Granted Patent B2

US 6,972,378 · App. 11/101,303 · Granted Dec 6, 2005

Abstract

Claims (84)

1. A method for manufacturing an insulator comprising the steps of:

a) providing a body that includes an axis, contains a fiber and a polymer, encloses a cavity, and includes a first end and a second end;

b) providing the first end of the body with a first outer diameter;

c) providing the second end of the body with a second outer diameter;

d) providing a first connector for assembly onto the body that includes a first connector axis and that has been cast and machined to provide an anchoring surface that is generally cylindrically shaped about the first connector axis;

e) providing a second connector for assembly onto the body that includes a second connector axis and that has been cast and machined to provide an anchoring surface that is generally cylindrically shaped about the second connector axis;

f) dimensioning the anchoring surface on the first connector so that the anchoring surface includes a first diameter that is smaller, at least before assembly onto the body, than the first outer diameter;

g) dimensioning the anchoring surface on the second connector so that the anchoring surface includes a second diameter that is smaller, at least before assembly onto the body, than the second outer diameter;

h) assembling the connectors onto the body so that, after assembly, the connectors and the body are generally coaxial;

i) providing a housing defining element that has been previously shaped to form at least one shed with shield layer portions one each side;

j) arranging the body and the housing defining element in relation to each other so that a distance exists between the body and the housing defining element that corresponds to a cylindrical thickness of a shield layer;

k) ejecting rubber into the housing defining element so that the rubber forms a housing comprising the shield layer and at least one shed; and

1 ) molding, at least in part, the shield layer portions simultaneously on each side of the shed.

2. The method for manufacturing an insulator according to claim 1 , wherein the anchoring surface of at least one of the connector includes a ridged shaped surface.

3. The method for manufacturing an insulator according to claim 1 , wherein the diameter on the anchoring surface of at least one of the connectors has been machined so that, after assembly onto the body, the diameter of the anchoring surface is smaller than the first diameter and the second diameter.

4. The method for manufacturing an insulator according to claim 1 , further comprising the step of ejecting the rubber immediately onto the body so that the rubber flows onto the body.

5. The method for manufacturing an insulator according to claim 1 , further comprising the step of ejecting the rubber so that the rubber substantially fills the distance between the housing defining element and the body.

6. The method for manufacturing an insulator according to claim 1 , wherein a portion of the housing contacting the body is dimensioned according to the location of the housing defining element.

7. The method for manufacturing an insulator according to claim 1 , wherein the rubber is ejected onto the body at a distance from an outer surface of die body that is substantially the same as the cylindrical thickness of the housing.

8. A method for manufacturing an insulator comprising the steps of:

a) providing a body that includes an axis, contains a fiber and a polymer, encloses a cavity, and includes a first end and a second end;

b) providing the first end of the body with a first diameter;

c) providing the second end of the body with a second diameter;

d) providing a connector for assembly onto the body that includes a connector axis and that has been cast and machined to provide a generally cylindrically shaped anchoring surface that includes, at least before assembly onto the body, a diameter that is smaller than the first diameter and the second diameter;

e) assembling the connector onto the body so that, during assembly, the diameter of the anchoring surface is smaller than the first diameter and the second diameter of the body and the connector and the body are generally coaxial;

f) providing a housing defining element that has been previously shaped to form at least one shed;

g) arranging the body and die housing defining element in relation to each other so as to provide a volume between the body and the housing defining element that corresponds to a cylindrical thickness of a shield layer;

h) ejecting rubber into the housing defining element so that the rubber substantially fills the volume between the body and the housing defining element thereby forming a housing that includes the shield layer and at lease one shed; and

i) housing the body and at least a portion of the anchoring surface within the housing.

9. The method for manufacturing an insulator according to claim 8 , wherein the anchoring surface of the connector includes a ridged shaped surface.

10. The method for manufacturing an insulator according to claim 8 , wherein the diameter on the anchoring surface has been machined so that, after assembly onto the body, the diameter of the anchoring surface is smaller than the first diameter and the second diameter.

11. The method for manufacturing an insulator according to claim 8 , further comprising the step of ejecting the rubber immediately onto the body so that the rubber flows onto the body.

12. The method for manufacturing an insulator according to claim 8 , wherein a portion of the housing contacting the body is dimensioned according to the location of the housing defining element.

13. The method for manufacturing an insulator according to claim 8 , wherein the rubber is ejected onto the body at a distance from an outer surface of the body that is substantially the same as the cylindrical thickness of the housing.

14. A method for manufacturing an insulator comprising the steps of:

a) providing a body that includes an axis, contains a fiber and a polymer, encloses a cavity, and includes a first end and a second end;

b) providing the first end of the body with a first outer diameter;

c) providing the second end of the body with a second outer diameter;

d) providing a first connector for assembly onto the body that includes a first connector axis and that has been cast and machined to provide a generally cylindrically shaped anchoring surface that includes a first diameter that, at least before assembly onto the body, is smaller than the first outer diameter of the body;

e) providing a second connector for assembly onto the body that includes an second connector axis and that has been cast and machined to provide a generally cylindrically shaped anchoring surface that includes a second diameter that, at least before assembly onto the body, is smaller than the second outer diameter of the body;

f) assembling the first connector onto the first end of the body so that, during assembly, the first diameter of the anchoring surface is smaller than the first outer diameter of the first end of the body and so that the first connector and the body are generally coaxial;

g) assembling the second connector onto the second end of the body so that, during assembly, the second diameter of the anchoring surface is smaller than the second outer diameter of the second end of the body and so that the second connector and the body are generally coaxial;

h) providing a housing defining element that has been previously shaped to form at least one shed with shield layer portions one each side;

i) arranging the body and the housing defining element in relation to each other so as to provide volume between the body and the housing defining element that corresponds to a cylindrical thickness of a shield layer;

j) ejecting rubber into the housing defining element so that the rubber forms a housing comprising the shield layer and at least one shed;

k) molding, at least in part, the shield layer portions simultaneously on each side of the shed; and

l) housing the body and at least a portion of the anchoring surfaces within the housing.

15. The method of manufacturing an insulator according to claim 14 , further comprising the steps of:

a) assembling the first connector onto the body so that the first diameter of the anchoring surface is smaller, after assembly, than the first outer diameter of the first end of the body; and

b) assembling the second connector onto the body so that the second diameter of the anchoring surface is smaller, after assembly, than the second outer diameter of the second end of the body.

16. The method for manufacturing an insulator according to claim 14 , further comprising the steps of ejecting the rubber immediately onto the body so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

17. The method for manufacturing an insulator according to claim 16 , further comprising the step of ejecting the rubber onto the body at a distance from an outer surface of the body that is substantially the same as the cylindrical thickness of the housing.

18. The method for manufacturing an insulator according to claim 14 , further comprising the step of providing the first and second connectors, wherein the anchoring surface of at least one of the connectors includes a ridged shaped surface.

19. The method for manufacturing an insulator according to claim 14 , further comprising the steps of:

a) providing the first connector, wherein the anchoring surface includes a ridged shaped surface;

b) providing the second connector, wherein the anchoring surface includes a ridged shaped surface;

c) assembling the first connector onto the body so that the first diameter of the anchoring surface is smaller, after assembly, than the first outer diameter of the first end of the body;

d) assembling the second connector onto the body so that the second diameter of the anchoring surface is smaller, after assembly, than the second outer diameter of the second end of the body; and

e) ejecting the rubber immediately onto the body so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

20. The method for manufacturing an insulator according to claim 14 , further comprising the steps of:

a) assembling the first connector onto the body so that the first diameter of the anchoring surface is smaller, after assembly, than the first outer diameter of the first end of the body;

b) assembling the second connector onto the body so that the second diameter of the anchoring surface is smaller, after assembly, than the second outer diameter of the second end of the body; and

c) ejecting the rubber onto the body at a distance from the body that is substantially the same as the cylindrical thickness of the housing so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

21. A method for manufacturing an insulator comprising the steps of:

a) providing a body that includes an axis, contains a fiber and a polymer, encloses a cavity, and includes a first end and a second end;

b) providing the first end of the body with a first diameter;

c) providing the second end of the body with a second diameter;

d) providing a connector for assembly onto the body that includes a connector axis and that has been cast and machined to provide an anchoring surface that is generally cylindrically shaped about the connector axis;

e) dimensioning the anchoring surface so that the anchoring surface includes a diameter that is smaller, during assembly onto the body, than the first diameter and the second diameter;

f) assembling the connector onto the body so that, after assembly, the connector and the body are generally coaxial;

g) providing a housing defining element that has been previously shaped to form at least one shed;

h) arranging the body and the housing defining element in relation to each other so that a distance exists between the body and the housing defining element that corresponds to a cylindrical thickness of a shield layer; and

i) ejecting rubber into the housing defining element so that the rubber forms a housing comprising the shield layer and at least one shed.

22. The method of manufacturing an insulator according to claim 21 , further comprising the step of assembling the connector onto the body so that the diameter of the anchoring surface is smaller, after assembly, than the first diameter of the first end of the body.

23. The method for manufacturing an insulator according to claim 21 , further comprising the steps of ejecting the rubber immediately onto the body so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

24. The method for manufacturing an insulator according to claim 21 , further comprising the step of ejecting the rubber onto the body at a distance from an outer surface of the body that is substantially the same as the cylindrical thickness of the housing.

25. The method for manufacturing an insulator according to claim 21 , further comprising the step of providing the connector, wherein the anchoring surface of the connector includes a ridged shaped surface.

26. The method for manufacturing an insulator according to claim 21 , further comprising the steps of:

a) providing the connector, wherein the anchoring surface includes a ridged shaped surface;

b) assembling the connector onto the body so that the diameter of the anchoring surface is smaller, after assembly, than the first diameter of the first end of the body; and

c) ejecting the rubber immediately onto the body so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

27. The method for manufacturing an insulator according to claim 21 , further comprising the steps of:

a) assembling the connector onto the body so that the diameter of the anchoring surface is smaller, after assembly, than the first diameter of the first end of the body;

b) ejecting the rubber onto the body at a distance from the body that is substantially the same as the cylindrical thickness of the housing so that the rubber flows onto the body and substantially fills the volume between the housing defining element and the body.

Assignments (8)