Support separators for high performance communications cable with optional hollow tubes for; blown optical fiber, coaxial, and/or twisted pair conductors

• US 20050103518A1
• Filed: 06/13/2003
• Published: 05/19/2005
• Est. Priority Date: 04/15/2003
• Status: Active Grant

• Current Assignee: Cable Components Group, LLC
• Original Assignee: Cable Components Group, LLC
• Inventors: Glew, Charles
• Granted Patent: US 7,241,953 B2
• Time in Patent Office: Days
• US Class Current: 174/113.R
• CPC Class Codes: G02B 6/4459 Ducts; Conduits; Hollow tubes for air blown fibres
• CPC Class Codes: G02B 6/4489 of central supporting members of lobe structure
• CPC Class Codes: H01B 11/04 with pairs or quads mutually positioned to reduce cross-talk
• CPC Class Codes: H01B 11/22 Cables including at least one electrical conductor together with optical fibres

Abstract

The present invention includes a high performance communications cable exhibiting reduced cross-talk between transmission media that includes one or more core support-separators having various shaped profiles which define a clearance to maintain a spacing between transmission media or transmission media pairs. The core may be formed of a conductive or insulative material to further reduce cross-talk. The central core region may include a hollow opening or duct for blown fiber (ABF). A method of producing this cable introduces a core support-separator as described above into a cable assembly. The specially shaped core support-separator can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extends along the longitudinal length of the communications cable. Alternatively, with no jacket for cable completion, a portion of the separator wherein a thin layer of material can act as a type of skin for future mechanical protection may exist. The specially shaped core support-separator has a central region that is either solid, partially solid, foamed, with a solid skin over the foam or hollow itself. The cable may include a plurality of shaped sections that extend outward from the central region along the length of the central region. Each of the adjacent specially shaped sections defines a distinct clearance channel that extends along the longitudinal length of the core support-separator. Each of the defined clearance channels allow for disposal therein of conductors and/or optical fibers.

Claims

1. A high performance communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising at least one symmetrical core with either a diamond-shaped or circular center outer hollow ring region with an optional inner central diamond-shaped or circular hollow ring region with optionally extending protrusions each extending in a preferred separation from each of said other extending protrusions extending from said outer hollow ring region.

2. The high performance communications cable of claim 1, wherein said central ring portion optionally includes a hollow region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber(s) or other conductor(s).

3. The high performance communications cable of claim 1, wherein said interior support, and said central circular region shaped core support-separator sections comprises solid, partially solid, or hollow, foamed organic or inorganic dielectric materials.

4. The high performance communications cable of claim 1, wherein said interior support, and said central circular region shaped core support-separator sections comprises solid, partially solid, or foamed thermoplastic or thermosetting dielectric materials

5. The high performance communications cable of claim 1, wherein channel walls of said central circular ring region with extending protrusions are corrugated including internal axial grooves separated by a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity and such that said conductor or conductor pairs are optionally forced against an edge of said grooves or sections of said channel walls.

6. The high performance communications cable of claim 5, wherein said interior support comprises a corrugated or convoluted external radial and axial surface extending along a longitudinal length of said communications cable, such that external surfaces of said symmetrical core with a central circular ring region include external radial grooves also extending along said longitudinal length of said support such that said interior support can itself function as a cable jacket for said communications cable.

7. The high performance communications cable of claim 1, wherein said at least one symmetrical core with a central circular ring region with said protrusions are optionally singularly filled with individual or paired metal or optionally coaxial electrical transmitting conductors or optical fiber light transmitting conductors, or filled with a combination of said individually or paired metal or optical conductors along said longitudinal length of said support and said cable.

8. The high performance communications cable of claim 7, wherein said metal conductors are copper with or without metallic shielding and said cable optionally comprises a form of metallic shielding.

9. The high performance communications cable of claim 8, wherein said metal conductors are aluminum with or without metallic shielding and said cable optionally comprises a form of metallic shielding.

10. The high performance communications cable of claims 1-9 wherein said cable comprises one or more axial strength members wherein said axial strength members optionally lie parallel to said interior support inside said communications cable jacket or within said hollow portion of said interior support along said longitudinal direction of said support and said cable.

11. An interior support-separator for a communications cable extending along a longitudinal length of said communications cable, comprising;

an external radial and axial surface, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising at least one symmetrical core with a central circular ring region with an optional inner central circular ring region with extending protrusions each extending in a preferred separation from each of said other extending protrusions.

12. The interior support-separator for a communications cable of claim 11, wherein said central ring portion optionally includes a hollow region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber or other conductors.

13. The interior support-separator for a communications cable of claim 11, wherein said interior support, and said central circular region shaped core support-separator sections comprises solid, partially solid, or hollow, foamed organic or inorganic dielectric materials.

14. The interior support-separator for a communications cable of claim 11, wherein said interior support, and said central circular region shaped core support-separator sections comprises solid, partially solid, or foamed thermoplastic or thermosetting dielectric materials.

15. The interior support-separator for a communications cable of claim 11, wherein channel walls of said central circular ring region with four extending rifled protrusions that are corrugated including internal axial grooves separated a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity and such that said conductor or conductor pairs are optionally forced against an edge of said grooves or sections of said channel walls wherein said interior support comprises a corrugated or convoluted external radial and axial surface extending along a longitudinal length of said communications cable, such that external surfaces of said symmetrical core with a central circular ring region include external radial grooves also extending along said longitudinal length of said support such that said interior support can itself function as a cable jacket for said communications cable.

16. The interior support-separator for a communications cable of claim 11, wherein said interior support comprises a corrugated or convoluted external radial and axial surface extending along a longitudinal length of said communications cable, such that external surfaces of core-support sections include external radial grooves also extending along said longitudinal length of said support such that said interior support can itself function as a cable jacket for said communications cable.

17. The interior support-separator for a communications cable of claim 11, wherein said at least one symmetrical core with a central circular ring region with said protrusions are optionally singularly filled with individual or paired metal or optionally coaxial electrical transmitting conductors or optical fiber light transmitting conductors, or filled with a combination of said individually or paired metal or optical conductors along said longitudinal length of said support and said cable.

18. The interior support-separator for a communications cable of claims 11-17 wherein said metal conductors are copper with or without metallic shielding and said cable optionally comprises a form of metallic shielding.

19. The interior support-separator for a communications cable of claim 18, wherein said metal conductors are aluminum with or without metallic shielding and said cable optionally comprises a form of metallic shielding.

20. The interior support-separator for a communications cable of claims 12 and 19 wherein said cable comprises one or more axial strength members wherein said axial strength members optionally lie parallel to said interior support inside said communications cable jacket or within said hollow portion of said interior support along said longitudinal direction of said support-separator and said cable.

39. An interior support of claim 11, providing a specified lay length by implementing a twisting of said hollow central region thereby providing said lay length twist into said support-separator prior to manufacturing said final communications cable assembly.

21. A high performance communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a hollow four-petal daisy shaped arrangement with a central core that may or may not be hollow, each of said hollow petals separated by 90 degrees along an axial plane that extends along a complete length of said communications cable allowing for individual or paired conductors to be placed within said hollow petals.

22. The high performance communications cable of claim 21 wherein said central portion of said four-petal daisy optionally includes at least one hollow region acting as a ductlet for an air blown fiber (ABF) which are available for filling with optical fiber(s) or other conductor(s).

23. The high performance communications cable of claim 21, wherein said petal portions of said four-petal daisy optionally includes at least one hollow region acting as a ductlet for an air blown fiber (ABF) which are available for filling with optical fiber(s) or other conductor(s).

24. An interior support-separator for a communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a hollow four-petal daisy shaped arrangement with a central core that may or may not be hollow, each of said hollow petals separated by 90 degrees along an axial plane that extends along a complete length of said communications cable allowing for individual or paired conductors to be placed within said hollow petals or within hollow sections of otherwise solid petals.

25. The interior support-separator of claim 24, wherein said central portion of said four-petal daisy optionally includes a hollow region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber(s) or other conductor(s).

26. The high performance communications cable of claim 24, wherein said petal portions of said four-petal daisy optionally includes at least one hollow region acting as a ductlet for an air blown fiber (ABF) which are available for filling with optical fiber(s) or other conductor(s).

27. A high performance communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising an inner cross-like separator section with rifled sections extending outward into four-quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like rifled separator sections encased within an outer insulated layer which is itself shaped in an identical cross-like pattern as said cross-like separator section so that dimensions of said outer insulated layer forms a cross-like pattern larger than said rifled inner cross and functions as a skin for said inner cross-like pattern.

28. The high performance communications cable of claim 27, wherein said central portion of said inner cross-like separator with said outer insulated layer optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber or other conductors.

29. An interior support-separator for a communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising an inner cross-like separator section with rifled sections extending outward into four quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like rifled separator sections encased within an outer insulated layer which is itself shaped in an identical cross-like pattern as said cross-like separator section so that dimensions of said outer insulated layer forms a cross-like pattern larger than said rifled inner cross and functions as a skin for said inner cross-like pattern.

30. The interior support-separator of claim 29, wherein said central portion of said inner cross-like separator with said outer insulated layer optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber or other conductors.

31. A high performance communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a cross-like separator section with zig-zag sections extending outward into four quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like zig-zag separator sections.

32. The high performance communications cable of claim 31, wherein said central portion of said cross-like separator with said extended zig-zag sections optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber or other conductors.

33. An interior support-separator for a communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a cross-like separator section with zig-zag sections extending outward into four quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like zig-zag separator sections.

34. The interior support-separator for a communications cable comprising as in claim 33, wherein said central portion of said cross-like separator with said extended zig-zag sections optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber or other conductors.

35. A high performance communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a cross-like separator section with zig-zag sections that have sickle-like ends at each of said sections zig-zag sections and extend outward into four quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like zig-zag separator sections with said sickle-like ends.

36. The high performance communications cable of claim 35, wherein said central portion of said cross-like separator with said extended zig-zag sections with said sickle-like ends optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber(s) or other conductor(s).

37. An interior support-separator for a communications cable comprising;

an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said interior support comprising a cross-like separator section with zig-zag sections that have sickle like ends that extend outward into four quadrants away from said central region, said quadrants defined by 90 degree right angles formed by an intersection of said extended cross-like zig-zag separator sections with sickle-like ends.

38. The interior support-separator as in claim 37, wherein said central portion of said cross-like separator with said extended zig-zag sections with said sickle-like ends optionally includes a hollow central region acting as a ductlet for an air blown fiber (ABF) which is available for filling with optical fiber(s) or other conductor(s).

40. A method for producing a high performance communications cable by introducing an interior support-separator section or sections with a longitudinal length, said external radial and axial surfaces having a central region extending along said longitudinal length of said interior support with said one or more hollow central ring portions optionally jacketed to complete said cable by;

passing a plurality of transmission conductors within said hollow central ring portions of said interior support-separator through a first die that aligns the plurality of transmission conductors with surface features of said internal support allowing for intentional twisting of said conductors, forcing each of said plurality of conductors into said hollow central region ring portions of said interior support-separator where said hollow central ring portions maintain a spatial relationship between each of said transmission conductors by optionally;

shielding and jacketing said interior support containing each of said conductors within said hollow central region sections and;

optionally pulling each of said transmission conductors through said hollow ring portion(s) or said support-separators either before during or after initial installation.

41. The method of producing a cable of claim 40, by omitting the step of jacketing said cable.

42. A high performance communications cable comprising;

an interior support-separator with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;

said support comprised of a thermoplastic based material capable of meeting specific flammability and smoke generation requirements as defined by UL 910, NAPA 262, and EN 50266-2-x, class B test specifications.

43. A method of upgrading a communications cable between a first node and a second node remote from the first said communications cable comprising an interior support;

said interior support comprising optionally at least one symmetrical core with a central circular ring region with optionally extending protrusions each extending in a preferred degree separation from each of said other extending protrusions, wherein said central ring portion optionally includes a hollow region acting as a ductlet extending from the first node to the second node and the duct containing a first transmission line which extends between the first and second nodes, the method optionally comprising the steps of;

attaching a supply of compressed gas to the duct at said first node;

flowing gas from said supply of compressed gas along said duct from said first node to said second node to cause viscous drag forces to act on said first transmission line, and withdrawing said first transmission line from said duct under the action of said viscous drag forces;

introducing a second transmission line into said duct at one of said nodes, supplying compressed gas to said duct at said one of said nodes to cause a flow of gas between said one node and said other node; and

;

advancing said second transmission line from said one node to said other node under said action of viscous drag forces caused by action on said second transmission line by gas flowing from said one of said nodes towards said other of said nodes.

44. A method as in claim 43, wherein said first transmission line comprises at least one multimode optical fiber and said second transmission line comprises at least one single mode optical fiber.

45. A method as in claim 44, wherein said first transmission line includes at least one electrical conductor and said second transmission line includes at least one optical fiber.

46. A method as claimed in claim 45, wherein said at least one optical fiber is a single mode optical fiber.

47. A method as claimed in claim 43, wherein said transmission line can include any transmission type media.