(12) United States Patent
`Clark et al.
`
`USOO6570095B2
`(10) Patent No.:
`US 6,570,095 B2
`(45) Date of Patent:
`*May 27, 2003
`
`(54) MULTI-PAIR DATA CABLE WITH
`CONFIGURABLE CORE FILLING AND PAIR
`SEPARATION
`
`DE
`FR
`
`4,487.992 A 12/1984 Tomita
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`(75) Inventors: William Clark, Lancaster, MA (US);
`697 378 C 12/1940
`Joseph Delagala, Shrewsbury, MA
`694 100 A 11/1930
`(US); Kenneth Consalvo, Leominster,
`OTHER PUBLICATIONS
`MA (US)
`C&M Corporation, “Engineering Design Guide', 1992, p.
`(73) ASSignee: Cable Design Technologies, Inc.,
`11.*
`Leominster, MA (US)
`Subject to any disclaimer, the term of this CM Corporation, the "Engineering Design Guide,” d'-
`patent is extended or adjusted under 35
`edition, p. 11.
`U.S.C. 154(b) by O dayS.
`* cited by examiner
`
`(*) Notice:
`
`66 - - - - - -
`
`:1, s2 1rd
`
`This patent is Subject to a terminal dis-
`claimer.
`
`Primary Examiner-Chau N. Nguyen
`(74) Attorney, Agent, or Firm Wolf, Greenfield & Sacks,
`P.C.
`(57)
`
`ABSTRACT
`
`21 Ap1. No.: 09.1853,512
`(21) Appl. No.: 09/853,
`(22) Filed:
`May 11, 2001
`(65)
`Prior Publication Data
`US 2002/0050394A1 May 2, 2002
`y 4,
`Related U.S. Application Data
`
`(63) Continuation of application No. 09/257,844, filed on Feb.
`25, 1999, now Pat. No. 6,248,954.
`
`An improved data telecommunications cable according to
`the invention includes a plurality of twisted pairs of insu
`lated conductors, and a dielectric pair Separator formed with
`a plurality of folds, to provide a plurality of grooves extend
`ing along a longitudinal length of the dielectric filler. Each
`twisted pair of insulated conductorS is disposed within a
`groove of the dielectric pair separator. The data communi
`cations cable also includes a jacket assembly enclosing the
`plurality of twisted pairs of insulated conductors and the
`dielectric pair separator. The dielectric pair Separator Sepa
`(51) Int. Cl. .................................................. H01B 1/02
`(52) U.S. Cl. ................................ 174113 R. 174/113 c rates each twisted pair of insulated conductors from every
`(58) Field of Search
`174/113 R, 113 C
`other twisted pair of insulated conductors with a Spacing
`- - - - - - - - - - 174/31A 117 F.3 6 121 A Sufficient to provide a desired crosstalk isolation between
`s
`s - s/s
`each of the plurality of twisted pairs of insulated conductors.
`With this arrangement, the data communications cable of the
`invention may be used in high Speed data transmissions
`while maintaining a form factor that has desired flexibility
`and workability, and provides a cable that is compatible with
`industry Standard hardware, Such as plugs and jacks. The
`data communications cable of the invention also has the
`additional benefit of a reduced size.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1883,269 A 10/1932 Yonkers
`1976,847 A * 10/1934 Gordon et al. .............. 174/112
`3,649,744 A 3/1972 Coleman
`3,911,200 A 10/1975 Simons et al.
`4,034,148 A 7/1977 Lang
`4,319,940 A 3/1982 Arrovo et al.
`
`ten,
`
`
`
`33 Claims, 8 Drawing Sheets
`
`

`

`US 6,570,095 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`4,500,748
`4,595,793
`4,605,818
`4,697,051
`4,777.325
`4,800,236
`5,132,488
`5,253,317
`5,298,680
`5,393.933
`
`2/1985
`6/1986
`8/1986
`9/1987
`10/1988
`1/1989
`7/1992
`10/1993
`3/1994
`2/1995
`
`Klein
`Arrovo et al.
`Arrovo et al.
`Beggs et al.
`Siwinski
`Lemke
`Tessier et al.
`Allen et al.
`Kenny
`Goertz
`
`5,399,813
`5,424,491
`5,493,071
`5,514,837
`5,789,711
`5,952.615
`5,969.295
`6,037.546
`6,194.663
`6.255,593
`
`3/1995
`A
`6/1995
`A
`2/1996
`A
`5/1996
`A
`8/1998
`A
`9/1999
`A
`10/1999
`A
`* 3/2000
`A
`B1 * 2/2001
`B1 * 7/2001
`
`McNeill et al.
`Walling
`Newmover
`Kennv et al.
`Gaeris et al.
`Prudhon
`Boucino et al.
`Mottine et al. ...... 174/113 RX
`Friesen et al. .......... 174/110 R
`Reede .................... 174/110 R
`
`

`

`U.S. Patent
`
`May 27, 2003
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`Sheet 1 of 8
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`US 6,570,095 B2
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`FIG. 1
`(RELATED ART)
`
`U.S. Patent
`
`May 27, 2003
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`Sheet 1 of 8
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`US 6,570,095 B2
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`FIG.
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`7
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`(RELATED ART)
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`U.S. Patent
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`May 27, 2003
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`Sheet 2 of 8
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`FIG. 2
`(RELATED ART)
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`U.S. Patent
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`May 27, 2003
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`Sheet 2 of 8
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`US 6,570,095 B2
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`2
`FIG.
`(RELATED ART)
`
`CommScope Exhibit 1043
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`U.S. Patent
`
`May
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`27, 2003
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`Sheet 2 of 8
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`
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`FIG.
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`2
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`(RELATED ART)
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`U.S. Patent
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`May 27, 2003
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`Sheet 3 of 8
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`US 6,570,095 B2
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`F/G, 3
`(RELATED ART)
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`U.S. Patent
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`May 27, 2003
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`Sheet 3 of 8
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`US 6,570,095 B2
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`3
`FIG.
`(RELATED ART)
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`U.S. Patent
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`May 27, 2003
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`Sheet 4 of 8
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`US 6,570,095 B2
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`FIG. 4
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`U.S. Patent
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`May 27, 2003
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`Sheet 4 of 8
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`US 6,570,095 B2
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`U.S. Patent
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`May 27, 2003
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`U.S. Patent
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`May 27, 2003
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`U.S. Patent
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`May 27, 2003
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`Sheet 6 of 8
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`US 6,570,095 B2
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`U.S. Patent
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`May 27, 2003
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`Sheet 7 of 8
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`US 6,570,095 B2
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`U.S. Patent
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`May 27, 2003
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`Sheet 7 of 8
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`US 6,570,095 B2
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`12
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`12
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`FIG.
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`CommScope Exhibit 1043
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`U.S. Patent
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`May 27, 2003
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`Sheet 7 of 8
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`US 6,570,095 B2
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`FIG.
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`U.S. Patent
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`May 27, 2003
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`Sheet 8 of 8
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`US 6,570,095 B2
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`FIG. 13A
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`FIG. 13B
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`U.S. Patent
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`May 27, 2003
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`Sheet 8 of 8
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`US 6,570,095 B2
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`13A
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`FIG.
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`13B
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`May 27, 2003
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`US 6,570,095 B2
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`13A
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`FIG. 13B
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`

`

`1
`MULTI-PAIR DATA CABLE WITH
`CONFIGURABLE CORE FILLING AND PAIR
`SEPARATION
`
`RELATED APPLICATION
`This application is a Continuation of, and claims priority
`under 35 U.S.C. S119(e) to, commonly-owned, U.S. patent
`application Ser. No. 09/257,844, now U.S. Pat. No. 6,248,
`954 B1, entitled, “Multi-Pair Data Cable with Configurable
`Core Filling and Pair Separation,” filed Feb. 25, 1999, which
`is hereby incorporated by reference in its entirety.
`FIELD OF THE INVENTION
`The present invention relates to high-speed data commu
`nications cables using at least two twisted pairs of insulated
`conductors. More particularly, the invention relates to high
`Speed data communications cables having a light-weight,
`configurable core-filling isolation pair Separator that pro
`vides geometrical Separation between the twisted pairs of
`insulated conductors.
`
`15
`
`DISCUSSION OF THE RELATED ART
`High-speed data communications media in current usage
`include pairs of insulated conductors twisted together to
`form a balanced transmission line. Such pairs of insulated
`conductors are referred to herein as “twisted pairs.” When
`twisted pairs are closely placed, Such as in a cable, electrical
`energy may be transferred from one twisted pair of a cable
`to another twisted pair. Such energy transferred between
`twisted pairs is referred to as crosstalk. AS operating fre
`quencies increase, improved crosstalk isolation between the
`twisted pairs becomes more critical.
`The Telecommunications Industry ASSociation and the
`Electronics Industry Association (TIA/EIA) have developed
`Standards which specify Specific categories of performance
`for cable impedance, attenuation, skew and particularly
`crosstalk isolation. One Standard for crosstalk or, in
`particular, crosstalk isolation, is TIA/EIA-568-A, wherein a
`category 5 cable is required to have 38 dB of isolation
`between the twisted pairs at 100 MHz and a category 6 cable
`is required to have 42 dB of isolation between the twisted
`pairs at 100 MHz. Various cable design techniques have
`been used to date in order to try to reduce crosstalk and to
`attempt to meet the industry Standards.
`For example, one cable implementation known in the
`industry that has been manufactured and Sold as a high
`Speed data communications cable, includes the twisted pairs
`formed with relatively tight twists, and the cable is formed
`into a round construction. In this conventional cable, each
`twisted pair has a Specified distance between twists along a
`longitudinal direction of the twisted pair, that distance being
`referred to as the “twist lay.” When adjacent twisted pairs
`have the same twist lay and/or twist direction, they tend to
`lie within a cable more closely spaced than when the twisted
`pairs have different twist lays and/or a different twist direc
`tion. Such close spacing increases the amount of undesirable
`crosstalk which occurs between the twisted pairs. In Some
`conventional cables, each twisted pair within the cable has
`a unique twist lay in order to increase the Spacing between
`pairs and thereby to reduce the crosstalk between twisted
`pairs of the cable. In addition, the twist direction of the
`twisted pairs may also be varied. However, this industry
`Standard configuration can only achieve limited crosstalk
`isolation.
`Another cable implementation 100 disclosed in U.S. Pat.
`No. 4,777,325, is illustrated in FIG. 1, wherein the twisted
`
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`US 6,570,095 B2
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`2
`pairs are enclosed within a jacket 102 that has a wide, flat
`configuration. In particular, aplurality of twisted pairs
`104a–104b, 106a-106b, 108a–108b, and 110a–110b are
`positioned Side-by-Side, each in Separate compartments 112,
`114, 116, and 118 formed within a flat hollow envelope of an
`extruded outer sheath 120. The cable is provided with
`separator ribs 122 between a top and a bottom of the sheath
`to divide the outer sheath into the Separate compartments
`and to prevent lateral movement of the twisted pairs out of
`their respective compartments. However, one problem with
`this flat configuration for a cable is that it has limited
`flexibility as compared to that of a round cable, which
`hinders installation of the cable in conduits and around
`bends.
`Another cable implementation which addresses the prob
`lem of twisted pairs lying too closely together within the
`cable is described, for example, in U.S. Pat. No. 5,789,711
`and is illustrated in FIG. 2. In particular, the cable includes,
`for example, four twisted pairs 124 disposed about a central
`pre-shaped Support 126, wherein the Support positions a
`twisted pair within grooves or channels 128 formed by the
`Support. In particular, the Support provides the grooves or
`channels which keep the twisted pairs at fixed positions with
`respect to each other. The Support can have any of a number
`of shapes, including, for example, a Standard “X”, a "+', or
`the Separator as is illustrated in FIG. 2. The prongs or
`protrusions 130 of the support preserve the geometry of the
`pairs relative to each other, which helps reduce and Stabilize
`crosstalk between the twisted pairs. However, Some prob
`lems with the Support is that the Support adds cost to the
`cable, may limit the flexibility of the cable and increases the
`size; e.g., the diameter, of the cable. Another problem may
`be that the material which forms the Support may result in
`the overall cable being a potential fire and/or Smoke hazard.
`Still another known industry cable implementation 132 is
`illustrated in FIG. 3. The cable utilizes a jacket 134 with
`inward protrusions 136 that form channels 138 within the
`cable. A twisted pair 140 of conductors 142,144 is disposed
`within each channel. The protrusions are used to provide
`adequate pair Separation. However, one problem with these
`protrusions is that they can be difficult to manufacture. In
`addition, the protrusions may not provide adequate Separa
`tion between the twisted pairs where the stability of the
`protrusions is difficult to provide, and thus performance
`repeatability of the cable is an issue. Further, another prob
`lem is that the jacket is not easily strippable. When the cable
`is to be Stripped by removing the outer jacket, which is often
`done with a sharp device Such as, for example, a razor, the
`protrusions will not be cut by the incision around the
`circumference of the jacket and will have to be broken off
`Separately in order to remove the jacket.
`Accordingly, Some of the problems with the above known
`configurations are that they are expensive, difficult to use,
`are generally undesirably large, and have decreased flex
`ibility of the cables and workability of the twisted pairs of
`WCS.
`
`SUMMARY OF THE INVENTION
`Therefore, a need exists for a high-Speed data cable
`having multiple twisted pair wires with desired crosstalk
`performance, improved handling and termination
`capabilities, that is inexpensive, flexible and has a desired
`size. This invention provides an improved data cable.
`According to the invention, a data communications cable
`has been developed so as to better facilitate the cable for its
`the intended use of high Speed data transmission, yet main
`
`

`

`US 6,570,095 B2
`
`3
`tain a form factor that has desired flexibility and workability,
`and that is compatible with industry Standard hardware, Such
`as plugs and jacks. The data communications cable of the
`invention has the additional benefit of a reduced cabled size
`relative to other known cables within its performance class.
`In particular, the present invention provides these advan
`tages by utilizing a configurable, highly flexible, core-filling,
`dielectric pair Separator to provide pair Separation for the
`cable.
`One embodiment of a data communications cable of the
`invention includes a first twisted pair of insulated
`conductors, a Second twisted pair of insulated conductors,
`and the dielectric pair Separator. The dielectric pair Separator
`is disposed between the first twisted pair of insulated con
`ductors and the Second twisted pair of insulated conductors
`and is folded and arranged to provide a Sufficient spacing
`between the first twisted pair of insulated conductors and the
`Second twisted pair of insulated conductors So as to provide
`a desired crosstalk isolation between the first twisted pair of
`insulated conductors and the Second twisted pair of insulated
`conductors. The data communications cable also includes
`ajacket assembly enclosing the first twisted pair of insulated
`conductors, the Second twisted pair of insulated conductors,
`and the dielectric pair Separator. With this arrangement, the
`data communications cable can be made with desired
`crosstalk isolation between the twisted pairs of insulated
`conductors. In addition, due to the conforming nature and
`the desired thickness of the dielectric pair Separator, the
`cable has desired flexibility, workability and size. Moreover,
`these advantages do not come at the expense of other
`properties of the cable Such as, for example, Size or reduced
`impedance Stability. The pair Separator also facilitates ter
`mination of the data communications cable to known indus
`try standard hardware.
`Another embodiment of a data communications cable of
`the invention includes a plurality of twisted pairs of insu
`lated conductors and the dielectric pair Separator, having a
`plurality of folds in the dielectric pair Separator to provide a
`plurality of grooves extending along a longitudinal length of
`the dielectric pair Separator. Each of a twisted pair of
`insulated conductorS is disposed within a groove of the
`dielectric pair Separator. The data communications cable
`also includes a jacket assembly enclosing the plurality of
`twisted pairs of insulated conductors and the dielectric pair
`Separator. This arrangement of the communications cable
`also has the above-described advantages.
`According to the invention, one embodiment of a method
`of manufacturing the data communications cable of the
`invention includes forming the pair Separator around a round
`cob to form a shaped pair Separator Such as a cylinder, and
`passing a plurality of twisted pairs of insulated conductors
`and the Shaped pair Separator through a first die which aligns
`the plurality of twisted pairs of insulated conductors with the
`shaped pair Separator. The shaped pair Separator is then
`further shaped or formed with a plurality of folds to provide
`a plurality of grooves along a longitudinal length of the
`formed pair Separator. The formed pair Separator and the
`plurality of twisted pairs of insulated conductors are then
`passed through corresponding apertures in a Second die to
`align the plurality of twisted pairs with the grooves of the
`formed pair Separator. The plurality of twisted pairs of
`insulated conductors and the formed pair Separator are then
`passed through a third die which forces the plurality of
`twisted pairs of insulated conductors into contact with the
`grooves of the formed pair Separator, and a jacket is pro
`vided around the plurality of twisted pairs of insulated
`conductors and the formed pair Separator, to form the data
`communications cable.
`
`15
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`4
`BRIEF DESCRIPTION OF DRAWINGS
`The objects, features and advantages of the present inven
`tion will become more apparent in View of the following
`detailed description of the invention when taken in conjun
`tion with the figures, in which:
`FIG 1 is a perspective view of an embodiment of a
`communications cable according to the related art;
`FIG. 2 is a cross-sectional view of another embodiment of
`a communications cable according to the related art;
`FIG.3 is a cross-sectional view of another embodiment of
`a communications cable according to the related art;
`FIG. 4 is a perspective view of a data communications
`cable according to one embodiment of the invention;
`FIG. 5 is a cross-sectional view of the embodiment of the
`data communications cable of FIG. 4;
`FIG. 6 is a cross-sectional view of a data communications
`cable according to another embodiment of the invention;
`FIG. 7 is a cross-sectional view of a data communications
`cable according to another embodiment of the invention;
`FIG. 8 is a cross-sectional view of a data communications
`cable according to another embodiment of the invention;
`FIG. 9 is a cross-sectional view of a data communications
`cable according to another embodiment of the invention;
`FIG. 10 is a cross-sectional view of a data communica
`tions cable according to embodiment of the invention;
`FIG. 11 is a croSS-Sectional view of a data communica
`tions cable according to another embodiment of the inven
`tion;
`FIG. 12 is a perspective View of a System for practicing
`a method of making a cable in accordance with an embodi
`ment of the invention;
`FIG. 13A illustrates a core of a four twisted pair cable; and
`FIG. 13B is an exploded view of the core of the cable of
`FIG. 13A, having a filler material according to the invention.
`
`DETAILED DESCRIPTION
`
`A number of embodiments of a data communications
`cable according to the invention will now be described in
`which the cable is constructed with a plurality of twisted
`pairs of insulated conductors and a core made from a
`configurable, dielectric pair Separator. However, it is to be
`appreciated that the invention is not limited to any number
`of twisted pairs or any profile for the configurable, dielectric
`pair Separator illustrated in any of these embodiments. The
`inventive principles can be applied to cables including
`greater or fewer numbers of twisted pairs and having dif
`ferent core profiles of the configurable dielectric pair Sepa
`rator. In addition, although these embodiments of the inven
`tion are described and illustrated in connection with twisted
`pair data communication media, it is to be appreciated that
`other high-Speed data communication media can be used
`instead of twisted pairs of conductors in the constructions of
`the cable according to the invention, Such as, for example,
`fiber optic media.
`FIG. 4 depicts an embodiment of a data communications
`cable 10 according to the present invention. The cable 10
`includes two twisted pairs 12 of insulated conductors 13.
`The twisted pairs 12 are separated by a low dielectric
`constant, low dissipation factor, polymer "pair Separator'
`14. The twisted pairs 12 and the pair separator 14 are
`encased within a jacket assembly 16. The outerjacket can be
`a PVC, a low-smoke, low-flame PVC, or any plenum or
`non-plenum rated thermoplastic.
`
`

`

`S
`FIG. 5 depicts a cross-sectional view of an embodiment of
`the cable of FIG. 4. The configurable pair separator 14 runs
`along a longitudinal length of the cable, and is configured
`Such that the twisted pairs are disposed within channels or
`grooves 15 of the pair Separator along the length of the cable.
`As illustrated, the grooves 15 do not form completely
`enclosed channels. Some of the advantages of this cable
`according to the invention are that the pair Separator pro
`vides Structural Stability during manufacture and use of the
`data communications cable, yet does not degrade the flex
`ibility and workability of the cable, and does not substan
`tially increase the size of the cable. In addition, the pair
`Separator improves the crosstalk isolation between the
`twisted pairs by providing desired spacing between the
`twisted pairs. Therefore, the configurable pair Separator of
`the invention lessens the need for complex and hard to
`control twist lay procedures, core filling arrangements and
`jacket embodiments described above with respect to the
`related art.
`The above-described embodiment of the data communi
`cations cable can be constructed using a number of different
`materials as the pair separator 14. While the invention is not
`limited to the materials described herein, the invention is
`advantageously practiced using these materials. In
`particular, the configurable pair Separator is preferably a
`flame-retardant, low-dielectric constant, low-dissipation
`factor, foamed polymer tape, Such as, for example, a foamed
`flame retardant, cellular polyolefin or fluoropolymer like
`NEPTC PP500 “SuperBulk”, a foamed fluorinated ethylene
`propylene (FEP) or a foamed polyvinyl chloride (PVC). The
`above-described pair Separators are preferably used in a
`non-plenum rated application where the cable is not required
`to pass industry standard flame and Smoke tests Such as the
`Underwriters Laboratories (UL) 910 test. Another preferable
`configurable pair Separator is a woven fiberglass tape nor
`mally used as a binder for cables, Such as, for example,
`Allied Fluoroglass CTX3X50. This woven fiberglass binder
`is preferably used in a plenum rated application where the
`cable must satisfy the UL910 test.
`Still another pair Separator material that may be used in
`the cable of the invention is a bulk filling material Such as
`a polyolefin or glass fiber filler that is flame-retardant and is
`typically shredded or fibrulated, but may also be solid, such
`as, for example, Chadwick AFT 033 Fiberglass. Such a bulk
`filling material is typically twisted up and used as a filling
`material in a core of the cable, with no other purpose. In
`particular, referring to FIG. 13A, the bulk filler is typically
`used as a core filling material that fills 100% of the core area
`50 between the illustrated four twisted pair, that is used to
`keep the cable in a more or less round construction.
`However, referring to FIG. 13B, according to the present
`invention it is preferable to provide less than 100% of the
`core area 50 with the filling material; and it is more
`preferable us use less than 42% of the core with the filler
`material 52 for providing isolation between the twisted
`pairs. In a preferred embodiment, approximately 32% of the
`overall core area between the four twisted pairs of the cable
`is filled with such a filler and shaped as described herein.
`Therefore, one aspect of the present invention is the recog
`nition that the filler or tape described above can be used to
`prevent physical contact between opposite and adjacent
`twisted pairs, thereby increasing the isolation between the
`twisted pairs, while not requiring the entire core area be
`filled, and therefore not Sacrificing the size, cost or flexibility
`of the overall cable.
`FIG. 6 depicts a cross-sectional view of a preferred
`embodiment of the data cable 10 of this invention. The cable
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`includes the low-dielectric constant, low-dissipation factor
`polymer pair Separator 14 formed into a cable core in Such
`a way as to physically Separate the four twisted pairs 12,
`thereby decreasing field coupling between the twisted pairs,
`providing a desired opposite twisted pair-to-pair physical
`distance, as well as providing a desired adjacent pair Sepa
`ration. It is to be appreciated that like components of the data
`communications cable illustrated in FIGS. 4-5 have been
`provided with like reference numbers and the description of
`these components applies with respect to each of the cable
`embodiments to be described herein.
`In the embodiment of the cable of FIG. 6, the pair
`Separator 14 is a flat configurable tape used as a core filler,
`that is shaped to have the illustrated profile and that is
`provided in the cable between the four twisted pairs 12. In
`particular, in this embodiment, the configured pair Separator
`has a shape Somewhat like a "+", providing four channels 15
`between each pair of protrusions 17 formed by the pair
`Separator. Each channel carries one twisted pair 12 that is
`placed within the channel during a process of manufacturing
`the cable that will be described in further detail below. AS is
`discussed above, the illustrated configurable core profile
`should not be considered limiting. In particular, although it
`is preferred that the pair Separator is Supplied as a flat
`extruded tape, the configurable pair Separator may be made
`by a process other than extrusion and may have a number of
`different shapes or provide a number of different channels,
`as is illustrated by some of the embodiments described in
`further detail below.
`Referring again to FIG. 6, the data communications cable
`may also be provided with a binder 19, as illustrated in
`phantom, that is wrapped around the configurable core pair
`separator 14 and the plurality of twisted pairs 12. For this
`embodiment, it is preferable that the configurable core pair
`Separator be an aluminum/mylar tape, with an aluminum
`layer on a Side of the tape facing the plurality of twisted
`pairs. In addition, it is preferred that the binder be made of
`the aluminum/mylar tape, with the aluminum layer of the
`tape facing the plurality of the twisted pairs So that the
`combination of the binder and the configurable pair Separa
`tor provide four electrically shielded, enclosed channels.
`With this embodiment, the four enclosed channels are iso
`lated from one another to provide desired croSStalk isolation.
`In addition, another benefit of the embodiment of the cable
`is that a cable adjacent this cable will have reduced coupling
`with the cable of the invention, or in other words, reduced
`alien croSS talk as it is known in the industry.
`The embodiment of FIG. 6 further illustrates a shield 21
`may also be laterally wrapped around the binder 19; the
`shield is preferably made from a foil or metal. The shield
`may be applied over the cable before jacketing the cable
`with the jacket 16, and is also used to help reduce crosstalk
`between the twisted pairs, to reduce alien crosstalk, and
`prevent the cable from causing or receiving electromagnetic
`interference. It is to be appreciated that the Shield can also
`be provided in lieu of the binder. In particular, greater
`crosstalk isolation between the twisted pairs of the cable,
`and reduced alien crosstalk may also be achieved by using
`a conductive shield 21 that is, for example, a metal braid, a
`Solid metal foil, or a conductive plastic that is in contact with
`ends of the protrusions 17 of the configurable filler 14. If the
`configurable pair Separator is also conductive or Semi
`conductive as described above for the aluminum/mylar tape,
`then the combination of the pair Separator and the shield
`forms conductive compartments that shield each twisted pair
`from the other twisted pairs. Referring to FIG. 6, the cable
`can advantageously include a metal drain wire 23 exposed,
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`for example, within the middle of the configurable pair
`separator 14. The metal drain wire runs the length of the
`cable and acts as a ground. However, it is to be appreciated
`that the metal drain wire need not be So placed and may also
`be arranged in arrangements known to those of Skill in the
`art Such as, for example, Spirally wrapped around the binder
`19 or the shield 21.
`It is preferable in the embodiments described herein that
`the protrusions 17 of the configurable pair Separator extend
`at least beyond a center axis of each twisted pair, known in
`the art as a pitch radius. The pitch radius is illustrated in FIG.
`6 as the radius R between the center of the cable core and the
`center axis of the twisted pairs 12 of conductors. This
`preferred configuration of the configurable pair Separator
`ensures that the twisted pairs do not escape their respective
`Spaces or channels. It is also to be appreciated that the
`process of jacketing of the cable, to be described in detail
`below, may bend the ends of the protrusions 17 over slightly
`(not illustrated), since the configurable pair separator is
`relatively formable.
`AS discussed above, it is to be appreciated that the twisted
`pairs of insulated conductors and configurable pair Separator
`of the communications data cable of the invention, can be
`configured in a variety of ways. FIGS. 7-12 depict cross
`Sectional views of various embodiments of the data com
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`munications cable of the invention. AS illustrated, for
`example, in FIGS. 7, 9 and 10, the configurable pair sepa
`rator may be configured such that the grooves 15 do not form
`completely enclosed channels. FIG. 7 depicts a cable 10
`wherein six twisted pairs 12 are encased within the jacket
`assembly 16, and are separated from each other by the
`configurable pair Separator 14. The pair Separator 14 is
`configured in a Somewhat “*” shape that provides Support
`and placement of the twisted pairs So that the twisted pairs
`12 have a desired spacial arrangement and do not come into
`direct physical contact with each other.
`FIG. 8 depicts still another embodiment of the data
`communications cable 10 having multiple twisted pairs 12
`encased within the jacket assembly 16 and having at least
`one of the twisted pairs isolated by the pair Separator 14,
`from the remainder of the twisted pairs. In particular,
`referring to FIG. 8, the twisted pairs have been labeled TP1,
`TP2, TP3 and TP4, wherein twisted pair TP4 is isolated from
`twisted pairs TP1, TP2 and TP3 by the pair separator 14. It
`is an advantage of this embodiment, that the pair Separator
`14 can be provided with an appropriate number of twists or
`wrappings around the twisted pair TP4, So as to provide
`selective isolation between twisted pair TP4 and twisted
`pairs TP1, TP2 and TP3. This embodiment of the cable
`according to the invention can be used, for example, to
`provide better isolation between a weakest one or a weakest
`combination of twisted pairs of cables, in an environment
`where there is known to be a low amount of isolation
`between a particular twisted pair and another twisted pair, or
`a plurality of twisted pairs. Accordingly, with this embodi
`ment of the cable of the invention, there can be selective
`enhancement of isolation between twisted pairs TP1-TP4,
`TP2-TP4, and TP3–TP4. It is to be appreciated that although
`the twisted pair TP4 has been illustrated as being isolated
`from the remainder of the twisted pairs, that any of the
`twisted pairs can be so wrapped with the filler and isolated.
`This embodiment of the invention may also be used in
`conjunction with a lessening of the twist layS requirements
`for the twisted pairs, to provide cable having a same amount
`of isolation between twisted pairs as a cable with tighter
`twist layS. Accordingly, this embodiment of the cable
`according to the invention allows for Selective design of
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`isolation between particular twisted pairs of the cable and
`lessening of the twist lay requirements for the cable.
`FIG. 9 depicts still another embodiment of the data
`communications cable 10 having multiple twisted pairs 12
`encased within the jacke