FORM 2
THE PATENT ACT, 1970
(39 OF 1970)
AND
THE PATENT RULES, 2005
COMPLETE SPECIFICATION (See Section 10; Rule 13)
TITLE OF THE INVENTION
“HIGH VOLTAGE HYBRID CABLE WITH POWER CABLES AND OPTICAL FIBER CABLES AND MANUFACTURING METHOD THEREOF”

FIELD OF THE INVENTION
[0001] The present disclosure relates to hybrid cables, and more
particularly to a high voltage hybrid cable together bundled with power cables and optical fiber cables and method of manufacturing thereof.
BACKGROUND OF THE INVENTION
[0002] Optical fiber is increasingly used for a number of application due
to which network operators faces increasing demands of power and data transmission for the conditions use of the optical fiber. Conventional mechanisms, considers power and data transmission separately due to which separate power cables and optical fiber cables are provided. This increases the over cost of the cables as they need to be separately deployed. There is need for smart/ intelligent cable solution to have suitable information and communication technology (ICT) and an appropriate power transmission and distribution infrastructure and therefore power and data transmission should not be considered as separate parts of a telecommunication network.
[0003] Further, multi-fiber cables including a configuration of the
power and optical fiber cables are known but are prone to various challenges due to poor design of the multi-fiber cables. For example, the optical fibers in the multi-fiber cables are prone to quick damage due to bending and load, the configuration of the power and optical fiber cables may uses excessive use of armoring and tapes as well as in efficient use of space in ducts or other routing guides of the cable.
[0004] Hence there remains a need of a high voltage hybrid cable design
that combines power cables with optical fiber cables in a space-efficient manner.

OBJECT OF THE INVENTION
[0005] The principal object of the embodiment herein is to provide a
high voltage hybrid cable. The proposed dens of the high voltage hybrid cable includes power cables and optical fiber cables together rather than separately, which distribution network operators can use as a means of expanding their information network. With the high-voltage hybrid cable, temperature monitoring can also be performed with fiber-optic cables with adequate accuracy.
[0006] Another object of the embodiment herein is to provide a method
for manufacturing the high voltage hybrid cable. The voltage grade and size of power cables and number of fibers in optical fiber cable can be designed as per specific requirement of customers.
SUMMARY OF THE INVENTION
[0007] In one aspect the object is satisfied by providing a high voltage
hybrid cable. The high voltage hybrid cable includes an optical fiber cable, a plurality of high-power cables, an inner sheath disposed around the optical fiber cable and the plurality of high-power cables, an armor layer wires disposed around the inner sheath, a rubberized material disposed around the armor layer, and an outer sheath disposed around the rubberized material. An empty space between the optical fiber cable and the plurality of high-power cables is filled by a polypropylene (PP) filler.
[0008] In an embodiment, each of high-power cable includes a water
tight aluminium conductor, a conductor screen disposed around the water tight aluminium conductor, a crosslinked Polyethylene insulation disposed around the conductor screen, an insulator screen disposed around crosslinked

Polyethylene insulation, a semiconductor water blocking tape disposed around the insulator screen, and a copper tape disposed around the semiconductor water blocking tape. The conductor screen provides conductor screening of extruded semiconductor compound and the insulator screen provides conductor screening of extruded semiconductor compound.
[0009] In an embodiment, the water tight aluminium conductor (9) is a
H2 Grade aluminum phase conductor.
[0010] In an embodiment, the armor layer is made of galvanized flat
steel strip.
[0011] In an embodiment, the inner sheath is an extruded
Polyethylene (PE) ST7 type inner sheath.
[0012] In an embodiment, the outer sheath is an extruded PE ST7 type
outer sheath.
[0013] In an embodiment, each of optical fiber cable includes a
Stranded Cable core strength member made of a Fiberglass-Reinforced Plastic (FRP) material, a plurality of loose tubes SZ stranded cabled around the Stranded Cable core strength member and each of the loose tube comprises a plurality of optical fibers, a polyester tape disposed around the Stranded Cable core Stranded Cable core strength member, a polymer coated ECCS (Electrochrome coated steel) coated ECCS (Electrochrome coated steel) polymer coated ECCS (Electrochrome coated steel) tape disposed around the polyester tape, a sheathing layer disposed around the polymer coated ECCS (Electrochrome coated steel) tape, and one or more ripcords provided the polyester tape and the polymer coated ECCS (Electrochrome coated steel) tape.

[0014] In an embodiment, an empty space between the loose tube and
the optical fibers is filled with a tube jelly.
[0015] In an embodiment, an empty space between the loose tube and
the Stranded Cable core strength member is filled with a core jelly.
[0016] In another aspect the object is satisfied by providing a method
of manufacturing a high voltage hybrid cable. The method includes providing an optical fiber cable, providing a plurality of high-power cables, filling an empty space between the optical fiber cable and the plurality of high-power cables by a polypropylene (PP) filler, applying an inner sheath around the optical fiber cable and the plurality of high-power cables, applying an armor layer wires around the inner sheath, applying a rubberized material around the armor layer, and applying an outer sheath around the rubberized material.
[0017] In an embodiment, the method includes manufacturing each of
the high-power cable by providing a water tight aluminium conductor, providing a conductor screen around the water tight aluminium conductor, providing a crosslinked Polyethylene insulation around the conductor screen, providing an insulator screen around the crosslinked Polyethylene insulation, providing a semiconductor water blocking tape around the insulator screen, and providing a copper tape around the semiconductor water blocking tape.
[0018] In an embodiment, the method includes manufacturing each of
high-power cable by providing a Stranded Cable core strength member made of a FRP material, providing a plurality of loose tubes SZ stranded cabled around the Stranded Cable core strength member in which each of the loose tube comprises a plurality of optical fibers, applying a polyester tape around

the Stranded Cable core strength member, applying a polymer coated ECCS (Electrochrome coated steel) tape around the polyester tape, applying a sheathing layer around the polymer coated ECCS (Electrochrome coated steel) tape, providing one or more ripcords on the polyester tape and the polymer coated ECCS (Electrochrome coated steel) tape.
[0019] In an embodiment, the method includes filling an empty space
between the loose tube and the optical fibers with a tube jelly.
[0020] In an embodiment, the method includes filling an empty space
between the loose tube and the Stranded Cable core strength member with a core jelly.
[0021] These and other aspects of the embodiment herein will be better
appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiment herein without departing from the spirit thereof, and the embodiment herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0022] The proposed high voltage hybrid cable and manufacturing
method are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiment herein will be better understood from the following description with reference to the drawings, in which:

[0023] FIG. 1 illustrates a cross section view of a high voltage hybrid
cable, according to embodiment as disclosed herein;
[0024] FIG. 2 illustrates a cross section view of an optical fiber cable of
the high voltage hybrid cable, according to embodiment as disclosed herein; and
[0025] FIG. 3 illustrates a method of manufacturing the high voltage
hybrid cable, according to embodiment as disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The embodiment herein and the various features and
advantageous details thereof are explained more fully with reference to the non-limiting embodiment that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiment herein. Also, the various embodiment described herein are not necessarily mutually exclusive, as some embodiment can be combined with one or more other embodiment to form new embodiment. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiment herein can be practiced and to further enable those skilled in the art to practice the embodiment herein. Accordingly, the examples should not be construed as limiting the scope of the embodiment herein.
[0027] The accompanying drawings are used to help easily understand
various technical features and it should be understood that the embodiment presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out

in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
[0028] Referring now to the drawings, and more particularly to FIGS. 1-
3, there are shown preferred embodiment.
[0029] FIG. 1 illustrates a cross section view of a high voltage hybrid
cable (1), according to embodiment as disclosed herein. The high voltage hybrid cable (1) includes an optical fiber cable (2) together bundled with a plurality of high-power cables (3). An empty space between the optical fiber cable (2) and the plurality of high-power cables (3) is filled by a polypropylene (PP) filler (4). Each of the high-power cable are arranged in around the optical fiber cable (2).
[0030] Further, the high voltage hybrid cable (1) includes an inner
sheath (5) disposed around the optical fiber cable (2) and the plurality of high-power cables (3), an armor layer (6) wires disposed around the inner sheath (5), a rubberized material (7) disposed around the armor layer (6) and an outer sheath (8) disposed around the rubberized material (7).
[0031] In an embodiment, the inner sheath (5) is an extruded
Polyethylene (PE) ST7 type inner sheath (5), the armor layer (6) is made of galvanized flat steel strip, and the outer sheath is an extruded PE ST7 type outer sheath.
[0032] In an embodiment, the each of high-power cable (3) includes a
water tight aluminium conductor (9), a conductor screen (10) disposed around the water tight aluminium conductor (9), a crosslinked Polyethylene

insulation (11) disposed around the conductor screen, an insulator screen (12) disposed around the crosslinked Polyethylene insulation (11), a semiconductor water blocking tape (13) disposed around the insulator screen, and a copper tape (14) disposed around the semiconductor water blocking tape (13).
[0033] In an embodiment, the conductor screen (10) provides
conductor screening of extruded semiconductor compound and the insulator screen (12) provides conductor screening of extruded semiconductor compound, and the water tight aluminium conductor (9) is a H2 grade aluminum phase conductor.
[0034] Unlike the conventional hybrid cable design, the proposed
design of the high voltage hybrid cable (1) is constructed by developing the optical fibre cables (2) integrated with the power cables (3) for high voltage distribution network. The network operators can use the proposed the high voltage hybrid cable (1) as a means of expanding their information network. With the proposed the high voltage hybrid cable (1), temperature monitoring can also be performed with fibre-optic cables with adequate accuracy.
[0035] FIG. 2 illustrates a cross section view of the optical fiber cable
(2) of the high voltage hybrid cable (1), according to embodiment as disclosed herein. Each of the optical fiber cable (2) includes a Stranded Cable core strength member (15), a plurality of loose tubes (16), a polyester tape (18), a polymer coated ECCS (Electrochrome coated steel) tape (19), a sheathing layer (20), and one or more ripcords (21).
[0036] The Stranded Cable core strength member (15) is made of a
Fiberglass-Reinforced Plastic (FRP) material.

[0037] The plurality of loose tubes (16) is SZ stranded cabled around
the Stranded Cable core strength member (15). Each of the loose tube (16) includes a plurality of optical fibers (17) or ribbon fibers, all made of thermoplastics such as Polybutylene Terephthalate (PBT). An empty space between the loose tube (16) and the Stranded Cable core strength member
(15) is filled with a core jelly (22). The core jelly is used to prevent water
ingress.
[0038] Further, an empty space between the loose tube (16) and the
optical fibers (17) is filled with a tube jelly (23), which allows fiber movement in the tube and blocks water to contact the optical fibers (17).
[0039] The polyester tape (18) disposed around the Stranded Cable
core strength member (15) to protect the core jelly (22) from spreading out of the Stranded Cable core strength member (15). In an embodiment, the polyester tape (18) is wrapped by using the two binders, to make loose tubes
(16) intact over the Stranded Cable core strength member (15).
[0040] The polymer coated ECCS (Electrochrome coated steel) tape
(19) is disposed around the polyester tape (18) to protect the polyester tape (18). In an embodiment, the polymer coated ECCS (Electrochrome coated steel) tape (19) is wrapped by using the two binders, to make loose tubes (16) intact over the Stranded Cable core strength member (15).
[0041] The sheathing layer (20) is disposed around the polymer coated
ECCS (Electrochrome coated steel) tape (19), which is having better dielectric constant.
[0042] The one or more ripcords (21) is provided the polyester tape
(18) and the polymer coated ECCS (Electrochrome coated steel) tape (19). The

ripcords (21) are placed diagonally opposite to each other for easy tearing of sheath material.
[0043] A voltage grade and a size of power cables (3) and number of
fibers (17) in the optical fiber cable (2) can be designed as per specific requirement of customers.
[0044] Fiber optic joint closure is meant for storage and protection of
spliced fiber optic cable.
[0045] While copper cable can be directly connected, the fiber optic
individual fibers (17) are very fragile and need to fuse together with the connecting fiber to prevent signal losses and provide long distance transmission. In-order to provide a secured environment for these splices, fiber optic joint closure is used.
[0046] All points of closure are sealed properly after maintenance at
cable entry as well as clamping points.
[0047] For the power cable (3), a triple extruded heat shrinkable
straight through jointing kit and terminations are used.
[0048] FIG. 3 illustrates a method of manufacturing the high voltage
hybrid cable (1), according to embodiment as disclosed herein. At step S1, the method includes providing an optical fiber cable (2). In an embodiment, the optical fiber cable (2) is made by providing a Stranded Cable core strength member (15) made of a Fiberglass-Reinforced Plastic (FRP) material, providing a plurality of loose tubes (16) SZ stranded cabled around the Stranded Cable core strength member (15), filling an empty space between the loose tube (16) and the Stranded Cable core strength member (15) with a core

jelly (22), filling an empty space between the loose tube (16) and the optical fibers with a tube jelly (23), applying a polyester tape (18) around the Stranded Cable core strength member (15), applying a polymer coated ECCS (Electrochrome coated steel) tape (19) around the polyester tape (18), applying a sheathing layer (20) around the polymer coated ECCS (Electrochrome coated steel) tape (19), providing one or more ripcords (21) on the polyester tape (18) and the polymer coated ECCS (Electrochrome coated steel) tape (19).
[0049] At step S2, the method includes providing a plurality of high-
power cables (3). In an embodiment, the high-power cables (3) is made by providing a water tight aluminium conductor (9), providing a conductor screen (10) around the water tight aluminium conductor (9) for conductor screening of extruded semiconductor compound, providing a crosslinked Polyethylene insulation (11) around the conductor screen, providing an insulator screen (12) around the crosslinked Polyethylene insulation (11) for conductor screening of extruded semiconductor compound, providing a semiconductor water blocking tape (13) around the insulator screen, and providing a copper tape (14) around the semiconductor water blocking tape (13). In an embodiment, the water tight aluminium conductor (9) is a H2 grade aluminum phase conductor.
[0050] At step S3, the method includes filling an empty space between
the optical fiber cable (2) and the plurality of high-power cables (3) by a polypropylene (PP) filler. The PP filler is to maintain the circularity of the cable.
[0051] At step S4, the method includes applying an inner sheath (5)
around the optical fiber cable (2) and the plurality of high-power cables (3). In an embodiment, the inner sheath (5) is an extruded Polyethylene (PE) ST7

type inner sheath (5). The inner sheath protects the laid up cores and provide bedding for the armouring.
[0052] At step S5, the method includes applying an armor layer (6)
wires around the inner sheath (5). In an embodiment, the armor layer (6) is made of galvanized flat steel strip. Armouring is used to protect the internal components of the cable from extreme temperature, abrasion, mechanical stress etc.
[0053] At step S6, the method includes applying a rubberized material
(7) around the armor layer (6). The rubberized material protect outer sheath from damage due to armouring during twisting of cable.
[0054] At step S7, the method includes applying an outer sheath around
the rubberized material (7). In an embodiment, the outer sheath is an extruded PE ST7 type outer sheath and it provides mechanical, thermal, chemical and environmental protection to the cable.
[0055] One of the advantages of the proposed design of the high voltage
hybrid cable (1) is that a complete system can be laid in one process and parallel laying of the power cables (3) and the optical fibre cables (2) is no longer necessary. The proposed high voltage hybrid cable (1) also has advantage of cable laying in narrow routes where power and communication cables cannot be laid in parallel.
[0056] The proposed high voltage hybrid cable (1) also provides a
scope to energy suppliers and network operators to expand their ICT system that will pay off later in networking of industrial clients, fibre to the home (FTTH) or leasing of spare fibres to telecommunication providers.

[0057] The proposed high voltage hybrid cable (1) also has a cost
benefit regarding civil works to lay the power cables (3) and the optical fibre cables (2) together rather than separately. Also, maintenance of these cables (2) and (3) can be dedicated to one party thus reducing the cost of separately maintaining power and optical fibre cables.
[0058] The foregoing description of the specific embodiment will so
fully reveal the general nature of the embodiment herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiment without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiment. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiment herein have been described in terms of preferred embodiment, those skilled in the art will recognize that the embodiment herein can be practiced with modification within the spirit and scope of the embodiment as described herein.

[0001] List to reference numerals:

Sr. No. Description
1 high voltage hybrid cable
2 optical fiber cable
3 high-power cable
4 polypropylene (PP) filler
5 inner sheath
6 armor layer
7 rubberized material
8 outer sheath
9 water tight aluminium conductor
10 conductor screen
11 crosslinked Polyethylene insulation
12 insulator screen
13 semiconductor water blocking tape
14 copper tape
15 Stranded Cable core strength member
16 loose tubes
17 optical fibers
18 polyester tape
19 polymer coated ECCS (Electrochrome coated steel) tape
20 sheathing layer
21 ripcords
22 core jelly
23 tube jelly

We Claim:
1. A high voltage hybrid cable (1) comprising:
an optical fiber cable (2);
a plurality of high-power cables (3), wherein an empty space between the optical fiber cable (2) and the plurality of high-power cables (3) is filled by a polypropylene (PP) filler (4);
an inner sheath (5) disposed around the optical fiber cable (2) and the plurality of high-power cables (3);
an armor layer (6) wires disposed around the inner sheath (5);
a rubberized material (7) disposed around the armor layer (6); and
an outer sheath (8) disposed around the rubberized material (7).
2. The high voltage hybrid cable (1) as claimed in claim 1, wherein each of
high-power cable (3) comprises:
a water tight aluminium conductor (9);
a conductor screen (10) disposed around the water tight aluminium conductor (9), wherein the conductor screen (10) provides conductor screening of extruded semiconductor compound;
a crosslinked Polyethylene insulation (11) disposed around the conductor screen;
an insulator screen (12) disposed around the crosslinked Polyethylene insulation (11), wherein the insulator screen (12) provides conductor screening of extruded semiconductor compound;
a semiconductor water blocking tape (13) disposed around the insulator screen; and
a copper tape (14) disposed around the semiconductor water blocking tape (13).

3. The high voltage hybrid cable (1) as claimed in claim 2, wherein the water tight aluminium conductor (9) is a H2 grade aluminum phase conductor.
4. The high voltage hybrid cable (1) as claimed in claim 1, wherein the armor layer (6) is made of galvanized flat steel strip.
5. The high voltage hybrid cable (1) as claimed in claim 1, wherein the inner sheath (5) is an extruded Polyethylene (PE) ST7 type inner sheath (5).
6. The high voltage hybrid cable (1) as claimed in claim 1, wherein the outer sheath is an extruded PE ST7 type outer sheath.
7. The high voltage hybrid cable (1) as claimed in claim 1, wherein each of the optical fiber cable (2) comprises:
a Stranded Cable core strength member (15) made of a Fiberglass-Reinforced Plastic (FRP) material;
a plurality of loose tubes (16) SZ stranded cabled around the Stranded Cable core strength member (15), wherein each of the loose tube (16) comprises a plurality of optical fibers (17);
a polyester tape (18) disposed around the Stranded Cable core strength member (15);
a polymer coated ECCS (Electrochrome coated steel) tape (19) disposed around the polyester tape (18);
a sheathing layer (20) disposed around the polymer coated ECCS (Electrochrome coated steel) tape (19); and
one or more ripcords (21) provided the polyester tape (18) and the polymer coated ECCS (Electrochrome coated steel) tape (19).

8. The high voltage hybrid cable (1) as claimed in claim 7, wherein an empty space between the loose tube (16) and the optical fibers (17) is filled with a tube jelly (23).
9. The high voltage hybrid cable (1) as claimed in claim 7, wherein an empty space between the loose tube (16) and the Stranded Cable core strength member (15) is filled with a core jelly (22).
10. A method of manufacturing a high voltage hybrid cable (1), wherein the
method comprising:
providing an optical fiber cable (2);
providing a plurality of high-power cables (3);
filling an empty space between the optical fiber cable (2) and the plurality of high-power cables (3) by a polypropylene (PP) filler;
applying an inner sheath (5) around the optical fiber cable (2) and the plurality of high-power cables (3);
applying an armor layer (6) wires around the inner sheath (5);
applying a rubberized material (7) around the armor layer (6); and
applying an outer sheath around the rubberized material (7).
11. The method as claimed in claim 10, wherein the method comprises
manufacturing each of the high-power cable (3), wherein the
manufacturing comprises:
providing a water tight aluminium conductor (9);
providing a conductor screen (10) around the water tight aluminium conductor (9), wherein the conductor screen (10) provides conductor screening of extruded semiconductor compound;
providing a crosslinked Polyethylene insulation (11) around the conductor screen;

providing an insulator screen (12) around the crosslinked Polyethylene insulation (11), wherein the insulator screen (12) provides conductor screening of extruded semiconductor compound;
providing a semiconductor water blocking tape (13) around the insulator screen; and
providing a copper tape (14) around the semiconductor water blocking tape (13).
12. The method as claimed in claim 11, wherein the water tight aluminium conductor (9) is a H2 grade aluminum phase conductor.
13. The method as claimed in claim 10, wherein the armor layer (6) is made of galvanized flat steel strip.
14. The method as claimed in claim 10, wherein the inner sheath (5) is an extruded Polyethylene (PE) ST7 type inner sheath (5).
15. The method as claimed in claim 10, wherein the outer sheath is an extruded PE ST7 type outer sheath.
16. The method as claimed in claim 10, the method comprises manufacturing each of optical fibers (17), wherein the manufacturing comprising:
providing a Stranded Cable core strength member (15) made of a Fiberglass-Reinforced Plastic (FRP) material;
providing a plurality of loose tubes (16) SZ stranded cabled around the Stranded Cable core strength member (15), wherein each of the loose tube (16) comprises a plurality of optical fibers (17);
applying a polyester tape (18) around the Stranded Cable core strength member (15);

applying a polymer coated ECCS (Electrochrome coated steel) tape (19) around the polyester tape (18);
applying a sheathing layer (20) around the polymer coated ECCS (Electrochrome coated steel) tape (19);
providing one or more ripcords (21) on the polyester tape (18) and the polymer coated ECCS (Electrochrome coated steel) tape (19).
17. The method as claimed in claim 16, wherein the method comprises filling an empty space between the loose tube (16) and the optical fibers with a tube jelly (23).
18. The method as claimed in claim 16, wherein the method comprises filling an empty space between the loose tube (16) and the Stranded Cable core strength member (15) with a core jelly (22).