(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2013/0248240A1
`Sep. 26, 2013
`(43) Pub. Date:
`Glew et al.
`
`US 20130248240A1
`
`COMPOSITIONS, METHODS, AND DEVICES
`PROVIDING SHIELDING IN
`COMMUNICATIONS CABLES
`
`Applicant: CABLE COMPONENTS GROUP,
`LLC, Pawcatuck, CT (US)
`Inventors: Charles A. Glew, Charlestown, RI (US);
`David Braun, North Attleborough, MA
`(US)
`Appl. No.: 13/795,808
`Filed:
`Mar 12, 2013
`Related U.S. Application Data
`Provisional application No. 61/610,211, filed on Mar.
`13, 2012.
`
`Publication Classification
`
`Int. C.
`H05K 9/00
`U.S. C.
`CPC .................................... H05K 9/0098 (2013.01)
`USPC .......................................................... 174/388
`
`(2006.01)
`
`ABSTRACT
`
`(51)
`
`(52)
`
`(57)
`
`Compositions, devices, and methods for providing shielding
`communications cables are provided. In some embodiments,
`compositions including electrically conductive elements are
`disclosed. In other embodiments, cable separators, tapes, and
`nonwoven materials including various electrically conduc
`tive elements are disclosed.
`
`(54)
`
`(71)
`
`(72)
`
`(21)
`(22)
`
`(60)
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 1 of 16
`
`US 2013/0248240 A1
`
`
`
`FIG. 1
`
`FIG. 2A
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 1 of 16
`
`US 2013/0248240 Al
`
`FIG. 1
`
`m
`
`40B
`
`y*
`
`
`
`
`
`
`
`
`
`
`
`FIG. 2A
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 2 of 16
`
`US 2013/0248240 A1
`
`y
`
`30
`
`!
`
`.
`
`.
`
`. . . . .
`
`.
`
`. . . . .
`
`. . .
`
`.
`
`. . . .
`
`. . .750
`
`20
`
`FIG. 2B
`
`say
`
`FIG. 3A
`
`FIG. 3B
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 3 of 16
`
`US 2013/0248240 A1
`
`
`
`FIG. 4
`
`FIG. 5
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 3 of 16
`
`US 2013/0248240 Al
`
`Vaw
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`FIG. 4
`
`may
`
`84C
`
`5
`
`.
`
`ion
`
`10 Veo
`
`LA
`
`
`
`
`
`84D
`
`
`
`ve |
`
`°
`
`| Sr
`
`wo
`
`FIG. 5
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 4 of 16
`
`US 2013/0248240 A1
`
`/ 6 OO
`
`FIG. 6A
`
`FIG. 6B
`
`
`
`STEP 1:
`MELT POLYMER PELLETS
`NWHICHAPLURALITY OF
`METAL INCLUSIONS ARE
`NCORPORATED
`
`STEP2:
`EXTRUDEMOLTENPELLETS
`TO FORMAN ARTICLE,
`E.G., ASEPARATOR
`
`FIG. 7
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 5 of 16
`
`US 2013/0248240 A1
`
`98
`
`100
`
`FIG. 8A
`
`
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 5 of 16
`
`US 2013/0248240 Al
`
`
`
`+—— 100
`
`98>
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 6 of 16
`
`US 2013/0248240 A1
`
`101
`
`102
`
`\to
`
`FIG. 9
`
`
`
`FIG 1 OA
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 6 of 16
`
`US 2013/0248240 Al
`
`HL 192
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`FIG. 10A
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 7 of 16
`
`US 2013/0248240 A1
`
`
`
`FIG. OD
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 7 of 16
`
`US 2013/0248240 Al
`
`
`
`
`
`FIG. 10D
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 8 of 16
`
`US 2013/0248240 A1
`
`
`
`
`
`FIG. 1 OE
`
`FIG. 1 OF
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 8 of 16
`
`US 2013/0248240 Al
`
`
`
`FIG. 10E
`
`
`
`FIG. 10F
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 9 of 16
`
`US 2013/0248240 A1
`
`
`
`
`
`373
`371
`
`FIG. 1 OH
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 9 of 16
`
`US 2013/0248240 Al
`
`
`
`FIG. 10G
`
`
`
`0
`
`v
`
`22
`90
`
`OS
`
`O0.59,5,5,
`
`C069
`
`
`
`
`
`$000 gar
`
`
`
`
`
`
`
`
`
`FIG. 10H
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 10 of 16
`
`US 2013/0248240 A1
`
`FIG. 11
`
`
`
`STEP 1
`MELT POLYMER PELLETS
`NWHICH A PLURALITY OF
`METAL INCLUSIONS ARE
`INCORPORATED
`
`STEP2:
`EXTRUDEMOLTEN PELLETS
`TOFORMAN ARTICLE,
`E.G., ATAPE
`
`FIG. 12
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 11 of 16
`
`US 2013/0248240 A1
`
`FIG 13A
`
`
`
`FIG. 13B
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 11 of 16
`
`US 2013/0248240 Al
`
`
`
`13
`
`
`
`—_
`
`
`
`
`AU
`iy
`
`
`
`
`
`
`ir,
`
`il
`
`\__
`
`115
`
`117
`
`FIG. 13A
`
`
`
`19
`
`
`
`—_/
`
`
`
`
`
`
`
`
`
`
`FIG. 13B
`
`
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 12 of 16
`
`US 2013/0248240 A1
`
`
`
`4
`
`135
`
`IT I I III
`IT I
`IT
`133
`
`V
`
`Z a
`
`
`
`
`
`FIG. 13C
`
`
`
`FIG 13D
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 12 of 16
`
`US 2013/0248240 Al
`
`
`
`
`
`
`
`
`
`
`
` | il TOES
`
`L aa
` |
`135/
`133
`137
`
`
`
`FIG. 13C
`
`
`
`
`
`
`
`
`
`
` 1477 1434
`
`
`
`
`
`FIG. 13D
`
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 13 of 16
`
`US 2013/0248240 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`FIG. 14
`
`FIG. 15A
`
`161
`
`Patent Application Publication
`
`Sep. 26, 2013
`
`Sheet 13 of 16
`
`US 2013/0248240 Al
`
`/
`
`LA
`vies
`
`va _
`
`\
`
`FIG. 14
`
`167
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`169
`
`
`
`
`FIG. 15A
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 14 of 16
`
`US 2013/0248240 A1
`
`FIG. 15B
`
`
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 14 of 16
`
`US 2013/0248240 Al
`
`
`
`FIG. 15B
`
`132
`
`
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 15 of 16
`
`US 2013/0248240 A1
`
`
`
`FIG. 17A
`
`148
`/7
`- 1/e a . . . . . . . . . . .
`
`.
`
`.
`
`. .
`
`.
`
`144
`
`142
`
`FIG. 17B
`
`

`

`Patent Application Publication
`
`Sep. 26, 2013 Sheet 16 of 16
`
`US 2013/0248240 A1
`
`156
`
`
`
`158
`
`FIG. 18A
`
`FIG. 18B
`
`Patent Application Publication
`
`Sep. 26,2013 Sheet 16 of 16
`
`US 2013/0248240 Al
`
`156
`
`FIG. 18A
`
`158
`
`FIG. 18B
`
`

`

`US 2013/0248240A1
`
`Sep. 26, 2013
`
`COMPOSITIONS, METHODS, AND DEVICES
`PROVIDING SHIELDING IN
`COMMUNICATIONS CABLES
`
`RELATED APPLICATIONS
`0001. This application claims priority to U.S. Provisional
`Application Ser. No. 61/610,211 filed on Mar. 13, 2012, the
`content of which is hereby incorporated by reference in its
`entirety.
`
`FIELD OF THE INVENTION
`0002 This invention relates generally to compositions,
`methods, and devices for providing shielding of communica
`tions cables.
`
`BACKGROUND OF THE INVENTION
`0003. Abroad range of electrical conductors and electrical
`cables are installed in modern buildings for a wide variety of
`uses. Such uses include, among others, data transmission
`between computers, Voice communications, video communi
`cations, power transmission over communications cables,
`e.g. power over Ethernet, as well as control signal transmis
`sion for building security, fire alarm, and temperature control
`systems. These cable networks extend throughout modern
`office and industrial buildings, and frequently extend through
`the space between the dropped ceiling and the floor above.
`Ventilation system components are also frequently extended
`through this space for directing heated and chilled air to the
`space below the ceiling and also to direct return air exchange.
`The horizontal space between the dropped ceiling and the
`floor above is commonly referred to as the "plenum area.
`Similarly, the vertical space of the walls between the floor and
`the ceiling include the networking of the aforementioned
`cable types. These vertical spaces are generally called the
`“riser cabling space. Electrical conductors and cables
`extending through plenum areas are governed by special pro
`visions of the National Electric Code (“NEC). Cables
`intended for installation in the air handling spaces (e.g., ple
`nums, risers, ducts, etc.) of buildings are specifically required
`by NEC/CEC/IEC to pass flame test specified by Underwrit
`ers Laboratories Inc. (UL), UL-910, or its Canadian Stan
`dards Association (CSA) equivalent, the FT-6. The UL-910,
`FT-6 and the NFPA 262, which represent the top of the fire
`rating hierarchy established by the NEC and CEC, respec
`tively. Also applicable are the UL 1666 Riser test and the IEC
`60332-3C and D flammability criteria. Cables possessing
`these ratings, generally known as "plenum' or "plenum
`rated or “riser' or “riser rated, may be substituted for cables
`having a lower rating (e.g., CMRCMCMX, FT4, FTI or their
`equivalents), while lower rated cables may not be used where
`plenum or riser rated cables are required.
`0004. Many communication systems utilize high perfor
`mance cables. These high performance cables normally have
`four or more twisted pairs of conductors for transmitting data
`and receiving data. A transmitting twisted pair and a receiving
`twisted pair often form a Subgroup in a cable having four
`twisted pairs. Other high performance cables can include
`coaxial cables, e.g., used singly or in conjunction with twisted
`pairs as a composite cable.
`0005. In a conventional cable, each twisted pair of con
`ductors has a specified distance between twists along the
`longitudinal direction. That distance is referred to as the pair
`lay. When adjacent twisted pairs have the same pair lay and/or
`
`twist direction, they tend to lie within a cable more closely
`spaced than when they have different pair lays and/or twist
`directions. Such close spacing increases the amount of unde
`sirable energy transferred between conductors, which is com
`monly referred to as cross-talk. Undesirable energy may also
`be transferred between adjacent cables (which is known as
`alien crosstalk) or alien near-end cross talk (anext) or alien
`far-end cross talk (afext).
`0006. The Telecommunications Industry Association and
`Electronics Industry Association (TIA/EIA) have defined
`standards for crosstalk, including TIA/EIA-568 A, B, and C
`including the most recent edition of the specification. The
`International Electrotechnical Commission (IEC) has also
`defined standards for data communication cable cross-talk,
`including ISO/IEC 11801. One high-performance standard
`for 100 MHz cable is ISO/IEC 11801, Category 5, or more
`recently referred to as Category 5e. Additionally, more strin
`gent standards have been implemented for higher frequency
`cables including Category 6, augmented Category 6 (Cat
`egory 6), Category 7, augmented Category 7 (Category 7A)
`which are rated for frequencies in the range of 1 MHz through
`1 GHZ.
`0007. There remains a need for communications cables
`that can operate reliably while minimizing or eliminating
`cross-talk between conductors within a cable or alien cross
`talk between cables, and also a need for separators for use in
`Such telecommunications cables. There also remains a need
`for communications cables that can provide low Smoke gen
`eration and overall flame retardancy, as required by the
`“NEC for use in plenum and riser areas of a building.
`
`SUMMARY OF THE INVENTION
`0008. In one aspect, a pellet composition is disclosed,
`which includes a base resin comprising a polymer and a
`plurality of electrically conductive elements distributed
`within the base resin. The polymer can be, for example, a
`fluoropolymer, a polyolefin, or combinations thereof. At least
`some of the electrically conductive elements can beformed at
`least partially of a metal.
`0009. In this embodiment and in other embodiments dis
`closed herein, the electrically conductive elements can com
`prise any of metal, metal oxide, or other electrically conduc
`tive materials, such as carbon nanotubes, carbon fullerenes,
`carbon fibers, nickel coated carbon fibers, single or multi
`wall graphene, or copper fibers, among others. By way of
`example, in Some embodiments, the electrically conductive
`inclusions include any of silver, aluminum, copper, gold,
`bronze, tin, Zinc, iron, nickel, indium, gallium, or stainless
`steel. In some embodiments, the electrically conductive
`inclusions can include metal alloys, Suchastinalloys, gallium
`alloys, or zinc alloys. In other embodiments, the electrically
`conductive inclusions can include metal oxides, such as cop
`per oxide, bronze oxide, tin oxide, Zinc oxide, zinc-doped
`indium oxide, indium tin oxide, nickel oxide, or aluminum
`oxide. In some embodiments, some of the electrically con
`ductive inclusions are formed of one material while others are
`formed of another material. Further, in some embodiments,
`the electrically conductive inclusion are formed of metals and
`are substantially free of any metal oxides.
`0010. In some embodiments, the at least one base polymer,
`e.g., fluoropolymer, polyolefin, or combinations thereof, in
`the pellet composition comprises at least about 50% by
`weight of the pellet composition, at least about 60% by
`weight of the pellet composition, at least about 70% by
`
`

`

`US 2013/0248240A1
`
`Sep. 26, 2013
`
`weight of the pellet composition, at least about 75% by
`weight of the pellet composition, at least about 80% by
`weight of the pellet composition, at least about 85% by
`weight of the pellet composition, at least about 90% by
`weight of the pellet composition, or at least about 95% by
`weight of the pellet composition.
`0011. In some embodiments, a weight ratio of the conduc
`tive elements to the one or more fluoropolymers or polyole
`fins can be in a range of about 1% to about 30%. In some
`embodiments the electrically conductive elements comprise
`at least about 5% by weight of the pellet composition, at least
`about 7% by weight of the pellet composition, at least about
`10% by weight of the pellet composition, at least about 15%
`by weight of the pellet composition, at least about 20% by
`weight of the pellet composition, or at least about 25% by
`weight of the pellet composition.
`0012. In some embodiments, the electrically conductive
`elements can also have a plurality of different shapes. For
`example, a first plurality of the conductive elements can have
`needle-like shapes and a second plurality of the conductive
`elements can have flake-like shapes (e.g., rectangular
`shapes).
`0013. In some embodiments, the at least one base polymer,
`e.g., fluoropolymer, polyolefin, or combinations thereof, can
`be melt-processable at an elevated temperature. For example,
`the at least one base fluoropolymer can be melt-processable at
`an elevated temperature of at least about 600°F.
`0014. In some embodiments, the at least one base polymer
`can be a polyolefin or a fluoropolymer. The fluoropolymer
`can be a perfluoropolymer, for example, a perfluoropolymer
`having a melting temperature at least about 600 F. For
`example, the perfluoropolymer can be any of FEP (fluori
`nated ethylene propylene), MFA (polytetrafluoroethylene
`perfluoromethylvinylether) and PFA (perfluoroalkoxy).
`0.015. In some embodiments, at least some of the conduc
`tive elements can be formed of a metal. In some embodi
`ments, the metal can include, without limitation, any of silver,
`aluminum, copper, gold, bronze, tin, Zinc, iron, nickel,
`indium, gallium, and stainless steel. In some embodiments, at
`least some of the conductive elements can be formed of a
`metal oxide. In some embodiments, the metal oxide can
`include, without limitation, any of copper oxide, bronze
`oxide, tin oxide, Zinc oxide, zinc-doped indium oxide, indium
`tin oxide, nickel oxide, and aluminum oxide.
`0016. In some embodiments, the conductive elements can
`include a plurality of metallic particles having an average
`particle size in a range of about 10 microns to about 6000
`microns. For example, the conductive elements can include a
`plurality of fibrils.
`0017. In another aspect, a foamable composition is dis
`closed, which comprises at least one base fluoropolymer or
`polyolefin, a plurality of electrically conductive elements
`distributed within the at least one base fluoropolymer or poly
`olefin, and a chemical foaming agent distributed within the at
`least one base fluoropolymer or polyolefin. In some embodi
`ments, at least a portion of the electrically conductive ele
`ments is formed of a metal. In some embodiments, the elec
`trically conductive elements have a plurality of different
`shapes. For example, a first plurality of the conductive ele
`ments have needle-like shapes and a second plurality of the
`conductive elements have flake-like shapes, e.g., rectangular
`shapes. In some embodiments, a first plurality of the conduc
`tive elements have a shape primarily configured to reflect
`electromagnetic radiation in a range of about 1 MHZ to about
`
`40 GHz. In some embodiments, a second plurality of the
`conductive elements have a shape primarily configured to
`dissipate electromagnetic radiation in range of about 1 MHZ
`to about 40 GHz.
`0018. In some embodiments of the above foamable com
`position having a chemical foaming agent, the at least one
`base fluoropolymer or polyolefin comprises at least about
`50% by weight, or at least about 60% by weight, or at least
`about 70% by weight, or at least about 75% by weight, or at
`least about 80% by weight, or at least about 85% by weight,
`or at least about 90% by weight, or at least about 95% by
`weight of the foamable composition. In some embodiments,
`the electrically conductive elements comprise at least about
`5% by weight, or at least about 7% by weight, or at least about
`10% by weight, or at least about 15% by weight, or at least
`about 20% by weight, or at least about 25% by weight of the
`foamable composition.
`0019. In some embodiments, in the above foamable com
`position, the at least one base polymer can be a polyolefin or
`a fluoropolymer. By way of example, the fluoropolymer can
`include a perfluoropolymer, e.g., FEP, MFA and PFA. In some
`embodiments, the foamable composition can include a per
`fluoropolymer that is melt-processable at an elevated tem
`perature, e.g., at an elevated temperature of at least about 600°
`F
`0020. In some embodiments, the chemical foaming agent
`comprises at least about 2% by weight of the foamable com
`position. In some embodiments, the chemical foaming agent
`comprises at least about 3%, or at least about 4%, or at least
`about 5%, or at least about 10%, or at least about 15% by
`weight of the foamable composition.
`0021. In some embodiments, wherein the chemical foam
`ing agent comprises talc.
`0022. In some embodiments, in the above foamable com
`position having a chemical foaming agent, a weight ratio of
`the conductive elements to the at least one base fluoropolymer
`or polyolefin is in a range of about 1 percent to about 30
`percent, e.g., in a range of about 1 percent to about 20 percent,
`or in a range of about 1 percent to about 10 percent.
`0023. In a related aspect, a separator for use in a telecom
`munications cable is disclosed, which comprises a plurality of
`polymeric fibers assembled as a non-woven fabric, and a
`plurality of electrically conductive elements distributed
`within the non-woven fabric. In some embodiments, the elec
`trically conductive elements comprise at least about 5% by
`weight, or at least about 7% by weight, or at least about 10%
`by weight, or at least about 15% by weight, or at least about
`20% by weight, or by at least about 25% by weight of the
`separator.
`0024. In some embodiments, the polymeric fibers are
`formed of a fluoropolymer, polyolefin, or combinations
`thereof. In some embodiments, the fluoropolymer can com
`prise a perfluoropolymer. In some embodiments, the perfluo
`ropolymer has a melting temperature of at least about 600°F.
`By way of example, the perfluoropolymer comprises any of
`FEP, MFA and PFA.
`0025. In some embodiments, the electrically conductive
`elements comprise a plurality of fibrils. In some embodi
`ments, the fibrils include a metal. In some embodiments, the
`metal comprises any of silver, aluminum, copper, gold,
`bronze, tin, Zinc, iron, nickel, indium, gallium, and stainless
`steel. In some embodiments, the fibrils include a metal oxide.
`In some embodiments, the metal oxide comprises any of
`
`

`

`US 2013/0248240A1
`
`Sep. 26, 2013
`
`copper oxide, bronze oxide, tin oxide, Zinc oxide, zinc-doped
`indium oxide, indium tin oxide, nickel oxide, and aluminum
`oxide.
`0026. In some embodiments, the separator includes elec
`trically conductive elements having a plurality of different
`shapes. For example, a first plurality of the conductive ele
`ments can have a needle-like shape and a second plurality of
`the conductive elements can have a flake-like shape. In some
`embodiments, the separator includes a first plurality of con
`ductive elements having a shape configured to primarily
`reflect electromagnetic radiation in a range of about 1 MHz to
`about 40 GHz and a second plurality of conductive elements
`having a shape configured to primarily dissipate electromag
`netic radiation in a range of about 1 MHz to about 40 GHz.
`0027. In some embodiments, the conductive elements
`comprise a plurality of particles having an average size in a
`range of about 10 microns to about 6000 microns, e.g., in a
`range of about 10 microns to about 50 microns, or in a range
`of about 50 microns to about 500 microns, or in a range of
`about 500 microns to about 1000 microns.
`0028. In some embodiments, the above separator exhibits
`a DC conductivity along an axial direction in a range of about
`1x10 Siemens/meter to about 3.5x10" Siemens/meter. In
`some embodiments, the above separator exhibits a sheet
`resistance in a range of about 1x10 ohms per square to about
`1x10 ohms per square.
`0029 Communications Cable
`0030. In further aspects, a communications cable is dis
`closed, which comprises at least a pair of insulated twisted
`conductors, and a non-woven tape wrapped around the
`twisted pair of conductors, wherein the non-woven tape com
`prises a polymer and a plurality of electrically conductive
`elements distributed therein for electromagnetically shield
`ing the twisted pair. The polymer can be, for example, a
`fluoropolymer, a polyolefin, or combinations thereof.
`0031. In some embodiments, the non-woven tape is not
`adapted to be electrically grounded. In some embodiments,
`the non-woven tape comprises a plurality of polymeric fibers.
`In some embodiments, the non-woven tape exhibits a DC
`electrical conductivity along an axial direction in a range of
`about 1x10 Siemens/meter to about 3.5x107 Siemens/meter.
`In some embodiments, the non-woven tape exhibits a sheet
`resistance in a range of about 1x10 ohms per square to about
`1x10 ohms per square.
`0032. In some embodiments, at least a portion of the elec
`trically conductive elements is formed of a metal. The metal
`can include, without limitation, any of silver, aluminum, cop
`per, gold, bronze, tin, Zinc, iron, nickel, indium, gallium, and
`stainless steel.
`0033. In some embodiments, at least a portion of the elec
`trically conductive elements is formed of a metal oxide. The
`metal oxide can include, without limitation, any of copper
`oxide, bronze oxide, tin oxide, Zinc oxide, zinc-doped indium
`oxide, indium tin oxide, nickel oxide, and aluminum oxide.
`0034. In some embodiments, the non-woven tape includes
`electrically conductive elements having a plurality of differ
`ent shapes. For example, a first plurality of the conductive
`elements can have a needle-like shape and a second plurality
`of the conductive elements can have a flake-like shape. In
`Some embodiments, the non-woven tape includes a first plu
`rality of conductive elements have a shape configured to
`primarily reflect electromagnetic radiation in a range of about
`1 MHz to about 40 GHz and a second plurality of conductive
`
`elements having a shape configured to primarily dissipate
`electromagnetic radiation in a range of about 1 MHZ to about
`40 GHZ.
`0035. In some embodiments, the communications cable is
`an unshielded cable. In some other embodiments, the cable is
`a shielded cable.
`0036. In some embodiments, the communications cable
`further comprises a jacket that at least partially surrounds the
`non-woven tape and the twisted pair of conductors. In some
`embodiments, the jacket can provide shielding of the electro
`magnetic radiation. By way of example, the jacket can pro
`vide shielding of the electromagnetic radiation at wave
`lengths in a range of about 1 MHz to about 40 GHz.
`0037 Cable Jacket
`0038. In further aspects, a jacket for a cable is disclosed,
`which comprises a polymeric shell extending from a proxi
`mal end to a distal end and adapted for housing one or more
`conductors, and an electrically conductive layer that is
`embedded in the polymeric shell. In some embodiments, the
`electrically conductive layer is adapted to provide electro
`magnetic shielding of the one or more conductors.
`0039. In some embodiments, the conductors housed
`within the polymeric shell are adapted for transmitting digital
`data.
`0040. In some embodiments, the electrically conductive
`layer embedded in the polymeric shell is formed of a metal. In
`Some embodiments, the metal includes, without limitation,
`any of silver, aluminum, copper, gold, bronze, tin, Zinc, iron,
`nickel, indium, gallium, and stainless steel.
`0041. In some embodiments, the electrically conductive
`layer comprises a continuous layer. In some embodiments,
`the electrically conductive layer comprises a checkered layer.
`0042. In some embodiments, the polymeric shell com
`prises a polymer. The polymer can be, for example, a fluo
`ropolymer, a polyolefin, or combinations thereof. By way of
`example, the fluoropolymer can be a perfluoropolymer, Such
`as FEP, MFA or PFA.
`0043. In further aspects, a jacket for a cable is disclosed,
`which comprises a polymeric shell extending from a proxi
`mal end to a distal end and adapted for housing one or more
`conductors, and a plurality of electrically conductive ele
`ments distributed within the shell. In some embodiments, the
`electrically conductive elements have a plurality of different
`shapes, e.g., some of them can have a needle-like shape and
`some of the others a flake-like shape.
`0044 Separators with Conductive Element
`0045. In further aspects, a separator for use in a telecom
`munication cable is disclosed, which comprises a polymeric
`preformed elongate Support element extending from a proxi
`mal end to a distal end and having at least one channel adapted
`for receiving a plurality of conductors, wherein the elongate
`Support element comprises at least one base polymer and a
`plurality of electrically conductive elements distributed in the
`at least one fluoropolymer. The polymer can be, for example,
`a fluoropolymer, a polyolefin, or combinations thereof.
`0046. In some embodiments, at least some of the electri
`cally conductive elements are formed at least partially of a
`metal. In some embodiments, the electrically conductive ele
`ments have a plurality of different shapes. For example, in
`some embodiments, a first plurality of the conductive ele
`ments have needle-like shapes and a second plurality of the
`conductive elements have flake-like shapes (e.g., rectangular
`shapes). In some embodiments, a first plurality of the con
`ductive elements have a shape primarily configured to reflect
`
`

`

`US 2013/0248240A1
`
`Sep. 26, 2013
`
`electromagnetic radiation in a range of about 1 MHZ to about
`40 GHz and a second plurality of the conductive elements
`have a shape primarily configured to dissipate electromag
`netic radiation in a range of about 1 MHz to about 40 GHz.
`0047. In some embodiments, the separator exhibits a DC
`electrical conductivity along an axial direction in a range of
`about 1x10 Siemens/meter to about 3.5x10 Siemens/meter.
`In some embodiments, the separator exhibits a sheet resis
`tance in a range of about 1x10 ohms per square to about
`1x10 ohms per square.
`0048. In some embodiments, a weight ratio of the conduc
`tive elements to the one or more polymers in the above sepa
`rator is in a range of about 1 percent to about 30 percent.
`0049. In some embodiments, the at least one base polymer,
`e.g., fluoropolymer, polyolefin, or combinations thereof,
`comprises at least about 50% by weight, or at least about 60%
`by weight, or at least about 60%, or at least about 70%, or at
`least about 75%, or at least about 80%, or at least about 85%,
`or at least about 90%, or at least about 95% of the separator.
`0050. In some embodiments, the electrically conductive
`elements comprise at least about 5% by weight, or at least
`about 7% by weight, or at least about 10% by weight, or at
`least about 15% by weight, or at least about 20% by weight,
`or at least about 25% by weight of the separator.
`0051. In further aspect, a separator for use in a cable is
`disclosed, which comprises a polymeric structure axially
`extending from a proximal end to a distal end and configured
`to provide at least two channels each of which is adapted for
`receiving one or more conductors. An electrically conductive
`element is embedded in the polymeric structure to provide
`shielding between conductors disposed in the at least two
`channels.
`0052. In further aspects, a separator for use in a cable is
`disclosed, which comprises a polymeric structure axially
`extending from a proximal end to a distal end and configured
`to provide at least two channels each of which is adapted for
`receiving one or more conductors, and an electrically conduc
`tive layer formed on at least a portion of an outer surface of the
`polymeric structure. In some embodiments, the electrically
`conductive layer is formed by a process of electroless plating.
`In some embodiments, the electrically conductive layer com
`prises a continuous layer while in other embodiments, the
`electrically conductive layer comprises a checkered layer.
`0053. Further understanding of various aspects of the
`invention can be achieved by reference to the following
`detailed description in conjunction with the associated draw
`1ngS.
`
`BRIEF DESCRIPTION OF DRAWINGS
`0054 FIG. 1 schematically depicts a plurality of pellets
`according to an embodiment of the invention;
`0055 FIG. 2A schematically depicts a separator accord
`ing to an embodiment of the invention;
`0056 FIG. 2B schematically depicts a cross-sectional
`view of the separator of FIG. 2A taken along line A-A:
`0057 FIG. 3A schematically depicts a needle-like con
`ductive inclusion having an elongated shape Suitable for use
`in some implementations of the separator of FIGS. 2A and
`2B:
`0058 FIG. 3B schematically depicts a flake-like conduc
`tive inclusion having a pancake-like shape Suitable for use in
`some implementations of the separator of FIGS. 2A and 2B:
`0059 FIG. 4 schematically shows a method for measuring
`electrical conductivity of a separator according to the teach
`
`ings of the invention in which a plurality of electrically con
`ductive inclusions are incorporated;
`0060 FIG. 5 schematically depicts a separator and a plu
`rality of conductors disposed in longitudinal channels pro
`vided by the separator;
`0061
`FIG. 6A schematically depicts an unshielded cable
`in accordance with an embodiment of the invention;
`0062 FIG. 6B schematically depicts an unshielded cable
`in accordance with an embodiment of the invention;
`0063 FIG. 7 is a flow chart of an exemplary method of
`manufacturing a cellular article, such as a separator, accord
`ing to an embodiment of the invention;
`0064 FIG. 8A schematically depicts a separator having a
`metal coating disposed on an external Surface thereof accord
`ing to an embodiment of the invention;
`0065 FIG. 8B schematically depicts a separator having a
`patchwork of metal portions disposed on an external Surface
`thereof according to an embodiment of the invention;
`0.066
`FIG. 9 schematically depicts a separator having an
`electrically conductive Strip disposed therein according to an
`embodiment of the invention;
`0067 FIG. 10A schematically depicts a cross-sectional
`end view of a separator having T-shaped flap portions accord
`ing to an embodiment of the invention;
`0068 FIG. 10B schematically depicts a cross-sectional
`end view of a separator having flap portions when the flaps are
`open according to an embodiment of the invention;
`0069 FIG. 10C schematically depicts a cross-sectional
`end view of a separator having flap portions when the flaps are
`closed according to an embodiment of the invention;
`(0070 FIG. 10D is an enlarged detail of a portion of the
`separator depicted in FIG. 10B according to an embodiment
`of the invention;
`0071
`FIG. 10E schematically depicts a cross-sectional
`end view of a separator having open channels according to an
`embodiment of the invention;
`0072 FIG. 10F schematically depicts a cross-sectional
`end view of a separator having Substantially closed channels
`according to an embodiment of the invention;
`0073 FIG. 10G schematically depicts a cross-sectional
`end view of a separator having offset arms according to an
`embodiment of the invention;
`0074 FIG. 11 schematically depicts a tape including a
`plurality of conductive inclusions according to an embodi
`ment of the inventio