`
`(12) United States Patent
`McNutt et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8.450,606 B2
`*May 28, 2013
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`(54)
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`(75)
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`(73)
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`(*)
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`(65)
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`(63)
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`(60)
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`(51)
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`(52)
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`COMMUNICATION CABLE HAVING
`ELECTRICALLY SOLATED SHIELD
`PROVIDING ENHANCED RETURN LOSS
`
`Inventors: Christopher W. McNutt, Woodstock,
`GA (US); James S. Tyler, Woodstock,
`GA (US); Michael Klepper, Hoisington,
`KS (US); Delton C. Smith, Abbeville,
`SC (US); Jörg-Hein Walling,
`Beaconsfield (CA)
`Assignee: Superior Essex Communication LP,
`Atlanta, GA (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 557 days.
`This patent is Subject to a terminal dis
`claimer.
`
`Notice:
`
`Appl. No.: 12/6S3,804
`
`Filed:
`
`Dec. 18, 2009
`
`Prior Publication Data
`US 2010/O1 O1853 A1
`Apr. 29, 2010
`
`Related U.S. Application Data
`Continuation-in-part of application No. 12/313,914,
`filed on Nov. 25, 2008, now Pat. No. 7,923,641, which
`is a continuation-in-part of application No.
`1 1/502,777, filed on Aug. 11, 2006, now abandoned.
`Provisional application No. 61/203,303, filed on Dec.
`19, 2008.
`
`Int. C.
`HOIB 700
`U.S. C.
`USPC ............................................................ 174/36
`
`(2006.01)
`
`(58) Field of Classification Search
`USPC ..................................... 173/36, 106 R, 113 R
`See application file for complete search history.
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`3,373.475 A
`3, 1968 Petersen
`4,604,497 A
`8, 1986 Bell et al.
`(Continued)
`FOREIGN PATENT DOCUMENTS
`2432963
`* 6/2007
`GB
`2000-90748
`* 3f2OOO
`JP
`2006-173044
`* 6, 2006
`JP
`WO WO2006 105166
`10, 2006
`OTHER PUBLICATIONS
`“Product Catalogue” 2 pgs. Enterprise Cabling R&M, May 2006.
`(Continued)
`Primary Examiner — Chau Nguyen
`(57)
`ABSTRACT
`A tape can comprise a strip of dielectric material, with adher
`ing patches of electrical conductive material. The patches can
`be substantially electrically isolated from one another. The
`strip can be disposed in a communication cable to provide a
`shield that is electrically discontinuous or has high resistance
`between opposite cable ends. Each patch can interact with
`electromagnetic radiation associated with electrical signals
`transmitting over the cable. The patches can collectively
`interact with the transmitting electrical signals in a cumula
`tive or resonant manner to produce a spike in return loss at a
`particular frequency of the transmitting signals. The fre
`quency location of the spike can depend upon the sizes of the
`patches, with size impacting manufacturability. The patches
`can be sized Such that the spike falls within an operating
`frequency of the transmitting signal but is Suppressed, so the
`cable meets return loss specifications while offering manu
`facturing advantage.
`44 Claims, 13 Drawing Sheets
`
`
`
`Page 1 of 26
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`US 8,450,606 B2
`Page 2
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`U.S. PATENT DOCUMENTS
`1, 1987
`4,638,272
`A
`Ive
`Rippingale
`4, 1991
`5,006,806
`A
`4, 1992
`Davis et al.
`5,106, 175
`A
`Rippingale et al.
`5, 1992
`5,114,517
`A
`9, 1999
`Deitz et al. .............
`5,956.445
`A ck
`2, 2004
`Starnes et al.
`6,687,437
`B1
`Syly via et al.
`5, 2004
`6,737,574
`B2
`8, 2004
`Patel
`6,770,819
`B2
`2, 2005
`Elliott
`6,850, 161
`B1
`Hazy et al.
`2, 2007
`7,173, 189
`Sparrowhawk
`2, 2008
`7,332,676
`2, 2008
`Pfeiler et al.
`7,335,837
`4, 2011
`Smith et al. ............
`7.923,641
`2, 2012
`Smith et al. ............
`8,119,906
`2006,004896.1
`3, 2006
`Pfeiler et al.
`
`385/100
`
`174,113 R
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`. 174.36
`
`2/2007 Sparrowhawk
`2007/0O37419 A1
`9, 2007
`Gibbons et al. ............... 429,144
`2007/0224495 A1*
`2008/0314636 A1* 12/2008 Ogura ........................... 174,350
`OTHER PUBLICATIONS
`“Draka' 12 pgs. Draka Comteq, Cable Solutions, Data cables, Sep.
`27, 2006.
`"10 Gigabit Ethernet Solutions' 8 pgs. R&M Convincing Cabling
`Solutions.
`Wetzikon, “R&M: The Rising Stars in Copper Cabling' 2 pgs. Sep.
`1, 1005.
`“R&M Star Real 10” 2 pgs. Mar. 2006.
`“Connections 29' 36 pgs. Sep. 2005.
`* cited by examiner
`
`Page 2 of 26
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`U.S. Patent
`U.S. Patent
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`May 28, 2013
`May28, 2013
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`Page 3 of 26
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`U.S. Patent
`U.S. Patent
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`May 28, 2013
`May28, 2013
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`U.S. Patent
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`May 28, 2013
`May28, 2013
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`Sheet 3 of 13
`Sheet 3 of 13
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`
`
`ASS
`TL
`
`703
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`Sheet 4 of 13
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`
`
`NNNNN
`NNNN
`N
`NNNNNNNNNN
`
`Fig. 2B
`
`Fig. 2C
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`Page 6 of 26
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`Sheet 5 of 13
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`A1 300
`
`Start Manufacture Cable with Segmented Tape Process
`
`Flat-sheet extruder produces roll of film of dielectric material, such as plastic,
`polymeric material, or polyester
`
`Material handling system transports roll of dielectric film to a metallization
`machine
`
`305
`
`31 O
`
`315
`Metallization machine unwinds roll of dielectric film; applies intermittent strips or
`patches of a conductive material, such as aluminum or copper, as the dielectric
`film is unwound; and winds the resulting film onto a take-up reel
`
`320
`Material handling system transports roll of film with conductive patches to slitting
`machine
`
`Operator enters diameter of cable(s) (or of cable cores) into slitting controller
`
`Controller moves slitting knives of the slitting machine to widths corresponding
`to circumferences of the cables
`
`325
`
`330
`
`Slitting machine unwinds the roll of film with conductive patches, slits the film
`into slender, intermittently conductive segments or segmented tapes, and winds
`each resulting tape onto a separate roll or spool
`
`
`
`335
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`
`
`
`
`Fig. 3A
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`Page 7 of 26
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`Sheet 6 of 13
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`Material handling system transports roll of segmented tape of appropriate width
`to cabling system and loads roll onto feed spindle
`
`340
`
`345
`
`Material handling system loads one, or two, or more reels of twisted pairs of
`conductors into feed area of cabling system
`
`350
`Cabling system unwinds roll of segmented tape and one or more reels of twisted
`pairs of conductors. The cabling system's feeding mechanisms position the
`twisted pairs of conductors adjacent the tape as each is unwound, e.g. so that
`the conductors are on top of the flat surface of the tape.
`
`A curling mechanism of the cabling system curls the segmented tape over the
`Conductor pairs as they move synchronously or continuously downstream in the
`production line. Thus, the segmented tape is wrapped lengthwise around the
`conductors.
`
`355
`
`Extruder of cabling system extrudes jacket over the segmented tape and the
`conductor pairs. Thus, the cabling system produces a cable with the conductors
`and the shielding film in the core of the cable, wherein the segmented tape
`provides a segmented shield for the conductors.
`
`
`
`360
`
`
`
`
`
`
`
`Take-up reel at downstream end of cabling system accumulates finished Cable
`
`365
`
`Fig. 3B
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`Page 8 of 26
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`
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`&- 3:33
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`Fig. A
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`Fig. its
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`Fig. iC
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`Nisos
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`Fig. 5A
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`... ?83
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`:33
`
`y
`V 3.
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`a:338
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`- 88
`
`- 888
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`... ?: 3
`-
`
`Fig. 5B
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`Fig. 5C
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`Fig. 5D
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`Page 11 of 26
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`Sheet 10 of 13
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`gf
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`
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`Fig. 7B
`Fig. 7B
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`U.S. Patent
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`May 28, 2013
`May28, 2013
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`*...
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` me
`
`Fig. 8A
`Fig. 8A
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`Page 13 of 26
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`Sheet 12 of 13
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`Return LOSS
`(dB)
`O.O
`
`
`
`900
`Y
`
`O
`
`50
`
`100
`
`150
`
`200
`
`250
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`300
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`Page 14 of 26
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`s :: -
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`8
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`8.
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`8.
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`Page 15 of 26
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`US 8,450,606 B2
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`1.
`COMMUNICATION CABLE HAVING
`ELECTRICALLY SOLATED SHIELD
`PROVIDING ENHANCED RETURN LOSS
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`2
`manufacture and/or cumbersome to install in the field. In
`particular, complications can arise when a cable is encased by
`a shield that is electrically continuous between the two ends
`of the cable.
`In a typical application, each cable end is connected to a
`terminal device Such as an electrical transmitter, receiver, or
`transceiver. The continuous shield can inadvertently carry
`Voltage along the cable, for example from one terminal device
`at one end of the cable towards another terminal device at the
`other end of the cable. If a person contacts the shielding, the
`person may receive a shock if the shielding is not properly
`grounded. Accordingly, continuous cable shields are typi
`cally grounded at both ends of the cable to reduce shock
`hazards and loop currents that can interfere with transmitted
`signals.
`Such a continuous shield can also set up standing waves of
`electromagnetic energy based on signals received from
`nearby energy sources. In this scenario, the shield's standing
`wave can radiate electromagnetic energy, somewhat like an
`antenna, that may interfere with wireless communication
`devices or other sensitive equipment operating nearby.
`Accordingly, to address these representative deficiencies in
`the art, what is needed is an improved capability for shielding
`conductors that may carry high-speed communication sig
`nals. Another need exists for technology for efficiently manu
`facturing communication cables that are resistant to noise. Yet
`another need exists for a cable construction that is manufac
`turable, that provides Suitable return loss performance, and
`that effectively suppresses crosstalk and/or other interference
`without providing an electrically conductive path between
`opposite ends of the cable. A capability addressing one or
`more of such needs would support increasing bandwidth
`without unduly increasing cost or installation complexity.
`
`SUMMARY
`
`The present invention Supports providing shielding for
`cables that may communicate data or other information.
`In one aspect of the present invention, a tape can comprise
`a narrow strip of dielectric material, for example in the form
`of a film. Electrically conductive areas or patches can be
`disposed against one or both sides of the tape, with the con
`ductive patches electrically isolated from one another. As an
`alternative to full electrical isolation, the patches can be in
`electrical communication with one another via one or more
`high resistance paths. The patches can comprise aluminum,
`copper, a metallic Substance, or some other material that
`readily conducts electricity. The patches can be printed,
`fused, transferred, bonded, vapor deposited, imprinted,
`coated, fastened, stapled, embossed, pressed, punched, or
`otherwise attached to or disposed adjacent to the strip of
`dielectric material. The tape can be wrapped around signal
`conductors, such as wires that transmit data, to provide elec
`trical or electromagnetic shielding for the conductors. The
`tape can be a shield that is electrically discontinuous or exhib
`its a high level of resistance between opposite ends of a cable.
`While electricity can flow freely in each individual patch, the
`isolating gaps can provide shield discontinuities or high resis
`tance paths for inhibiting electricity from flowing freely in the
`tape along the full length of the cable.
`The patches can be sized or dimensioned to facilitate
`manufacturing, for example each patch being at least about
`1.5 meters in length with the spacing between adjacent
`patches being at least about 1.5 millimeters. The cable can
`operate across a range of signal frequencies in connection
`with transmitting data or information. The patches can reso
`nant, or setup a standing wave of electrical or electromagnetic
`
`10
`
`This application claims priority to U.S. Provisional Patent
`Application No. 61/203,303, filed on Dec. 19, 2008 in the
`name of Christopher McNutt et al. and entitled “Communi
`cation Cable Having Electrically Isolated Shield Providing
`Enhanced Return Loss, and is a continuation-in-part of and
`claims priority to co-assigned U.S. patent application Ser. No.
`12/313,914 filed on Nov. 25, 2008 now U.S. Pat. No. 7,923,
`641 in the name of Delton C. Smith et al. and entitled “Com
`15
`munication Cable Comprising Electrically Isolated Patches
`of Shielding Material.” which claims priority as a continua
`tion-in-part of co-assigned U.S. patent application Ser. No.
`1 1/502.777, filed Aug. 11, 2006 now abandoned in the name
`of Delton C. Smith et al. and entitled “Method and Apparatus
`for Fabricating Noise-Mitigating Cable.” The entire contents
`of each of the patent applications identified above are hereby
`incorporated herein by reference.
`This application is related to the co-assigned U.S. patent
`application entitled “Communication Cable Comprising
`Electrically Discontinuous Shield Having Nonmetallic
`Appearance' filed on Nov. 25, 2008 and assigned U.S. patent
`application Ser. No. 12/313,910, the entire contents of which
`are hereby incorporated herein by reference.
`This application is related to the co-assigned U.S. patent
`application entitled “Communication Cable Shielded With
`Mechanically Fastened Shielding Elements' filed on Aug. 26,
`2009 and assigned U.S. patent application Ser. No. 12/583,
`797, the entire contents of which are hereby incorporated
`herein by reference.
`This application is related to the co-assigned U.S. patent
`application entitled “Communication Cable With Electrically
`Isolated Shield Comprising Holes' filed on Sep. 10, 2009
`assigned U.S. patent application Ser. No. 12/584,672, the
`entire contents of which are hereby incorporated herein by
`reference.
`
`25
`
`30
`
`35
`
`40
`
`FIELD OF THE TECHNOLOGY
`
`The present invention relates to communication cables that
`are shielded from electromagnetic radiation and more spe
`cifically to a communication cable shielded with patches of
`conductive material adhering to a dielectric film that is
`wrapped around wires of the cable.
`
`45
`
`50
`
`BACKGROUND
`
`As the desire for enhanced communication bandwidth
`escalates, transmission media need to convey information at
`higher speeds while maintaining signal fidelity and avoiding
`crosstalk, including alien crosstalk. However, effects such as
`noise, interference, crosstalk, alien crosstalk, and/or alien
`elfext crosstalk can strengthen with increased data rates,
`thereby degrading signal quality or integrity. For example,
`when two cables are disposed adjacent one another, data
`transmission in one cable can induce signal problems in the
`other cable via crosstalk interference.
`One approach to addressing crosstalk between communi
`cation cables is to circumferentially encase each cable in a
`continuous shield, such as a flexible metallic tube or a foil that
`coaxially surrounds the cable's conductors. However, shield
`ing based on convention technology can be expensive to
`
`55
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`60
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`4
`FIG. 8B is an illustration of an exemplary segmented tape
`comprising metallization in accordance with certain embodi
`ments of the present invention.
`FIGS. 9A, 9B, and 9C are three exemplary plots of return
`loss as a function of frequency in accordance with certain
`exemplary embodiments of the present invention.
`Many aspects of the invention can be better understood
`with reference to the above drawings. The elements and fea
`tures shown in the drawings are not to Scale, emphasis instead
`being placed upon clearly illustrating the principles of exem
`plary embodiments of the present invention. Moreover, cer
`tain dimensions may be exaggerated to help visually convey
`Such principles. In the drawings, reference numerals desig
`nate like or corresponding, but not necessarily identical, ele
`ments throughout the several views.
`
`5
`
`10
`
`15
`
`3
`interaction, that produces a spike in return loss. The patches
`can be sized so that the return loss spike is located within the
`cable's operating frequency range, but is Suppressed to avoid
`compromising a return loss specification.
`The discussion of shielding conductors presented in this
`Summary is for illustrative purposes only. Various aspects of
`the present invention may be more clearly understood and
`appreciated from a review of the following detailed descrip
`tion of the disclosed embodiments and by reference to the
`drawings and the claims that follow. Moreover, other aspects,
`systems, methods, features, advantages, and objects of the
`present invention will become apparent to one with skill in the
`art upon examination of the following drawings and detailed
`description. It is intended that all Such aspects, systems, meth
`ods, features, advantages, and objects are to be included
`within this description, are to be within the scope of the
`present invention, and are to be protected by the accompany
`ing claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`25
`
`FIG. 1A is a cross sectional view of an exemplary commu
`nication cable that comprises a segmented shield in accor
`dance with certain embodiments of the present invention.
`FIGS. 1B and 1C are cross sectional views of exemplary
`communication cables that comprise segmented shields in
`accordance with certain embodiments of the present inven
`tion.
`FIGS. 2A and 2B are, respectively, overhead and cross
`30
`sectional views of an exemplary segmented tape that com
`prises a pattern of conductive patches attached to a dielectric
`film substrate in accordance with certain embodiments of the
`present invention.
`FIG. 2C is an illustration of an exemplary technique for
`wrapping a segmented tape lengthwise around a pair of con
`ductors in accordance with certain embodiments of the
`present invention.
`FIGS. 3A and 3B, collectively FIG. 3, are a flowchart
`depicting an exemplary process for manufacturing cable in
`accordance with certain embodiments of the present inven
`tion.
`FIGS. 4A, 4B, and 4C, collectively FIG.4, are illustrations
`of exemplary segmented tapes comprising conductive
`patches disposed on opposite sides of a dielectric film in
`accordance with certain embodiments of the present inven
`tion.
`FIGS.5A, 5B, 5C, and 5D, collectively FIG. 5, are illus
`trations, from different viewing perspectives, of an exemplary
`segmented tape comprising conductive patches disposed on
`opposite sides of a dielectric film in accordance with certain
`embodiments of the present invention.
`FIG. 6 is an illustration of an exemplary geometry for a
`conductive patch of a segmented tape in accordance with
`certain embodiments of the present invention.
`FIG. 7A is an illustration of an exemplary orientation for
`conductive patches of a segmented tape with respect to a
`twisted pair of conductors in accordance with certain embodi
`ments of the present invention.
`FIG. 7B is an illustration of a core of a communication
`cable comprising conductive patches disposed in an exem
`plary geometry with respect to a twist direction of twisted
`pairs and to a twist direction of the cable core in accordance
`with certain embodiments of the present invention.
`FIG. 8A is an illustration of an exemplary segmented tape
`in accordance with certain embodiments of the present inven
`tion.
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`
`The present invention Supports shielding a communication
`cable, wherein at least one break or discontinuity in a shield
`ing material electrically isolates shielding at one end of the
`cable from shielding at the other end of the cable. As an
`alternative to forming a continuous or contiguous conductive
`path, the tape can be segmented or can comprise intermit
`tently conductive patches or areas.
`Cables comprising segmented tapes, and technology for
`making such cables, will now be described more fully here
`inafter with reference to FIGS. 1-9, which describe represen
`tative embodiments of the present invention. In an exemplary
`embodiment, the segmented tape can be characterized as
`shielding tape or as tape with segments or patches of conduc
`tive material. FIGS. 1A, 1B, and 1C provide end-on views of
`cables comprising segmented tape. FIGS. 2A, 2B, 4, 5, and 6
`illustrate representative segmented tapes. FIG. 2C depicts
`wrapping segmented tape around or over conductors. FIG. 3
`offers a process for making cable with segmented shielding.
`FIG. 7 describes orientations of patches in cables. FIG. 8A
`illustrates a segmented tape comprising patches that are sized
`to promote manufacturability. FIG. 8B illustrates a seg
`mented tape comprising a high resistance path that Supports
`limited electrical communication among patches. FIGS. 9A,
`9B, and 9C illustrate cable return loss plots.
`The invention can be embodied in many different forms
`and should not be construed as limited to the embodiments set
`forth herein; rather, these embodiments are provided so that
`this disclosure will be thorough and complete, and will fully
`convey the scope of the invention to those having ordinary
`skill in the art. Furthermore, all “examples’ or “exemplary
`embodiments’ given herein are intended to be non-limiting,
`and among others Supported by representations of the present
`invention.
`Turning now to FIG. 1A, this figure illustrates a cross
`sectional view of a communication cable 100 that comprises
`a segmented shield 125 according to certain exemplary
`embodiments of the present invention.
`The core 110 of the cable 100 contains four pairs of con
`ductors 105, four being an exemplary rather than limiting
`number. Each pair 105 can be a twisted pair that carries data,
`for example in a range of 1-10Gbps or some other appropriate
`range. The pairs 105 can each have the same twist rate (twists
`per-meter or twists-per-foot) or may be twisted at different
`rates.
`The core 110 can be hollow as illustrated or alternatively
`can comprise a gelatinous, Solid, or foam material, for
`example in the interstitial spaces between the individual con
`ductors 105. In one exemplary embodiment, one or more
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`members can separate each of the conductor pairs 105 from
`the other conductor pairs 105. For example, the core 110 can
`contain an extruded or pultruded separator that extends along
`the cable 110 and that provides a dedicated cavity or channel
`for each of the four conductor pairs 105. Viewed end-on or in
`cross section, the separator could have a cross-shaped geom
`etry or an X-shaped geometry.
`Such an internal separator can increase physical separation
`between each conductor pair 105 and can help maintain a
`random orientation of each pair 105 relative to the other pairs
`105 when the cable 100 is field deployed.
`A segmented tape 125 surrounds and shields the four con
`ductor pairs 105. As discussed in further detail below, the
`segmented tape 125 comprises a dielectric substrate 150 with
`patches 175 of conductive material attached thereto. As illus
`trated, the segmented tape 125 extends longitudinally along
`the length of the cable 100, essentially running parallel with
`and wrapping over the conductors 105.
`In an alternative embodiment, the segmented tape 125 can
`wind helically or spirally around the conductor pairs 105.
`More generally, the segmented tape 125 can circumferen
`tially cover, house, encase, or enclose the conductor pairs
`105. Thus, the segmented tape 125 can circumscribe the
`conductors 105, to extend around or over the conductors 105.
`Although FIG.1.A depicts the segmented tape 125 as partially
`circumscribing the conductors 105, that illustrated geometry
`is merely one example. In many situations, improved block
`age of radiation will result from overlapping the segmented
`tape 125 around the conductors 105, so that the segmented
`tape fully circumscribes the conductors 105. Moreover, in
`certain embodiments, the side edges of the segmented tape
`125 can essentially buttup to one another around the core 110
`of the cable 100. Further, in certain embodiments, a signifi
`cant gap can separate these edges, so that the segmented tape
`125 does not fully circumscribe the core 110.
`In one exemplary embodiment, one side edge of the seg
`mented tape 125 is disposed over the other side edge of the
`tape 125. In other words, the edges can overlap one another,
`with one edge being slightly closer to the center of the core
`110 than the other edge.
`An outerjacket 115 of polymer seals the cable 110 from the
`environment and provides strength and structural Support.
`The jacket 115 can be characterized as an outer sheath, a
`jacket, a casing, or a shell. A Small annular spacing 120 may
`separate the jacket 115 from the segmented tape 125. In
`45
`certain exemplary embodiments, the segmented tape 125 is
`bonded to the outer jacket 115.
`In one exemplary embodiment, the cable 100 or some other
`similarly noise mitigated cable can meet a transmission
`requirement for “10G Base-T data com cables.” In one exem
`plary embodiment, the cable 100 or some other similarly
`noise mitigated cable can meet the requirements set forth for
`10Gbps transmission in the industry specification known as
`ANSI/TIA 568-C.2 and/or the industry specification known
`as ISO 11801. Accordingly, the noise mitigation that the
`segmented tape 125 provides can help one or more twisted
`pairs of conductors 105 transmit data at 10 Gbps or faster
`without unduly experiencing bit errors or other transmission
`impairments. As discussed in further detail below, an auto
`mated and scalable process can fabricate the cable 100 using
`the segmented tape 125.
`FIGS. 1B and 1C illustrate alternative cable embodiments.
`The exemplary cable 101 illustrated in FIG. 1B comprises a
`tape 102 disposed between the segmented tape 125 and the
`conductors 105 and formed around the conductors 105. In an
`exemplary embodiment, the tape 102 can comprise (or con
`sist of) a strip of polyester, plastic, polymer, electrically insu
`
`6
`lating, or dielectric material. In certain exemplary embodi
`ments, the tape 102 comprises a second segmented tape.
`The exemplary cable 104 illustrated in FIG. 1C comprises
`two tapes 103, each formed around a respective pair of con
`ductors 105. In an exemplary embodiment, each of the tapes
`103 can comprise (or consist of) a strip of polyester, plastic,
`polymer, electrically insulating, or dielectric material. In cer
`tain exemplary embodiments, one or both of the tapes 103
`comprises a second segmented tape.
`Turning now to FIGS. 2A and 2B, these figures respec
`tively illustrate overhead and cross sectional views of a seg
`mented tape 125 that comprises a pattern of conductive
`patches 175 attached to a dielectric substrate 150 according to
`certain exemplary embodiments of the present invention.
`That is, FIGS. 2A and 2B depict an exemplary embodiment of
`the segmented tape 125 shown in FIGS. 1A, 1B, and 1C and
`discussed above. More specifically, FIGS. 1A, 1B, and 1C
`each illustrates a cross sectional cable view wherein the cross
`section cuts through one of the conductive patches 175, per
`pendicular to the major axis of the segmented tape 125.
`The segmented tape 125 comprises a dielectric substrate
`film 150 of flexible dielectric material that can be wound
`around and stored on a spool. That is, the illustrated section of
`segmented tape 125 can be part of a spool of segmented tape
`125. The film can comprise a polyester, polypropylene, poly
`ethylene, polyimide, or some other polymer or dielectric
`material that does not ordinarily conduct electricity. That is,
`the segmented tape 125 can comprise a thin strip of pliable
`material that has at least some capability for electrical insu
`lation. In one exemplary embodiment, the pliable material
`can comprise a membrane or a deformable sheet. In one
`exemplary embodiment, the substrate is formed of the poly
`ester material sold by E.I. DuPont de Nemours and Company
`under the registered trademark MYLAR.
`The conductive patches 175 can comprise aluminum, cop
`per, nickel, iron, or some metallic alloy or combination of
`materials that readily transmits electricity. The individual
`patches 175 can be separated from one another so that each
`patch 175 is electrically isolated from the other patches 175.
`That is, the respective physical separations between the
`patches 175 can impede the flow of electricity between adja
`cent patches 175.
`The conductive patches 175 can span fully across the seg
`mented tape 125, between the tape's long edges. As discussed
`in further detail below, the conductive patches 175 can be
`attached to the dielectric substrate 150 via gluing, bonding,
`adhesion, printing, painting, welding, coating, heated fusion,
`melting, or vapor deposition, to name a few examples.
`In one exemplary embodiment, the conductive patches 175
`can be over-coated with an electrically insulating film, Such as
`a polyester coating (not shown in FIGS. 2A and 2B). In one
`exemplary embodiment, the conductive patches 175 are sand
`wiched between two dielectric films, the dielectric substrate
`150 and another electrically insulating film (not shown in
`FIGS. 2A and 2B).
`The segmented tape 125 can have a width that corresponds
`to the circumference of the core 110 of the cable 100. The
`width can be slightly smaller than, essentially equal to, or
`larger than the core circumference, depending on whether the
`longitudinal edges of the segmented tape 125 are to be sepa
`rated, butted together, or overlapping, with respect to one
`another in the cable 100.
`In one exemplary embodiment, the dielectric substrate 150
`has a thickness of about 1-5 mils (thousandths of an inch) or
`about 25-125 microns. Each conductive patch 175 can com
`prise a coating of aluminum having a thickness of about 0.5
`mils or about 13 microns. In many applications, signal per
`
`30
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`40
`
`50
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`Page 18 of 26
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`US 8,450,606 B2
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`7
`formance benefits from a thickness that is greater than 2 mils,
`for example in a range of 2.0-2.5 mils, 2.0-2.25 mils, 2.25-2.5
`mils, 2.5-3.0 mils, or 2.0-3.0 mils.
`Each patch 175 can have a length of about 1.5 to 2 inches or
`about 4 to 5 centimeters. Other exemplary embodiments can
`have dimensions following any of these ranges, or some other
`values as may be useful. The dimensions can be selected to
`provide electromagnetic shielding over a specific band of
`electromagnetic frequencies or above or below a designated
`frequency threshold, for example.
`In certain exemplary embodiments, each patch 175 has a
`length of about 2 meters, with the gaps between adjacent
`patches 175 about /16 of an inch. The resulting shield con
`figuration provides a return loss Spike in the operating band of
`the cable 100, which should be avoided by conventional
`thinking. However, the spike is unexpectedly Suppressed,
`thereby providing an acceptable cable with segment and gap
`dimensions that offer manufacturing advantages. Thus,
`increasing the patch lengths benefits manufacturing while
`providing acceptable performance. The peak in return loss is
`surprisingly suppressed, and the cable 100 meets perfor
`mance standards and network specifications.
`In certain exemplary embodiments, each patch 175 covers
`a hole (not illustrated) in the dielectric substrate 150. In other
`words, the dielectric substrate 150 comprises holes or win
`dows, with a patch 175 disposed over each hole or window.
`Typically, each patch 175 is slightly bigger than its associated
`window, so the patch 175 extends over the window edges. The
`windows eliminate a substantial portion of the flammable
`film substrate material, thereby achieving betterburn charac
`teristics, via producing less Smoke, heat, and flame.
`Turning now to FIG. 2C, this figure illustrates wrapping a
`segmented tape 125 lengthwise around a pair of conductors
`105 according to certain exemplary embodiments of the
`present invention. Thus, FIG. 2C shows how the segmented
`tape 125 discussed above can be wrapped around or over one
`or more pairs of conductors 125 as an intermediate step in
`forming a cable 100 as depicted in FIG. 1A and discussed
`above. While FIG. 1A depicts four pairs of wrapped conduc
`tors 10
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