United States Patent (19)
`Gaeris et al.
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`USOO578971 1A
`Patent Number:
`11
`45 Date of Patent:
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`5,789,711
`Aug. 4, 1998
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`HGH-PERFORMANCE DATA CABLE
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`Inventors: Galen Mark Gaeris, Richmond, Ind.,
`Paul Z. Wanderlaan, Oxford, Ohio
`Assignee: Belden Wire & Cable Company.
`Richmond, Ind.
`
`Appl. No.: 629,509
`Filed:
`Apr. 9, 1996
`Int. Cl. ...r. H01B 11/02
`U.S. Cl. .................................... 174/113 C: 174/131. A
`Field of Search .................................. 174/28, 29, 36,
`174/13 R, 1 3 C, 113 AS., 131 A. 34
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`483.285 9/1892 Guilleaume ......................... 174/113 R
`1977,209 10/1934 Sargent ............
`... 73/.264 X
`2,204.737
`6/1940 Swallow et al. ......
`... 174/28
`3.588,313
`6/1971 Delves-Broughton .................... 174/28
`3,603,715 9/1971 Winnhorst et al. ....
`... 174/15 X
`3,621,118 11/1971 Bunish et al. ...................... 174/115 X
`3,927247 12/1975 Timmons .................................. 174/36
`4,038,489 7/1977 Stenson et al.
`174/70 R
`4.374,881
`2/1983 Hamilton .................................. 428/36
`4,683,349 7/1987 Takebe .........
`... 174/69 X
`4,729,409 3/1988 Paul ........................................ 138/115
`4,778.246 10/1988 Carroll ................................. 350/96.23
`
`7/1992 Tessier et al. ............................ 174/34
`5.132.488
`... 138/08
`4/1994 Roy, Sr. .........
`5.305,797
`5,574.250 1 1/1996 Hardie et al. ...
`... 174/36
`
`FOREIGN PATENT DOCUMENTS
`24598.44 7/1976 Germany ........................... 74/3 C
`5-101711
`4/1993 Japan ................................. 17.4/13 C
`13434.47 10/1987 U.S.S.R. ............................ 1747 13 C
`
`Primary Examiner-Kristine L. Kincaid
`Assistant Examiner-Chau N. Nguyen
`Attorney; Agent, or Firm-Laff. Whitesel. Conte & Saret,
`Ltd.: Robert F. I. Conte
`57
`ABSTRACT
`The present invention is for a high performance data cable
`which has an interior support or star separator. The star
`separator or interior support extends along the longitudinal
`length of the data cable. The star separator or interior support
`has a central region. A plurality of prongs or splines extend
`outward from the central region along the length of the
`central region. Each prong or spline is adjacent with at least
`two other prongs or splines. The prongs or splines may be
`helixed or S-Z shaped as they extend along the length of the
`star separator or interior support. Each pair of adjacent
`prongs or splines defines grooves which extend along the
`longitudinal length of the interior support. At least two of the
`grooves have disposed therein an insulated conductor.
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`3 Claims, 2 Drawing Sheets
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`U.S. Patent
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`US. Patent
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`an interior support which allows for a variety of twisted
`pair dimensions.
`Previous cables have used supports designed for coaxial
`cables. The supports in these cables are designed to place the
`center conductor coaxially within the outer conductor. This
`cable has numerous advantageous features over coaxial
`designs.
`The novel interior support provides grooves which pre
`cisely place twisted pairs with relative ease. The precise
`O placement controls NEXT between pairs. The supports of
`the coaxial designs, however, are not directed towards
`accommodating twisted pairs. The slots in the coaxial Sup
`port remain free of any conductor. The slots in the coaxial
`support are merely a side effect of the design's direction to
`center a conductor within an outer conductor with a minimal
`material cross section to reduce costs. In fact, one would
`really not even consider these coaxial cable supports in
`concurrence with twisted pair technology.
`Some cables have used supports in connection with
`twisted pairs. These cables, however, suggest using a stan
`dard "X", or "+" shaped support, hereinafter both referred to
`as the "X" support. The standard "X" support is completely
`different than this support.
`Protrusions extend from the standard "X" support. These
`protrusions have substantially parallel sides.
`The prongs or splines in this invention provide a superior
`crush resistance to the protrusions of the standard "X"
`support. The superior crush resistance better preserves the
`geometry of the pairs relative to each other and of the pairs
`relative to the other parts of the cables such as the shield. In
`addition, the prongs or splines in this invention preferably
`have a pointed or slightly rounded apex top which easily
`accommodates an overall shield.
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`G. PERFORMANCE DATA CABLE
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`5.789,711
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`FIELD OF INVENTION
`This invention relates to a high performance data cable
`utilizing twisted pairs. The data cable has an interior support
`or star separator around which the twisted pairs are disposed.
`BACKGROUND OF THE INVENTION
`Many data communication systems utilize high perfor
`mance data cables having at least four twisted pairs.
`Typically, two of the twisted pairs transmit data and two of
`the pairs receive data. A twisted pair is a pair of conductors
`twisted about each other. A transmitting twisted pair and a
`receiving twisted pair often form a subgroup in a cable
`having four twisted pairs.
`A high performance data cable utilizing twisted pair
`technology must meet exacting specifications with regard to
`data speed and electrical characteristics. The electrical char
`acteristics include such things as controlled impedance.
`controlled near-end cross-talk (NEXT), controlled ACR
`(attenuation minus cross-talk) and controlled shield transfer
`impedance.
`One way twisted pair data cables have tried to meet the
`electrical characteristics, such as controlled NEXT. is by
`utilizing individually shielded twisted pairs (ISTP). These
`shields insulate each pair from NEXT. Data cables have also
`used very complex lay techniques to cancel E and B fields
`to control NEXT. Finally, previous data cables have tried to
`meet ACR requirements by utilizing very low dielectric
`constant insulations. The use of the above techniques to
`control electrical characteristics has problems.
`Individual shielding is costly and complex to process.
`Individual shielding is highly susceptible to geometric insta
`bility during processing and use. In addition, the ground
`plane of individual shields, 360° in ISTP's, lessens electrical
`stability.
`Lay techniques are also complex, costly and susceptible
`to instability during processing and use.
`Another problem with many data cables is their suscep
`tibility to deformation during manufacture and use. Defor
`mation of the cable's geometry, such as the shield, lessens
`electrical stability. Applicant's unique and novel high per
`formance data cable meets the exacting specifications
`required of a high performance data cable while addressing
`the above problems.
`This novel cable has an interior support with grooves.
`Each groove accommodates at least one twisted pair. The
`interior support provides needed structural stability during
`manufacture and use. The grooves also improve NEXT
`control by allowing for the easy spacing of the twisted pairs.
`The easy spacing lessens the need for complex and hard to
`control lay procedures and individual shielding.
`The interior support allows for a single overall shield
`having a much smaller ground plane than individual shields.
`The smaller ground plane improves electrical stability. For
`instance, the overall shield improves shield transfer imped
`ance. The overall shield is also lighter, cheaper and easier to
`terminate than ISTP designs.
`This novel cable produces many other significant advan
`tageous results such as:
`improved impedance determination because of the ability
`to precisely place twisted pairs;
`the ability to meet a positive ACR value from twisted pair
`to twisted pair with a cable that is no larger than an
`ISTP cable; and
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`SUMMARY OF THE INVENTION
`In one embodiment, we provide a data cable which has a
`one piece plastic interior support. The interior support
`extends along the longitudinal length of the data cable. The
`interior support has a central region which extends along the
`longitudinal length of the interior support. The interior
`support has a plurality of prongs. Each prong is integral with
`the central region. The prongs extend along the longitudinal
`length of the central region and extend outward from the
`central region. The prongs are arranged so that each prong
`of said plurality is adjacent with at least two other prongs.
`Each pair of adjacent prongs define a groove extending
`along the longitudinal length of the interior support. The
`prongs have a first and second lateral side. A portion of the
`first lateral side and a portion of the second lateral side of at
`least one prong converge towards each other.
`The cable further has a plurality of insulated conductors
`disposed in at least two of the grooves.
`A cable covering surrounds the interior support. The cable
`covering is exterior to the conductors. Applicants' inventive
`cable can be alternatively described as set forth below.
`The cable has an interior support extending along the
`longitudinal length of the data cable. The interior support
`has a central region extending along the longitudinal length
`of the interior support. The interior support has a plurality of
`prongs. Each prong is integral with the central region. The
`prongs extend along the longitudinal length of the central
`region and extend outward from the central region. The
`prongs are arranged so that each prong is adjacent with at
`least two other prongs.
`Each prong has a base. Each base is integral with the
`central region. At least one of said prongs has a base which
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`has a horizontal width greater than the horizontal width of a
`portion of said prong above said base. Each pair of the
`adjacent prongs defines a groove extending along the lon
`gitudinal length of the interior support.
`A plurality of conductors is disposed in at least two of said
`grooves.
`A cable covering surrounds the interior support. The cable
`covering is exterior to the conductors. The invention can
`further be alternatively described by the following descrip
`tion.
`An interior support for use in a high-performance data
`cable. The data cable has a diameter of from about 0.300" to
`about 0.400". The data cable has a plurality of insulated
`conductor pairs.
`15
`The interior support in said high-performance data cable
`has a cylindrical longitudinally extending central portion. A
`plurality of splines radially extend from the central portion.
`The splines also extend along the length of the central
`portion. The splines have a triangular cross-section with the
`base of the triangle forming part of the central portion, each
`triangular spline has the same radius. Adjacent splines are
`separated from each other to provide a cable chamber for at
`least one pair of conductors. The splines extend longitudi
`nally in a helical, S. or Z-shaped manner.
`Accordingly, the present invention desires to provide a
`data cable that meets the exacting specifications of high
`performance data cables, has a superior resistance to defor
`mation during manufacturing and use, allows for control of
`near-end cross talk, controls electrical instability due to
`30
`shielding, and can be a 300 MHz cable with a positive ACR
`ratio.
`It is still another desire of the invention to provide a cable
`that does not require individual shielding, and that allows for
`the precise spacing of conductors such as twisted pairs with
`relative ease.
`It is still a further desire of the invention to provide a data
`cable that has an interior support that accommodates a
`variety of AWG's and impedances, improves crush
`resistance, controls NEXT, controls electrical instability due
`to shielding, increases breaking strength, and allows the
`conductors such as twisted pairs to be spaced in a manner to
`achieve positive ACR ratios.
`Other desires, results. and novel features of the present
`invention will become more apparent from the following
`drawing and detailed description and the accompanying
`claims.
`
`4
`FIG. 1 is a cross-section taken along the horizontal plane
`of one embodiment of this novel cable. The shown embodi
`ment has an interior support or star separator (10). The
`interior support or star separator runs along the longitudinal
`length of the cable as can be seen in FIG. 2. The interior
`support or star separator, hereinafter, in the detailed
`description, both referred to as the "star separator". has a
`central region (12) extending along the longitudinal length
`of the star separator. The star separator has four prongs or
`splines. Each prong or spline (14), hereinafter in the detailed
`description both referred to as splines, extends outward from
`the central region and extends along the longitudinal length
`of the central region. The splines are integral with the central
`region. Each spline has a base portion (15). Each base
`portion is integral with the central region. Each spline has a
`base portion which has a horizontal width greater than the
`horizontal width of a portion of said spline above said base.
`Each spline also has a first lateral side (16) and a second
`lateral side (17). The first and second lateral sides of each
`spline extend outward from the central region and converge
`towards each other to form a top portion (18). Each spline
`has a triangular cross section with preferably an isosceles
`triangle cross section. Each spline is adjacent with at least
`two other splines. For instance, spline (14) is adjacent to
`both adjacent spline (20) and adjacent spline (21).
`The first lateral side of each spline is adjacent with a first
`or a second lateral side of another adjacent spline. The
`second lateral side of each spline is adjacent to the first or
`second side of still another adjacent spline.
`Each pair of adjacent splines defines a groove (22). The
`angle (24) of each groove is greater than 90°. The adjacent
`sides are angled towards each other so that they join to form
`a crevice (26), The groove extends along the longitudinal
`length of the star separator. The splines are arranged around
`the central region so that a substantial congruency exists
`along a straight line (27) drawn through the center of the
`horizontal cross section of the star separator. Further, the
`splines are spaced so that each pair of adjacent splines has
`a distance (28), measured from the center of the top of one
`spline to the center of the top of an adjacent spline (top to
`top distance) as shown in FIG. 3. The top to top distance (28)
`being substantially the same for each pair of adjacent
`splines.
`In addition, the shown embodiment has a preferred "tip to
`crevice" ratio of between about 2.1 and 2.7. Referring to
`FIG. 3. The "tip distance” (30) is the distance between two
`top portions opposite each other. The "crevice distance" (32)
`is the distance between two crevices opposite each other.
`The ratio is measured by dividing the "tip" distance by the
`'crevice' distance.
`The specific"tip distance", "crevice distance" and "top to
`top” distances can be varied to fit the requirements of the
`user such as various AWG's and impedances. The specific
`material for the star separator also depends on the needs of
`the user such as crush resistance, breaking strengths, the
`need to use gel fillings, the need for safety, and the need for
`flame and smoke resistance. One may select a suitable
`copolymer. The star separator is solid beneath its surface.
`A strength member may be added to the cable. The
`strength member (33) in the shown embodiment is located in
`the central region of the star separator. The strength member
`runs the longitudinal length of the star separator. The
`strength member is a solid polyethylene or other suitable
`plastic, textile (nylon, aramid, etc.), fiberglass (FGE rod). or
`metallic material.
`Conductors, such as the shown insulated twisted pairs.
`(34) are disposed in each groove. The pairs run the longi
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`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a cross-sectional view taken along the horizontal
`plane of one embodiment of this invention.
`FIG. 2 is a top right perspective view of this invention.
`The view shows the cable cut away to expose its various
`elements. The view further shows the helical twist of the
`prongs or splines.
`FIG. 3 is a cross-section of the interior support or star
`separator taken along the horizontal plane showing some of
`the dimensions of the interior support or star separator.
`FIG. 4 is a horizontal cross section of the interior or star
`separator support showing the features of the prongs or
`splines.
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`DETALED DESCRIPTION
`The following description will further help to explain the
`inventive features of this cable.
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`tudinal length of the star separator. The twisted pairs are
`insulated with a suitable copolymer. The conductors are
`those normally used for data transmission. The twisted pairs
`may be Belden's DataTwist(E) 350 twisted pairs. Although
`the embodiment utilizes twisted pairs, one could utilize
`various types of insulated conductors with the star separator.
`The star separator may be cabled with a helixed or S-Z
`configuration. In a helical shape. the splines extend helically
`along the length of the star separator as shown in FIG. 2. The
`helically twisted splines in turn define helically twisted
`conductor receiving grooves which accommodate the
`twisted pairs.
`The cable (37) as shown in FIG. 2 is a high performance
`shielded 300 Mhz data cable. The cable has an outer jacket
`(36) the outer jacket can be polyvinyl chloride or neoprene.
`Over the star separator is a polymer binder sheet (38). The
`binder is wrapped around the star separator to enclose the
`twisted pairs. The binder has an adhesive on the outer
`surface to hold a laterally wrapped shield (40). The shield
`(40) is a tape with a foil or metal surface facing towards the
`interior of the jacket. The shield in the shown embodiment
`is of foil and has an overbelt (shield is forced into round
`smooth shape) (41) which may be utilized for extremely
`well controlled electricals. A metal drain wire (42) is spirally
`wrapped around the shield. The drain spiral runs the length
`of the cable. The drain functions as a ground.
`My use of the term "cable covering" refers to a means to
`insulate and protect my cable. The cable covering being
`exterior to said star member and insulated conductors dis
`posed in said grooves. The outer jacket, shield, drain spiral
`and binder described in the shown embodiment provide an
`example of an acceptable cable covering. The cable
`covering. however, may simply include an outer jacket.
`The cable may also include a gel filler to fill the void space
`(46) between the interior support, twisted pairs and a part of
`the cable covering.
`The splines of applicants' novel cable allow for precise
`support and placement of the twisted pairs. The star sepa
`rator will accommodate twisted pairs of varying AWG's and
`impedance. The unique triangular shape of the splines
`provides a geometry which does not easily crush.
`The crush resistance of applicants' star separator helps
`preserve the spacing of the twisted pairs, and control twisted
`pair geometry relative to other cable components. Further,
`adding a helical or S-Z twist improves flexibility while
`preserving geometry.
`The use of a single shield around the star separator allows
`a minimum ground plane surface over the twisted pairs.
`about 45° of covering. The improved ground plane provided
`by applicants' shield, allows applicants' cable to meet a very
`low transfer impedance specification. The overall shield
`may have a more focused design for ingress and egress of
`cable emissions and not have to focus on NEXT duties.
`The strength member located in the central region of the
`star separator allows for the placement of stress loads away
`from the pairs.
`It will of course, be appreciated that the embodiment
`which has just been described has been given by way of
`illustration, and the invention is not limited to the precise
`embodiments described herein; various changes and modi
`fications may be effected by one skilled in the art without
`departing from the scope or spirit of the invention as defined
`in the appended claims.
`We claim:
`1. In a high performance data cable having a diameter of
`from about 0.300" to about 0.400", a plurality of insulated
`conductor pairs, and an interior support, said interior support
`comprising:
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`a cylindrical longitudinally extending central portion:
`a plurality of splines radially extending from said central
`portion along the length of said central portion. Said
`splines having a triangular cross-section with the base
`of the triangle forming part of the central portion, each
`of said triangular splines having the same radius;
`each spline of said plurality of splines being adjacent to
`two other splines of said plurality of splines;
`said splines longitudinally extending in a helical or S-Z
`shaped manner;
`a shield having a lateral fold, said shield supported by said
`triangular splines, said shield and splines defining a
`plurality of at least four conductor compartments;
`a twisted pair conductor disposed in each of said com
`partments; and
`said splines have a tip-to-crevice ration from about 2.1 to
`about 2.8.
`2. A high performance data cable comprising:
`an interior support extending along a longitudinal length
`of the data cable, said interior support having a central
`region. said central region extending along a longitu
`dinal length of said interior support;
`a plurality of prongs, each of said prongs being integral
`with said central region, said prongs extending along a
`longitudinal length of the central region and extending
`outward from said central region;
`an arrangement of said plurality of prongs wherein each
`of said prongs is adjacent with at least two other of said
`prongs, said arrangement forming a plurality of pairs of
`adjacent prongs;
`a groove defined by each of said pairs of adjacent prongs.
`said groove extends along the longitudinal length of the
`interior support, said plurality of pairs of adjacent
`prongs defining a plurality of said grooves;
`in said plurality of prongs, each of said prongs having a
`first and second lateral side, a portion of said first lateral
`side and a portion of said second lateral side of at least
`one of said prongs converging towards each other;
`a plurality of conductor compartments, each of said
`conductor compartments defined by a pair of said
`plurality of pairs of adjacent prongs and a foil shield
`having a lateral fold;
`a twisted pair of insulated conductors in each of said
`conductor compartments; and
`said prongs have a tip-to-crevice ratio of about 2.1 to
`about 2.8.
`3. A high performance data cable comprising:
`an interior support extending along a longitudinal length
`of the data cable, said interior support having a central
`region, said central region extending along a longitu
`dinal length of said interior support;
`a plurality of prongs, each of said prongs being integral
`with said central region, said prongs extending along a
`longitudinal length of the central region and extending
`outward from said central region;
`an arrangement of said plurality of prongs wherein each
`of said prongs is adjacent with at least two other
`prongs, said arrangement forming a plurality of pairs of
`adjacent prongs;
`a groove defined by each of said Pairs of adjacent prongs.
`said groove extends along the longitudinal length of the
`interior support, said plurality of pairs of adjacent
`prongs defining a plurality of Said grooves;
`a plurality of conductor compartments, each of said
`conductor compartments defined by a pair of said
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`plurality of pairs of adjacent prongs and a foil shield
`having a lateral fold;
`a twisted pair of insulated conductors in each of said
`conductor compartments; and
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`said prongs have a tip-to-crevice ratio of about 2.1 to
`about 2.8.
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`—
`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`
`
`
`—
`
`DATED
`INVENTOR(S) :
`
`Aug. 4, 1998
`Galen M. Gareis, etal
`
`It is certified that error appears in the above-indentified patent and that said letters Patent is hereby
`corrected as shown below:
`On the title page,
`Below "United States Patent. --Gareis et al.--
`
`75 Delete “Gaeris' and insert-Gareis
`
`Signed and Sealed this
`Twenty-second Day of June, 1999
`
`2.73%
`
`Q. TODD DICKINSON
`
`Attesting Officer
`
`A 'ring Cunnissioner of Puttents and Trude marks
`
`