Electrical cable comprising geometrically optimized conductors

• US 20040256139A1
• Filed: 06/19/2003
• Published: 12/23/2004
• Est. Priority Date: 06/19/2003
• Status: Abandoned Application

• Current Assignee: Belden Technologies, LLC (Belden Inc.)
• Original Assignee: Belden Technologies, LLC (Belden Inc.)
• Inventors: Clark, William T.
• Application Number:
  US10/465,017
• Publication Number:
  US 20040256139A1
• Time in Patent Office: Days
• US Class Current: 174/110R
• CPC Class Codes: H01B 11/002 Pair constructions
• CPC Class Codes: H01B 7/184 Sheaths comprising grooves, ribs or other projections
• CPC Class Codes: H01B 7/185 Sheaths comprising internal cavities or channels
• CPC Class Codes: H01B 7/189 Radial force absorbing layers providing a cushioning effect H01B7/185 takes precedence

Abstract

A number of examples of insulated conductors having geometrically optimized shapes and form factors, that may be used in twisted-pair cables and other types of communication cable to enhance the performance of, and/or reduce the cost of manufacturing such cables.

Claims

1. An insulated conductor comprising:

a conductive core; and

a first insulating layer surrounding the conductive core along its length;

wherein at least one of the insulating layer and the conductive core has an irregularly-shaped outer circumference.

2. The insulated conductor as claimed in claim 32, wherein the first insulating layer is disposed surrounding the conductive core along its length and covering the plurality of indentations so as to provide a plurality of open cells disposed between the conductive core and the first insulating layer.

3. The insulated conductor as claimed in claim 32, wherein the first insulating layer at least partially fills the plurality of indentations.

4. The insulated conductor as claimed in claim 1, wherein

the first insulating layer includes a plurality of fine filaments projecting outwardly from an outer surface of the first insulating layer.

5. A cable comprising a plurality of twisted pairs of insulated conductors, each twisted pair of insulated conductors including a first insulated conductor and a second insulated conductor;

wherein the first and second insulated conductors are the insulated conductor according to claim 4.

23. The insulated conductor as claimed in claim 1.

wherein insulated conductor has a substantially non-circular radial cross-section.

25. The insulated conductor as claimed in claim 1

wherein the first insulation layer comprises:

a first annular region of a first insulation material, the first annular region shaped so as to define a plurality of indentations along a circumference of the first annular region;

a second annular region of the first insulation material; and

a third annular region of a second insulation material.

32. The insulated conductor as claimed in claim 1, wherein the conductive core has an irregularly-shaped outer surface that defines a plurality of indentations spaced about a circumference of the conductive core.

6. A twisted pair of insulated conductors comprising:

a first insulated conductor comprising a first conductive core and a first insulation surrounding the first conductive core along its length; and

a second insulated conductor comprising a second conductive core and a second insulation surrounding the second conductive core along its length;

wherein at least one of the first insulation and the first conductive core and second insulations are has an irregularly-shaped outer circumference;

wherein at least one of the second insulation and the second conductive core has an irregularly-shaped outer circumference; and

wherein the first and second insulated conductors are twisted together to form the twisted pair.

7. The twisted pair of insulated conductors as claimed in claim 6, wherein the first and second insulations have an oval radial cross-section.

8. The twisted pair of insulated conductors as claimed in claim 7, wherein the first insulation comprises thicker portions and thinner portions, relative to one another, so as to provide the oval cross-section, and wherein the first insulation comprises two indentations in the thinner portions, the two indentations disposed opposite one another.

9. The twisted pair of insulated conductors as claimed in claim 6, wherein the first insulation includes at least one fin that protrudes outwardly from the first insulation.

10. The twisted pair of insulated conductors as claimed in claim 9, wherein the first insulation includes a first fin and a second fin, the first and second fins being disposed on opposite outer sides of the first insulation.

11. The twisted pair of insulated conductors as claimed in claim 10, wherein the second insulation comprises a third fin and a fourth fin, the third and fourth fins disposed on opposite outer sides of the second insulation.

12. The twisted pair of insulated conductors as claimed in claim 11, wherein the first and second insulated conductors are twisted together such that the first fin at least partially engages at least one of the third and fourth fins so as to provide an intra-locked twisted pair.

13. The twisted pair of insulated conductors as claimed in claim 6, wherein the first insulation comprises a cavity extending toward, but not reaching, the first conductive core.

14. The twisted pair of insulated conductors as claimed in claim 13, wherein the first insulation comprises a plurality of cavities spaced about an outer surface of the first insulation and extending inward toward, but not reaching, the first conductive core.

33. The twisted pair as claimed in claim 6, wherein each of the first and second insulations are substantially non-circular such that the first and second insulated conductors each has a substantially non-circular radial cross-section.

15. A twisted pair of insulated conductors comprising:

a first insulated conductor including a first conductive core and a first insulating layer surrounding the first conductive core along its length;

the first insulating layer comprising a first plurality of openings disposed about an outer surface of the first insulating layer and extending inward from the outer surface toward the first conductive core; and

a second insulated conductor including a second metal conductive core and a second insulation layer surrounding the second conductive core along its length, the second insulating layer comprising a second plurality of openings disposed about an outer surface of the second insulating layer and extending inward from the outer surface toward the second conductive core;

wherein the first and second insulated conductors are twisted together to form the twisted pair.

16. The twisted pair of insulated conductors as claimed in claim 15, wherein the first insulating layer comprises a first covering film disposed over the outer surface of the first insulating layer covering the first plurality of openings so as to form a first plurality of closed cells, and wherein the second insulating layer comprises a second covering film disposed over the outer surface of the second insulating layer covering the second plurality of openings so as to form a second plurality of closed cells.

17. The twisted pair of insulated conductors as claimed in claim 15, wherein the first insulated conductor further comprises a third insulating layer surrounding the first insulating layer along its length such that the first plurality of openings are covered by the third insulating layer, thereby forming a first plurality of air pockets disposed circumferentially about the first insulated conductor between the first and third insulating layers.

18. The twisted pair of insulated conductors as claimed in claim 17, wherein the second insulated conductor further comprises a fourth insulating layer surrounding the second insulating layer along its length and covering the second plurality of openings so as to form a second plurality of air pockets disposed circumferentially about the second insulated conductor between the second and fourth insulating layers.

19. A twisted pair of insulated conductors comprising:

a first insulated conductor including a first conductive core, a first insulating layer surrounding the first conductive core along its length, and a second insulating layer surrounding the first insulating layer along its length; and

a second insulated conductor including a second conductive core, a third insulating layer surrounding the second conductive core along its length, and a fourth insulating layer surrounding the third insulating layer along its length;

wherein the first and third insulating layers each is constructed to define at least one void within each of the first and third insulating layers disposed adjacent the first and second conductive cores, respectively; and

wherein the first and second insulated conductors are twisted together to form the twisted pair.

20. The twisted pair of insulated conductors as claimed in claim 19, wherein the first and third insulating layers are constructed so as to define a plurality of closed voids within each of the first and third insulating layers.

21. The twisted pair of insulated conductors as claimed in claim 20, wherein the first and third insulating layers are foamed.

22. The twisted pair of insulated conductors as claimed in claim 19, wherein the first insulating layer is constructed to define a plurality of openings spaced about an inner surface of the first insulating layer, adjacent an outer circumference of the first conductive core and extending outward into the first insulating layer and away from the first conductive core.

24. (canceled)

27. The insulated conductor of claim 27, wherein the first annular region is disposed between the second and third annular regions such that the plurality of indentations are disposed along an interface between the first annular region and the second annular region.

26. The insulated conductor of claim 27, wherein the first annular region is disposed adjacent the conductive core and the plurality of indentations are disposed along an inner circumference of the first annular region, adjacent the conductive core.

28. The insulated conductor of claim 27, wherein the first annular region is disposed between the second and third annular regions such that the plurality of indentations are disposed along an interface between the first annular region and the third annular region.

29. A method of making a twisted pair of insulated conductors comprising:

abrading an outer surface of a first metal core so as to provide the first metal core with an irregularly-shaped outer surface having a first plurality of indentations;

surrounding the first metal core with a first insulating layer to provide a first insulated conductor;

abrading an outer surface of a second metal core so as to provide the second metal core with an irregularly-shaped outer surface having a second plurality of indentations;

surrounding the second metal core with a second insulating layer to provide a second insulated conductor; and

twisting together the first and second insulated conductors to form the twisted pair.

30. The method as claimed in claim 29, wherein the steps of surrounding the first and second metal cores includes extruding first and second insulating layers to respectively surround the first and second metal cores.

31. The method as claimed in claim 30, wherein the steps of surrounding the first and second metal cores includes extruding the first and second insulating layers at a pressure sufficient to cause the first and second insulating layers to respectively at least partially fill the first and second plurality of indentations.