be
perforated to allow controlled leakage of RF energy for certain specialized
radiating cable applications. The outer conductor 64 is preferably a thin walled
aluminum sheath having a wall thickness selected so as to maintain a T/D ratio
(ratio of wall thickness to outer diameter) of less than 2.5 percent and preferably
less than 1.6 percent. Although the outer conductor 64 can be corrugated, it is
preferably smooth-walled. The smooth-walled construction optimizes the
geometry of the cable to reduce contact resistance and variability of the cable when
connectorized and to eliminate signal leakage at the connector.

In the embodiment illustrated in Figure 3, the outer conductor 64 is
preferably made from an aluminum strip that is formed into a tubular configuration
with the opposing side edges butted together, and with the butted edges
continuously joined by a continuous longitudinal weld, indicated at 65.
Nevertheless, other materials such as a copper strip can be used in place of the
aluminum strip. While production of the outer conductor 64 by longitudinal
welding has been illustrated as preferred for this embodiment, persons skilled in
the art will recognize that other methods for producing a mechanically and
electrically continuous thin walled tubular copper sheath could also be employed
such as overlapping the longitudinal edges of the aluminum strip.
The inner surface of the outer conductor 64 is preferably
continuously bonded throughout its length and throughout its circumferential
extent to the outer surface of the dielectric layer 62 by a thin layer of adhesive 66
(e.g. less than 1 mil) using the adhesive materials discussed above.
As shown in Figure 3, a protective jacket 68 can optionally be
included to surround the outer conductor 64. Suitable compositions for the outer
protective jacket 68 include thermoplastic coating materials such as those
discussed above. Although the jacket 68 illustrated in Figure 3 consists of only
one layer of material, laminated multiple jacket layers may also be employed to
improve toughness, strippability, burn resistance, the reduction of smoke
generation, ultraviolet and weatherability resistance, protection against rodent
gnaw through, strength resistance, chemical resistance and/or cut-through
resistance.
In accordance with the invention, at least an outer portion of the
outer conductor 20 (Figures 1 and 2) and the outer conductor 64 (Figure 3) is
coated with a corrosion-inhibiting coating. The corrosion-inhibiting coating is
coated on the outer conductor in an amount sufficient to protect the outer
conductor from moisture and to prevent corrosion of the outer conductor.
Preferably, the corrosion-inhibiting coating is coated on at least a significant
portion of the outer surface of the outer conductor, e.g., to provide 95% or greater
surface coverage of the outer portion of the outer conductor. The corrosion-
inhibiting coating comprises a corrosion-inhibiting compound and is formed by

heating the corrosion-inhibiting composition discussed below. In addition, the
corrosion-inhibiting coating can include a residual amount of an oil dispersant
and/or a residual amount of a stabilizer. For example, the corrosion-inhibiting
coating preferably includes less than 5% by weight of the oil and less than 5% by
weight of the stabilizer, more preferably less than 2% of each of these components.
The corrosion-inhibiting composition of the invention includes a
corrosion-inhibiting compound dispersed in an oil, and a stabilizer to maintain the
dispersion. The corrosion-inhibiting compound is typically an oil-soluble, water-
insoluble compound and can be selected from the group consisting of petroleum
sulfonates, benzotriazoles, alkylbenzotriazoles, benzimidazoles, guanadino
benzimidazoles, phenyl benzimidazoles, tolyltriazoles, metcaptotriazoles,
mercaptobenzotriazoles, and. salts thereof. Preferably, the corrosion-inhibiting
compound is a petroleum sulfonate salt. The petroleum sulfonate salts of the
invention are preferably produced by partially oxidizing an aliphatic petroleum
fraction to produce oxygenated hydrocarbons. The oxygenated hydrocarbons are
then neutralized with calcium and blended with a minor amount of sodium
petroleum sulfonate and a hydrotreated heavy naphthenic petroleum distillate to
facilitate handling. Alternatively, the petroleum sulfonate salts can be produced by
other known methods such as by reacting sulfuric acid and petroleum distillates to
produce olefinic sulfonic acids, neutralizing the olefinic sulfonic acids using an
alkali metal hydroxide, alkaline earth metal hydroxide or ammonium hydroxide,
removing the sulfonates from the oil by suitable extraction media, and then further
concentrating and purifying the petroleum sulfonate salts. The petroleum sulfonate
salts are typically calcium, barium, magnesium, sodium, potassium, or ammonium
salts, or mixtures thereof. Preferably, the petroleum sulfonate salts are calcium
salts either alone or in combination with barium and/or sodium salts. The
petroleum sulfonate salts preferably have a molecular weight of greater than about
400. In the preferred compositions used with the present invention, the petroleum
sulfonate salts have an activity of greater than 0 to about 25% based on the calcium
salt. Typically, the corrosion-inhibiting composition includes from about 5 to
about 40 percent by weight, preferably from about 15 to about 30 percent by
weight, of the corrosion-inhibiting compound (e.g. the petroleum sulfonate salt).

The corrosion-inhibiting compound is dispersed in an oil in
accordance with the present invention. Preferably, the oil is a paraffinic oil such as
a mineral oil. The paraffinic oil includes long chain aliphatic components and
preferably has a low molecular weight of less than about 600, more preferably, less
than about 500 (e.g. from about 400 to about 500). In addition, the oil can include
a small amount of a hydrotreated heavy naphthenic petroleum distillate as these
distillates are often used to facilitate handling of the corrosion-inhibiting
compound. The oil is present in the corrosion-inhibiting composition in an amount
from about 50 to about 90 percent by weight, more preferably from about 60 to
about 80 percent by weight.
The corrosion-inhibiting composition further includes a stabilizer to
maintain the dispersion between the corrosion-inhibiting compound and the oil. In
particular, the stabilizer is selected from the group consisting of propylene based
glycol ethers, propylene based glycol ether acetates, ethylene based glycol ethers,
and ethylene based glycol ether acetates. For example, dipropylene glycol methyl
ether acetate, propylene glycol methyl ether, dipropylene glycol methyl ether,
tripropylene glycol methyl ether, propylene glycol t-butyl ether, propylene glycol
methyl ether acetate, ethylene glycol methyl ether, ethylene glycol ethyl ether,
ethylene glycol butyl ether, diethylene glycol methyl ether, diethylene glycol ethyl
ether, diethylene glycol butyl ether, ethylene glycol ethyl ether acetate, ethylene
glycol butyl ether acetate, diethylene glycol ethyl ether acetate, diethylene glycol
butyl ether acetate, and mixtures thereof, can be used as stabilizers in the present
invention. Preferably, the stabilizer for use in the invention is a dipropylene glycol
ether acetate and is more preferably dipropylene glycol methyl ether acetate. The
corrosion-inhibiting composition preferably includes from about 1% to about 10%
by weight of the stabilizer, more preferably from about 3 to about 8 percent by
weight of the stabilizer.
The stabilizers mentioned above have.been found to be particularly
useful in the compositions of the invention in preventing the corrosion-inhibiting
compounds, and particularly, the petroleum sulfonate salts, from precipitating out
of the oil. Specifically, the stabilizers allow for larger amounts of the corrosion-
inhibiting compounds (about 15% by weight or greater) to be used in the

corrosion-inhibiting compositions without precipitation of the corrosion-inhibiting
compounds.
For use with the cables of the invention, the corrosion-inhibiting
composition preferably has a viscosity of from about 50 to about 450 SSU at
100°F. A particularly preferred composition for use with the cables of the
invention is a combination of a calcium petroleum sulfonate, mineral oil, and a
dipropylene glycol methyl ether acetate stabilizer. This composition is
commercially available, e.g., from ArroChem Inc. in Mount Holly, North Carolina
as Anti Corrosion Lube 310, which has a flash point > 200°C, a specific gravity of
0.8393, a viscosity of from 290 to 310 SSU at 100°F, and an activity of 10% based
on the calcium salt.
Figure 4 illustrates a preferred method of making the coaxial cable
10 of the invention. As shown in Figure 4, the center conductor 14 is advanced
from a reel 70 along a predetermined path of travel (from left to right in Figure 4).
In order to produce a coaxial cable having a continuous center conductor 14, the
terminal edge of the center conductor from one reel is mated with the initial edge
of the center conductor from a subsequent reel and welded together. It is important
in forming a continuous cable to weld the center conductors from different reels
without adversely affecting the surface characteristics and therefore the electrical
properties of the center conductor 14.
As the center conductor 14 advances, a suitable apparatus 72 such
as an extruder apparatus or a spraying apparatus applies the thin polymeric layer
18. The coated center conductor then further advances to an extruder apparatus 74
that applies a polymer melt composition around the center conductor 14 and
polymeric layer 18. As described above, the polymer melt composition is
preferably a foamable polyethylene composition. Once the coated center
conductor leaves the extruder apparatus 74, the polymer melt composition expands
to form the dielectric layer 16. The center conductor 14, polymeric layer 18 and
dielectric layer 16 form the cable core 76 of the cable 10. Once the cable core 76
leaves the extruder apparatus 74 and is properly cooled, it can then be continuously
advanced through the process shown in Figure 4 or can be collected on a reel
before being further advanced through the process.

As shown in Figure 4, as the cable core 76 advances, a shielding
tape 22 is supplied from a reel 78 and is longitudinally wrapped or "cigarette-
wrapped" around the cable core to form an electrically conductive shield. As
mentioned above, the shielding tape 22 is preferably a bonded metal-polymer-
metal laminate tape having an adhesive on one surface thereof. The shielding tape
22 is applied with the adhesive surface positioned adjacent the underlying cable
core 76. If an adhesive layer is not already included on the shielding tape 22, an
adhesive layer can be applied by suitable means such as extrusion prior to
longitudinally wrapping the shielding tape around the cable core 76. One or more
guiding rolls 80 direct the shielding tape 22 around the cable core 76 with
longitudinal edges of the shielding tape preferably overlapping to provide a
conductive shield having 100% shielding coverage of the cable core.
Once the shielding tape 22 is applied around the cable core 76, the
corrosion-inhibiting composition of the invention can optionally be applied to the
outer surface of the shielding tape by suitable means such as by using felt 81 to
wipe the composition onto the outer surface. Alternatively, other means such as
extruding or spraying the corrosion-inhibiting composition onto the outer surface
of the shielding tape, or immersing the cable in the composition, can be used. As
described below for the cable 10, the corrosion-inhibiting composition of the
invention is preferably applied to the surrounding braided or helically served wires,
and the shielding tape 22 precoated with a corrosion-inhibiting composition.
Shielding tapes precoated with corrosion-inhibiting compositions and suitable for
use in the invention are available, e.g., from Facile Holdings, Inc. in Paterson, NJ.
As mentioned above, in the preferred embodiment of the invention
illustrated in Figure 1, a braid 40 is formed around the shielding tape 22 and
combined with the shielding tape forms the outer conductor 20 of the cable 10. As
shown schematically in Figure 4, the braid 40 is formed by feeding a first plurality
of aluminum wires 42 and a second plurality of aluminum wires 44 from a
plurality of bobbins 82 and interlacing the wires to form the braid. Preferably, the
braid wires 42 and 44 are coated with the corrosion-inhibiting composition of the
invention prior to braiding. Advantageously, the corrosion-inhibiting compound
also acts as a lubricant and thus aids in the braiding of the wires. The corrosion-

inhibiting composition of the invention can be applied to the braid wires 42 and 44
either at wire drawing, spooling or braiding such as by wiping the composition
onto the surface of the braid wires. For example, felts 84 can be used to wipe the
corrosion-inhibiting composition onto the outer surface of the braid wires 42 and
44. Alternatively, the corrosion-inhibiting composition can be applied by spraying
the braid wires 42 and 44 or immersing the braid wires in the composition prior to
braiding, by wiping or spraying the braid with the composition after it is formed, or
by immersing the braided cable in the composition after the braid is formed.
As an alternative to the embodiment of Figure 1, a plurality of
elongate aluminum wires 46 can be helically arranged or "served" around the
shielding tape 22 instead of forming a braid as shown in Figure 2. In this
embodiment, the elongate wires 46 drawn from the bobbins 82 are not interlaced to
form a braid but are instead helically wound around the shielding tape 22. The
elongate wires 46 are preferably coated with the corrosion-inhibiting composition
in the same manner as the braid wires 42 and 44 described above by wiping the
composition onto the wires using, for example, the felts 81, or can be applied by
the other means described above. Although not illustrated in Figure 4, an
additional plurality of bobbins can be used to apply a second plurality of elongate
wires around the first plurality of elongate strands 46, preferably having a helical
orientation opposite that of the first plurality of elongate strands and coated with
the corrosion-inhibiting composition.
Once either the braid 40 has been formed around the shielding tape
22 or the elongate wires 46 helically wound around the shielding tape 22 to form
the outer conductor 20, the cable can be advanced to an extruder apparatus 86 and
a polymer melt extruded at an elevated temperature (e.g. greater than about 250°F)
around the elongate strands to form the cable jacket 50. The heat of the polymer
melt activates the adhesive between the laminate tape 30 to form a bond between
the laminate tape and the underlying dielectric 16. In addition, the heat of the
polymer melt causes the oil and the dispersant in the corrosion-inhibiting
composition to evaporate leaving the corrosion-inhibiting compound behind on the
surface of the outer conductor 20. The cable jacket 50 can then be allowed to cool
and the completed cable 10 taken up on a reel 88 for storage and shipment.

Although a jacket is preferably applied as discussed above, the
cable can be heated to evaporate the oil and dispersant in the corrosion-inhibiting
composition without applying a jacket to the cable. Moreover, although less
preferred, the corrosion-inhibiting composition can be left on the cable without
heating the cable.
Figures 5A and 5B illustrate another method embodiment of the
invention corresponding to cables such as the cable 60 illustrated in Figure 3. As
illustrated in Figure 5A, the center conductor 61 is directed from a suitable supply
source, such as a reel 90. As mentioned above, to provide a coaxial cable having a
continuous center conductor 14, the terminal edge of the center conductor from one
reel is mated with the initial edge of the center conductor from a subsequent reel
and welded together, preferably without adversely affecting the surface
characteristics and therefore the electrical properties of the center conductor.
The center conductor 61 is then preferably advanced to an extruder
apparatus 98 or other suitable apparatus wherein it is coated with a polymeric
material to form the thin polymeric layer 63. The coated center conductor 61 is
then advanced to an extruder apparatus 100 that continuously applies a foamable
polymer composition concentrically around the coated center conductor.
Preferably, high-density polyethylene and low-density polyethylene are combined
wim nucleating agents in the extruder apparatus 100 to form the polymer melt.
Upon leaving the extruder 100, the foamable polymer composition foams and
expands to form a dielectric layer 62 around the center conductor 61.
In addition to the foamable polymer composition, an ethylene
acrylic acid (EAA) adhesive composition or other suitable composition is
preferably coextruded with the foamable polymer composition around the center
conductor to form adhesive layer 66. Extruder apparatus 100 continuously
extrudes the adhesive composition concentrically around the polymer melt to form
an adhesive coated core 102. Although coextrusion of the adhesive composition
with the foamable polymer composition is preferred, other suitable methods such
as spraying, immersion, or extrusion in a separate apparatus can also be used to
apply the adhesive layer 66 to the dielectric layer 62 to form the adhesive coated
core 102.

In order to produce low foam dielectric densities along the center
conductor 61 of the cable 60, the method described above can be altered to provide
a gradient or graduated density dielectric. For example, for a multilayer dielectric
having a low density inner foam layer and a high density foam or solid outer layer,
the polymer compositions forming the layers of the dielectric can be coextruded
together and can further be coextruded with the adhesive composition forming
adhesive layer 66. Alternatively, the dielectric layers can be extruded separately
using successive extruder apparatus. Other suitable methods can also be used. For
example, the temperature of the inner conductor 61 may be elevated to increase the
size and therefore reduce the density of the cells along the inner conductor to form
a dielectric having a radially increasing density.
After leaving the extruder apparatus 100, the adhesive coated core
102 is preferably cooled and then collected on a suitable container, such as reel
110, prior to being advanced to the manufacturing process illustrated in Figure 5B.
Alternatively, the adhesive coated core 102 can be continuously advanced to the
manufacturing process of Figure 5B without being collected on a reel 110.
As illustrated in Figure 5B, the adhesive coated core 102 can be
drawn from reel 110 and further processed to form the coaxial cable 60. A narrow
elongate strip S, preferably formed of aluminum, from a suitable supply source
such as reel 114 is directed around the advancing core 102 and bent into a
generally cylindrical form by guiderolls 116 so as to loosely encircle the core to
form a tubular sheath 64. Opposing longitudinal edges of the strip S can then be
moved into abutting relation and the strip advanced through a welding apparatus
118 that forms a longitudinal weld 65 by joining the abutting edges of the strip S to
form an electrically and mechanically continuous sheath 64 loosely surrounding
the core 102. Alternatively, the strip S can be arranged such that the opposing
longitudinal edges of the strip S overlap to form the electrically and mechanically
continuous sheath 64.
Once the sheath 64 is longitudinally welded, the sheath 64 can be
formed into an oval configuration and weld flash scarfed from the sheath as set
forth in U.S. Patent No. 5,959,245, especially if thin walled sheaths are being
formed. Alternatively, or after the scarfing process, the core 102 and surrounding

sheath 64 can advance directly through at least one sinking die 120 that sinks the
sheath onto the core 102, thereby causing compression of the dielectric 16. A
lubricant is preferably applied to the surface of the sheath 64 as it advances
through the sinking die 120. The cable then advances from the sinking die 120 to a
suitable apparatus for applying the corrosion-inhibiting composition of the
invention to the outer surface of the sheath 64. Preferably, the corrosion-inhibiting
composition is applied to the sheath 64 by wiping the composition onto the sheath,
e.g., by using felt 122 as illustrated in Figure 5B. Alternatively, other means such
as extruding or spraying the corrosion-inhibiting composition onto the outer
surface of the sheath 64, or immersing the thus-formed cable 60 in the composition
can be used.
Once the corrosion-inhibiting composition has been applied to the
sheath 64, the cable can optionally be advanced to an extruder apparatus 124 and a
polymer melt extruded concentrically around the sheath to produce a protective
polymeric jacket 68. If multiple polymer layers are used to form the jacket 68, the
polymer compositions forming the multiple layers may be coextruded together in
surrounding relation to form the protective jacket. Additionally, a longitudinal
tracer stripe of a polymer composition contrasting in color to the protective jacket
68 can be coextruded with the polymer composition forming the jacket for labeling
purposes.
The heat of the polymer melt that produces the jacket 68 activates
the adhesive layer 66 between the sheath 64 and the dielectric layer 62 to form a
bond between the sheath and dielectric layer. In addition, the heat of the polymer
composition causes the oil and dispersant in the corrosion-inhibiting composition
to evaporate leaving the corrosion-inhibiting compound behind on the surface of
the outer conductor 20. Once the protective jacket 68 has been applied, the coaxial
cable is subsequently cooled to harden the jacket. However, as discussed above,
the cable can be heated without applying a jacket or, less preferably, can proceed
without heating. The thus produced cable can then be collected on a suitable
container, such as areel 126 for storage and shipment.
Unlike the flooding compounds and water-blocking compounds of
the prior art, the corrosion-inhibiting coating of the invention do not have a greasy

or sticky feel or texture in the finished cable. In particular, the oil and the
stabilizer in the corrosion-inhibiting composition generally evaporate after the
cable has been heated (e.g. by the application of the cable jacket) in much the same
way that the lubricating oil used in braiding evaporates when heated such that the
outer conductor includes only a residual amount of the oil and/or the stabilizer, if
any. As a result, the outer conductor of the finished cable generally does not
include the oily feel that the corrosion-inhibiting composition has at the time of
application. Thus, unlike prior art corrosion-inhibiting coatings, the corrosion-
inhibiting coating of the invention does not interfere with installation or
connectorization of the cable. As would be understood by those skilled in the art,
this is an important feature of the present invention and provides a real advantage
over prior art corrosion-inhibiting compounds. As would be understood by those
skilled in the art, in constructions that do not use cable jackets, the cable can be
heated in a separate process step to evaporate the oil and provide the corrosion-
protected cables of the invention.
The corrosion-inhibiting compositions of the invention have been
found to be particularly useful with outer conductors formed of aluminum.
Specifically, with respect to aluminum outer conductors, it has been found that the
corrosion-inhibiting compound produces a bond with the aluminum such that it is
well maintained on the surface of the outer conductor.
The corrosion-inhibiting compositions of the invention provide
excellent protection to the outer conductor of the cable, and the cable as a whole.
Although the present invention has been described for use with drop cable and
trunk and distribution cable above, the present invention is not limited to these
embodiments. In particular, the corrosion-inhibiting composition can be used with
any type of cable wherein limiting the corrosion at conductors in the cable is
important. In addition, although the corrosion-inhibiting compositions have been
described for use with the outer conductor of coaxial cables, it would be
understood by those skilled in the art that it could also be applied to the inner
conductors, or could be used with metals in other types of applications to provide
corrosion protection.

It is understood that upon reading the above description of the
present invention and reviewing the accompanying drawings, one skilled in the art
could make changes and variations therefrom. These changes and variations are
included in the spirit and scope of the following appended claims.

WE CLAIM:
1. A coaxial cable (10, 60), comprising:
an elongate center conductor (14, 61);
a dielectric layer (16, 62) surrounding said center conductor (14, 61);
an outer conductor (20, 64) surrounding said dielectric layer wherein the outer
conductor is formed of aluminium or aluminium alloy; and
a corrosion-inhibiting composition on at least an outer portion of said outer
conductor, said corrosion-inhibiting composition comprising a water-insoluble corrosion-
inhibiting compound dispersed in an oil, and a stabilizer selected from the group
consisting of propylene based glycol ethers, propylene based glycol ether acetates, ethy-
lene based glycol ethers and ethylene based glycol ether acetates.
2. A coaxial cable (10, 60) as claimed in claim 1, wherein the water-insoluble corro-
sion-inhibiting compound is selected from the group consisting of petroleum sulfonates,
benzotriazoles, alkylbenzotriazoles, benzimidazoles, guanadino benzimidazoles, phenyl
benzimidazoles, tolyltriazoles, metcaptotriazoles, mercaptobenzotriazoks, and salts
thereof.
3. The coaxial cable (10, 60) as claimed in claim 1 or 2, wherein the corrosion-
inhibiting compound is a petroleum sulfonate salt.
4. The coaxial cable (10, 60) as claimed in claim 3, wherein the petroleum sulfonate
salt is selected from the group consisting of calcium, barium, magnesium, sodium,
potassium and ammonium salts, and mixtures thereof.
5. The coaxial cable (10, 60) as claimed in claim 3, wherein the petroleum sulfonate
salt comprises a calcium salt.

6. The coaxial cable (10, 60) as claimed in claim 5, wherein the petroleum sulfonate
salt has an activity of greater than 0 to 25% based on the calcium salt.
7. The coaxial cable (10, 60) as claimed in claim 5, wherein the petroleum sulfonate
salt is also a salt selected from the group consisting of barium and sodium salts.
8. The coaxial cable (10, 60) as claimed in any of claims 1 to 7, having a corrosion-
inhibiting layer (18, 63) between the center conductor (14, 61) and the dielectric layer
(16, 62) comprising a benzotriazole compound and a polymeric compound.
9. The coaxial cable (10, 60) as claimed in claim 8, wherein said benzotriazole
compound is benzotriazole.
10. The coaxial cable (10, 60) as claimed in claim 8, wherein said polymeric
compound is a foamed, low-density polyethylene.

11. The coaxial cable (10, 60) as claimed in any of claims 1 to 10, wherein said outer
conductor (20) has a bonded aluminium-polymer-aluminium laminate tape (22) extending
longitudinally of the cable.
12. The coaxial cable (10, 60) as claimed in claim 11, wherein said laminate tape (22)
has overlapping longitudinal edges.

13. The coaxial cable (10, 60) as claimed in claim 11, wherein said corrosion-
inhibiting coating (18) is on an outer surface of said laminate tape (22).
14. The coaxial cable (10, 60) as claimed in claim 11, wherein said outer conductor
(20) has a braid (40) surrounding said laminate tape (22) and formed of wires (42) coated
with said corrosion-inhibiting coating.

15. The coaxial cable (10, 60) as claimed in claim 11, having a plurality of wires
helically (46) arranged around said laminate tape (22) and coated with said corrosion-
inhibiting coating.
16. The coaxial cable (10, 60) as claimed in any of claims 1 to 15, wherein said outer
conductor (20, 64) has a longitudinally-welded sheath (64), and said corrosion-inhibiting
coating is on an outer surface of said sheath (64).
17. The coaxial cable (10, 60) as claimed in any of claims 1 to 16, having a polymer
jacket (68) surrounding said outer conductor.
18. The coaxial cable (10, 60) as claimed in any of claims 1 to 17, wherein said
corrosion-inhibiting composition is formed by heating a composition comprising a water-
insoluble corrosion-inhibiting compound dispersed in an oil, and a stabilizer selected
from the group consisting of propylene based glycol ethers, propylene based glycol ether
acetates, ethylene based glycol ethers and ethylene based glycol ether acetates such that a
substantial portion of the oil and the stabilizer evaporate to leave a corrosion-inhibiting
coating comprising said corrosion-inhibiting compound on said outer conductor.
19. A method of making a coaxial cable (10, 60), comprising the steps of:
advancing a center conductor (14, 61) along a predetermined path of travel;
applying a dielectric layer (16, 62) around the center conductor (14, 61);
applying an outer conductor (20, 64) formed of aluminum or aluminium alloy
around the dielectric layer; and
applying a corrosion-inhibiting composition to said outer conductor, said
corrosion-inhibiting composition comprising a water soluble corrosion-inhibiting
compound dispersed in an oil, and a stabilizer selected from the group consisting of
propylene based glycol ethers, propylene based glycol ether acetates, ethylene based
glycol ethers and ethylene based glycol ether acetates.

20. The method as claimed in claim 19, involving the step of heating said cable (10,
60) to evaporate the oil and the stabilizer in the corrosion-inhibiting composition.
21. The method as claimed in claim 20, wherein said heating step comprises applying
a polymer melt at an elevated temperature around the outer conductor (20, 64) to heat
said cable (10, 60).
22. The method as claimed in any of claims 19 to 21, wherein the stabilizer is selected
from the group consisting of dipropylene glycol methyl ether acetate, propylene glycol
methyl ether, dipropylene glycol methyl ether, tripropylene glycol methyl ether, propylene
glycol t-butyl ether, propylene glycol methyl ether acetate, ethylene glycol methyl ether,
ethylene glycol ethyl ether, ethylene glycol butyl ether, diethylene glycol methyl ether, di-
ethylene glycol ethyl ether, diethylene glycol butyl ether, ehtylene glycol ethyl ether ac-
etate, ethylene glycol butyl ether acetate, diethylene glycol ethyl ether acetate, diethylene
glycol butyl ether acetate, and mixtures thereof.
23. The method as claimed in claim 22, wherein the stabilizer is a dipropylene glycol
ether acetate.
24. The method as claimed in claim 22, wherein the stabilizer if dipropylene glycol
methyl ether acetate.

25. The method as claimed in any of claims 19 to 24, wherein the corrosion-
inhibiting compound is selected from the group consisting of petroleum sulfonates,
benzotriazoles, alkylbenzotriazoles, benzimidazoles, guanadino benzimidazoles, phynyl
benzimidazoles, tolyltriazoles, metcaptortriazoles, mercaptobenzotriazoles, and salts
thereof.
26. The method as claimed in claim 25, wherein the corrosion-inhibiting compound is
a petroleum sulfonate salt.

27. The method as claimed in claim 26, wherein the petroleum sulfonate salt is
selected from the group consisting of calcium, barium, magnesium, sodium, potassium
and ammonium salts, and mixtures thereof.
28. The method as claimed in claim 27, wherein the petroleum sulfonate salt
comprises a calcium salt.
29. The method as claimed in claim 28, wherein the petroleum sulfonate salt has an
activity of greater than 0 to 25% based on the calcium salt.
30. The method as claimed in claim 30, wherein the petroleum sulfonate salt is also a
salt selected from the group consisting of barium and sodium salts.
31. The method as claimed in any of claims 19 to 30, wherein the oil is a paraffinic
oil.
32. The method as claimed in claim 31, wherein the paraffinic oil has a molecular
weight of less than 600.

33. The method as claimed in claim 31, wherein the paraffinic oil is a mineral oil.
34. The method as claimed in any of claims 19 to 33, wherein the corrosion-inhibiting
compound is present in an amount of from 5 to 40% by weight, the oil is present in an
amount of from 50 to 90% by weight, and the stabilizer is present in an amount of from 1
to 10% by weight.
35. The method as claimed in any of claims 19 to 34, wherein the corrosion-
inhibiting compound is present in an amount of from 14 to 30% by weight, the oil is
present in an amount of from 60 to 80% by weight, and the stabilizer is present in an
amount of from 3 to 8% by weight.

36. The method as claimed in any of claims 19 to 35, wherein the corrosion-
inhibiting composition has a viscosity of from 7 to 100m2m-1V (50 to 450 SSU) at 37.8°C
(100°F).
37. The method as claimed in any of claims 19 to 36, wherein said step of applying an
outer conductor (20, 64) involves the step of directing an aluminium-polymer-aluminium
laminate tape around the dielectric layer and overlapping longitudinal edges of the lami-
nate tape to form the outer conductor.
38. The method as claimed in any of claims 19 to 37, wherein said step of applying a
corrosion-inhibiting composition to the outer conductor (20, 64) comprises wiping the
outer surface of the outer conductor (20, 64) with the corrosion-inhibiting composition.
39. The method as claimed in any of claims 19 to 37, wherein said step of applying a
corrosion-inhibiting composition to the outer conductor (20, 64) comprises immersing the
cable in the corrosion-inhibiting composition.
40. The method as claimed in any of claims 37 to 39, wherein said step of applying an
outer conductor (20) involves the step of forming wires (46) into a braid (40) around the
laminate tape (22) after said directing step.
41. The method as claimed in claim 40, wherein said step of applying a corrosion-
inhibiting composition to the outer conductor (20) involves the step of applying the
corrosion-inhibiting composition to the wires prior to said forming step.
42. The method as claimed in claim 41, wherein said step of applying the
corrosion-inhibiting composition to the wires comprises wiping the wires (44) with the
corrosion-inhibiting composition (18).

43. The method as claimed in any of claims 37 to 39, wherein said step of applying an
outer conductor (20) involves the step of arranging a plurality of wires (46) helically
around the laminate tape after said directing step.
44. The method as claimed in claim 43, wherein said step of applying a corrosion-
inhibiting composition to the outer conductor involves the step of applying the corrosion-
inhibiting composition to the wires (46) prior to said arranging step.
45. The method as claimed in claim 44, wherein said step of applying the corrosion-
inhibiting composition to the wires (46) comprises wiping the wires (46) with the
corrosion-inhibiting composition.
46. The method as claimed in any of claims 19 to 36, wherein said step of applying an
outer conductor (64) comprises directing an aluminium strip (64) around the dielectric
layer and longitudinally-welding abutting edges of said strip (64) to form the outer
conductor.

The present invention is a corrosion-protected cable, a method of
making a corrosion-inhibiting cable, and a corrosion-inhibiting composition. The
corrosion-inhibiting composition includes a water-insoluble corrosion-inhibiting
compound dispersed in an oil, and a stabilizer selected from the group consisting
of propylene based glycol ethers, propylene based glycol ether acetates, ethylene
based glycol ethers and ethylene based glycol ether acetates. The corrosion-
inhibiting composition is preferably applied to the outer conductor of the coaxial
cable, e.g., by wiping or by immersion, and heated to provide a corrosion-
inhibiting coating that is not tacky or greasy.

Documents:

954-kol-2005-granted-abstract.pdf

954-kol-2005-granted-claims.pdf

954-kol-2005-granted-correspondence.pdf

954-kol-2005-granted-description (complete).pdf

954-kol-2005-granted-examination report.pdf

954-kol-2005-granted-form 1.pdf

954-kol-2005-granted-form 2.pdf

954-kol-2005-granted-form 3.pdf

954-kol-2005-granted-form 5.pdf

954-kol-2005-granted-gpa.pdf

954-kol-2005-granted-reply to examination report.pdf

954-kol-2005-granted-specification.pdf

954-kol-2005-granted-translated copy of priority document.pdf


Patent Number 230171
Indian Patent Application Number 954/KOL/2005
PG Journal Number 09/2009
Publication Date 27-Feb-2009
Grant Date 25-Feb-2009
Date of Filing 18-Oct-2005
Name of Patentee COMMSCOPE, INC.
Applicant Address 1375 LENOIR-RHYNE BLVD., HICKORY, NC
Inventors:
# Inventor's Name Inventor's Address
1 HOUSTON EDDY 1748 FOREST STREET, NEWTON NC 28658
2 MARESCA BENEDICT 222 TIMBERLAND DRIVE, BELMONT NC 28012
PCT International Classification Number D02G 3/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 09/552,903 2000-04-20 U.S.A.