Flame retardant and smoke suppressant composite high performance support-separators and conduit tubes

• US 20050199415A1
• Filed: 01/06/2005
• Published: 09/15/2005
• Est. Priority Date: 01/07/2004
• Status: Active Grant

• Current Assignee: Cable Components Group, LLC (Berkshire Hathaway Incorporated)
• Original Assignee: Cable Components Group, LLC (Berkshire Hathaway Incorporated)
• Inventors: Glew, Charles A.
• Granted Patent: US 7,202,418 B2
• Time in Patent Office: Days
• US Class Current: 174/113.00C
• CPC Class Codes: G02B 6/4429 Means specially adapted for strengthening or protecting the cables
• CPC Class Codes: G02B 6/4435 Corrugated mantle
• CPC Class Codes: G02B 6/4459 Ducts; Conduits; Hollow tubes for air blown fibres
• CPC Class Codes: H01B 13/06 Insulating conductors or cables H01B13/32 takes precedence
• CPC Class Codes: H01B 7/185 Sheaths comprising internal cavities or channels
• CPC Class Codes: H01B 7/292 using material resistant to heat
• CPC Class Codes: H01B 7/295 using material resistant to flame
• CPC Class Codes: H02G 3/0412 Heat or fire protective means for fire in electric circuits A62C3/16
• CPC Class Codes: H02G 3/0481 with a circular cross-section H02G3/0468, H02G3/0475 take precedence
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

The present invention includes a high performance communications cable exhibiting reduced cross-talk of any form 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 and improve other electrical properties as well as reduce flame and smoke spread. The cable and separators are comprised of principally polymer blends that include olefin and/or fluoropolymer and/or chlorofluoropolymer based resins with and without inorganic additive such as nano-clay composites. These unique blends offer both flame and smoke suppression while maintaining the characteristics necessary to improve electrical performance and allow for severe cost reduction over conventional separators. The specially shaped core support-separators can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extend 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 is provided. The specially shaped core support-separator has both a central region as well as a plurality of shaped sections that extend outward from the central region that are either solid or partially solid, foamed or foamed with a solid skin surface. In addition, the invention includes the optional incorporation of hollow ducts that can be used to provide optical or metal conductor media either before, during, or after installation of the cable primarily by gas driven means.

Claims

1. A high performance communications cable comprising;

an interior support with an external radial and axial surface, said interior support is also a support-separator 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 of said communications cable;

said interior support comprising one or more outwardly extended shaped portions and optional conduit tubes extended from said central region wherein said central region, outwardly extended portions, and optional conduit tubes are comprised primarily of organic polymer blends.

2. The high performance communications cable and/or interior support of claim 1, wherein said interior support, said central region, said outwardly extended portions and said optional conduit tubes are comprised of a combination of inorganic and organic polymer blends.

3. The high performance communications cable and/or interior support of claim 1, wherein said interior support, said central region, said outwardly extended portions and optional conduit tubes are comprised of a combination of inorganic fillers or additives with said inorganic and/or organic polymer blends.

4. The high performance communications cable of and/or interior support of claim 1, wherein said interior support, said central region, and said outwardly extended portions and optional conduit tubes are capable of shielding conductors that transmit data at 10 Gbit while substantially mitigating or eliminating all forms of crosstalk and specifically alien crosstalk.

5. The high performance communications cable and/or interior support of claim 2, wherein said interior support, said central region, and said outwardly extended portions and optional conduit tubes are comprised of said combination of inorganic and organic polymer blends including any of the following;

homo and copolymers of ethylene or polyvinyl chloride or fluorinated ethylene propylene, fluorinated ethylene, chlorinated ethylene propylene, fluorochloronated ethylene, perfluoroalkoxy, fluorochloronated propylene, a copolymer of tetrafluoroethylene and perfluoromethylvinylether (MFA), a copolymer of ethylene and chlorotrifluoroethelyene (ECTFE), as well as homo and copolymers of ethylene and/or propylene with fluorinated ethylene, polyvinylidene fluoride (PVDF), as well as blends of polyvinyl chloride, polyvinylidene chloride, nylons, polyesters, polyurethanes as well as unsubstituted and substituted fullerenes primarily comprised of C₆₀ molecules including nano-composites of clay and other inorganics such as ZnO and TiO₂ also employed as nano-sized particles, wherein any and all combinations may be used to provide said polymer blends.

6. The high performance communications cable and/or interior support of claim 2, wherein wherein said interior support, said central region, and said outwardly extended portions and optional conduit tubes are comprised of said combination of inorganic and organic polymer blends and also include inorganic additives or fillers comprising;

metal oxides including magnesium trioxides, metal hydrates, including magnesium hydrates, silica or silicon oxides, brominated compounds, phosphated compounds, metal salts including magnesium hydroxides, ammonium octyl molybdate, calcium molybdate, or any effective combination thereof.

7. The high performance communications cable of claim 1 and/or interior support, wherein said interior support, said central region, said outwardly extended portions and optional conduit tubes are may also be comprised of compounds such as acid gas scavengers that scavenge gasses such as hydrogen chloride and hydrogen fluoride and other halogenated gasses during combustion.

8. The high performance communications cable and/or interior support of claim 1, wherein said interior support, said central region, said outwardly extended portions, and said optional conduit tubes are comprised of blends that each may include the use of recycled or reground thermoplastics in an amount up to 100%.

9. The high performance communications cable and/or interior support of claim 1, wherein said interior support, said central region, said outwardly extended portions and optional conduit tubes are comprised of a polymer blend ratio of fluorinated or otherwise halogenated polymers or copolymers to ethylene or vinyl chloride polymers or copolymers of from 0.1% to up to 99.9% of said fluorinated or otherwise halogenated polymers or copolymers to said ethylene or vinyl chloride polymers or copolymers.

10. The high performance communications cable of claim 9, wherein said interior support, said central region, said outwardly extended portions, and optional conduit tubes are comprised of a foamed polymer blend ratio of halogenated polymers or copolymers to ethylene or vinyl chloride polymers or copolymers of from 0.1% to up to 99.9% of said halogenated polymers to said ethylene or vinyl chloride polymers or copolymers and wherein said foam polymer blend includes a nucleating agent of polytetrafluoroethylene, carbon black, color concentrate, or boron trinitride or other acceptable nucleating or blowing agent.

11. The high performance communications cable of claim 1, wherein said interior support, said central region, said outwardly extended sections and optional conduit tubes comprise solid, partially solid, or foamed organic or inorganic dielectric materials, wherein said dielectric materials optionally include a solid skin surface with any one of said materials.

13. The high performance communications cable of and/or interior support of claim 1, wherein said interior support is a support-separator and said central region includes anvil shaped core support-separator sections.

14. The high performance communications cable and/or interior support of claim 1, wherein said interior support comprises a center portion, wherein said center portion of said interior support may be hollow along a longitudinal length of said communications cable.

15. The high performance communications cable and/or interior support of claim 13, wherein each of said anvil-shaped core support-separator sections comprises channel walls defining said one or more clearance channels and where said clearance channels are defined by a semi-circular geometry such that there remains a 180 degree opening along an external radial and axial surface of said interior support.

16. The high performance communications cable and/or interior support of claim 15, wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a semi-closed semi-circular geometry such that there remains less than a 160 degree opening along said exterior radial and axial surface, but more than a 10 degree opening along said external surface of said interior support of said clearance channels.

17. The high performance communications cable and/or interior support of claim 13, wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remains closed but optionally includes a flap-top allowing for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.

18. The high performance communications cable and/or interior support of claim 17, wherein said flap-top is comprised of a press-fit arrangement that is hinged allowing for opening and closing said exterior radial and axial surfaces of said channel walls of said clearance channels.

19. The high performance communications cable and/or interior support of claim 17, wherein said flap-top is sealed by use of heat, tape, interlocking, or by skin extrusion of said hinged press-fit arrangement.

20. The high performance communications cable and/or interior support of claim 17, wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remains closed but optionally includes an interlocking double flap-top, where said double flap-top is adhered to or adjoined with a surface on each side of said clearance walls for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.

21. The high performance communications cable and/or interior support of claim 20, wherein said double flap-top is comprised of a press-fit arrangement on each end that may remain in an opened or closed position for said exterior radial and axial surfaces of said channel walls of said clearance channels.

22. The high performance communications cable and/or interior support of claim 20, wherein said channel walls comprise interior surfaces that 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.

23. The high performance communications cable and/or interior support of claim 22, wherein said channel walls comprise interior surfaces that are corrugated including internal axial grooves separated by a sufficient distance such that individual conductors or conductor pairs forced into said grooves maintain required electrical integrity.

24. The high performance communications cable and/or interior support of claim 13, 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 anvil shaped 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.

25. The high performance communications cable and/or interior support of claim 13, wherein each of said anvil shaped core-support sections 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.

26. The high performance communications cable and/or interior support of claim 1, wherein said metal conductors are copper with or without metallic shielding.

27. The high performance communications cable and/or interior support of claim 1, wherein said metal conductors are aluminum with or without metallic shielding.

28. The high performance communications cable and/or interior support of claim 1, wherein said cable comprises an axial strength member wherein said axial strength member optionally lies parallel to said interior support inside a communications cable jacket or within said hollow portion of said interior support along said longitudinal direction of said support and said cable.

29. The high performance communications cable and/or interior support of claim 1, wherein said at least one anvil shaped support-separator section comprises an optional slotted section distinct from said support-separator sections that is sufficient to contain a grounding wire with an optional shielding tape.

30. The interior support of claim 20, wherein said double flap-top is sealed by use of heat, tape, or interlocking of said hinged press-fit arrangement.

31. The interior support of claim 22, wherein said channel walls comprise interior surfaces that 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.

32. The interior support of claim 31, wherein said channel walls comprise interior surfaces that are ribbed including internal radial grooves separated by a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity.

33. The interior support of claim 22, wherein said interior support comprises a corrugated convoluted external radial and axial surface extending along a longitudinal length such that external surfaces of said anvil shaped core-support sections include external radial grooves also extending along said longitudinal length of said support such that said interior support itself functions as a cable jacket.

34. The interior support of claim 13, wherein said at least one anvil shaped support-separator section comprises rounded edges of said anvil shaped supports at an outer radial end of said anvil shaped sections sufficient to reduce overall weight and size of said support-separator and subsequently said cable.

35. The interior support of claim 13, wherein said at least one anvil shaped support-separator sections comprise minimized dual lobes at an outer radial end of said multi-anvil shaped sections sufficient to minimize and reduce overall weight and size of said support-separator and subsequently said cable.

36. The interior support of claim 13, wherein said anvil shaped core support-separator sections themselves are twisted to a specified lay length.

43. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable cross-section instead comprising a pendulum shaped configuration with two ends and with two semi-circular disc pendants that comprise a circular central region of said pendulum shaped separator and an optional hollow orifice in a center region of said central portion of said interior support-separator.

44. The interior support-separator of claim 43, wherein said semi-circular disc pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.

45. The interior support-separator of claim 43, extending along a longitudinal length of said communications cable wherein said support-separator'"'"'s cross-section comprises instead a pendulum shaped configuration with two ends with a pendant shaped sections being semi-elliptical disc shaped pendants that comprise a central region of said pendulum shaped separator and an optional hollow orifice in a center region of said central portion of said interior support-separator.

46. The interior support-separator of claim 44, where said semi-elliptical disc pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.

47. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable cross-section comprising instead a pendulum shaped configuration with two ends with a pendant shaped section comprising triangular shaped pendants with apexes that face in opposite directions along a horizontal plane in a central region of said pendulum shaped separator comprising a diamond-like shape and an optional hollow orifice in a center region of said central portion of said interior support-separator.

48. The interior support-separator of claim 47, where said triangular shaped pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.

49. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable cross-section comprising instead, a dual-lobed shaped pendulum-like configuration with curved elongated lobed end portions along a top portion and a bottom portion of said pendulum-like separator creating at least two clearance channels for conductors or conductor pairs and an optional hollow orifice in a center region of said central portion of said interior support-separator.

50. The interior support-separator for a communications cable as in claim 1, comprising instead at least two symmetrical or asymmetrical intersecting arms that intersect in a cross-like manner along an essentially horizontal and vertical axis;

said intersecting arms provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like pattern along said horizontal and vertical axis said intersecting arms providing four or more separate clearance channels and wherein said arms are comprised of solid or foamed material.

51. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of a said communications cable, comprising instead at least two intersecting arms that intersect in a cross-like manner along an essentially horizontal and vertical axis;

said intersecting arms optionally provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like saw-tooth pattern along said horizontal and vertical axis and;

a central portion of said intersection of said arms, said central portion comprising a solid predetermined shaped member that includes step-like portions cut away from said central solid member and an optional hollow orifice in a center region of said central portion of said interior support-separator and where said central region is void of a saw-tooth member along at least one or more of said horizontal and vertical axis.

52. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable comprising instead at least two spatial quadrants defined by a horizontal arm member of said support including a two sided drill-bit-like shaped central member with geometrically symmetric sections in opposite quadrants and;

each said drill-bit-like shape a mirror image of said other drill-bit-like shape in said other quadrant and said support in sum appears to be shaped as a mirrored battleship and an optional hollow orifice in a center region of said central portion of said interior support-separator.

53. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable comprising instead, at least two intersecting arms that intersect in a cross-like manner comprising a cross-like support separator along an essentially horizontal and vertical axis;

said intersecting arms optionally provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like saw-tooth pattern along said horizontal and vertical axis and;

a central portion of said intersection of said arms, said central portion comprising an optional hollow center wherein said vertical and horizontal intersecting arms are initially wide or narrow along a horizontal or vertical axis and become finally narrow or wide along same said horizontal or vertical axis such that said cross-like support separator comprises an asymmetric pattern.

54. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable comprising instead at least two spatial quadrants defined by a horizontal member of said support optionally comprising rifle-like saw-blade tooth sections along either a top or bottom portion of said horizontal member.

55. The interior support-separator for a communications cable of claim 54, wherein said horizontal member is optionally comprised of a semi-flexible material, a semi-flexible thermoplastic material, or a semi-rigid thermoset material.

56. The interior support-separator for a communications cable as in claim 1, extending along a longitudinal length of said communications cable comprising instead at least two spatial quadrants defined by two horizontal members with two sides of said support connected by a vertical member with two sides such that said complete support appears as a symmetric or skewed angle iron with a z-like shape and where each of said members may be longer, shorter or the same length as each of the other two members.

57. The interior support-separator of claim 56, wherein said complete support-separator optionally includes rifle-like saw-blade tooth sections along any or all members of said support and along either side of each member of said support.

58. The interior support-separator of claim 57, wherein said support-separator void of any rifle-like saw-blade sections and is simply a film.

59. The interior support-separator of claim 1, providing a specified lay length by implementing a twisting of said clearance channels thereby providing said lay length twist into said support-separator prior to manufacturing said final communications cable assembly.

60. The interior support-separator of claim 1, providing a specified lay length by implementing a twisting of said clearance channels thereby providing said lay length twist into said support-separator during manufacturing of said final communications cable assembly.

61. The interior support-separator of claim 1, wherein said cable and/or separator comprises 24 pair of electrical conductors and a twenty fifth pair of electrical conductors wherein said twenty fifth pair is placed within an orifice within said central region of said interior support-separator.

68. The high performance communications cable and interior support of claim 1 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 ring region.

69. The high performance communications cable and interior support of claim 68, 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).

70. The high performance communications cable and interior support of claim 69, 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.

71. The high performance communications cable and interior support of claim 68, 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.

72. The high performance communications cable and interior support of claim 68, 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.

73. The high performance communications cable and interior support of claim 68, 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.

74. The high performance communications cable and interior support of claim 68, 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.

76. The high performance communications cable of claim 74, wherein said metal conductors are aluminum with or without metallic shielding.

77. The high performance communications cable and interior support of claim 68, 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.

78. The high performance communications cable and interior support of claim 1 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.

79. The high performance communications cable of claim 78, 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).

80. The high performance communications cable of claim 78, wherein said interior support comprises 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.

81. The interior support-separator of claim 80, 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).

82. The high performance communications cable of claim 1 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.

83. The high performance communications cable of claim 82, 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.

84. The high performance communications cable of claim 1 comprising;

an interior support with 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.

85. The high performance communications cable of claim 78, 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.

86. The high performance communications cable of claim 78, 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.

87. The high performance communications cable of claim 86, 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).

88. The high performance communications cable as in claim 87, also 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.

94. A method of upgrading a communications cable comprising an interior support-separator as in claim 1, wherein between a first node and a second node remote from said communications cable comprising an interior support-separator;

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

attaching a supply of compressed gas to said 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.

95. A method as in claim 94, 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.

96. A method as in claim 95, wherein said first transmission line includes at least one electrical conductor and said second transmission line includes at least one optical fiber.

97. A method as claimed in claim 96, wherein said at least one optical fiber is a single mode optical fiber.

98. A method as claimed in claim 94, wherein said transmission line can include any transmission type media.

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

along its cross-section a maltese-cross shaped configuration with two arm members such that said maltese-cross shape is optionally skewed along one arm member with an axis along said arm member providing a length along said one axis of said arm member that is longer than along any other axis and providing larger blunt tipped ends at both ends of said arm member than blunt tipped ends at both ends of an arm member with a length shorter than said other longer arm member and an optional hollow orifice in a center region of a central portion of said interior support-separator.

38. An interior support-separator for a communications cable as in claim 37, wherein said maltese-cross shaped cross-sectional configuration along said cross-section includes step-like sections along a perimeter of said support-separator providing small interstitial sectional grooves along an inner circumferential portion of clearance channels provided by said support-separator and an optional hollow orifice said center region of said central portion of said interior support-separator.

39. An interior support-separator for a communications cable as in claim 38, extending along a longitudinal length of a communications cable, comprising along its cross-section a central region of a solid diamond shaped configuration with an optional hollow orifice in said center region of said central portion of said interior support-separator.

40. The interior support-separator of claim 39, comprising within said cross-section, two hollow triangular orifices in said central region of said interior support-separator, said hollow triangular orifices shaped as equilateral triangles, one said triangular orifice facing upright and said other triangular orifice facing downward such that a peak of each triangular orifice is facing in opposite directions.

41. The interior support-separator of claim 40, comprising within said cross-section, a diamond shaped orifice in said central region of said interior support-separator.

42. The interior support-separator of claim 41, comprising within said cross-section, a center slit orifice in said central region of said interior support-separator.

62. A method for producing a high performance communications cable by using organic or organic/inorganic polymer blends 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 clearance channels into a jacket of said cable by;

passing a plurality of transmission conductors within said clearance channels of said interior support-separator through a first die that aligns the plurality of t transmission conductors with surface features of said internal support allowing for intentional twisting of said conductors,

forcing each of said plurality of conductors into a proper clearance channel of said interior support-separator where said clearance channels are optionally closed by single or double flap-tops, thereby maintaining a spatial relationship between each of said transmission conductors by use of a second die,

heating said second die allowing for closing of said exterior surface of said channels,

taping and twisting said interior support allowing for closing of said exterior surface of said channels, and;

jacketing said interior support containing each of said conductors within said clearance channels.

63. The method of producing a cable of claim 62, by omitting the step of heating.

64. The method of producing a cable of claim 62, by omitting the use of a second die.

65. The method of producing a cable of claim 62, by including the use of a metal ring for forcing said conductors into a proper clearance channel and forcing closure of said flap-tops.

66. The method of producing a cable of claim 62, by omitting the step of taping and twisting.

67. The method of producing a cable of claim 62, by omitting the step of jacketing said cable.

75. The high performance communications cable of 74, wherein said metal conductors are copper with or without metallic shielding.

89. A method for producing a high performance communications cable utilizing organic and/or inorganic polymer blends 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 wherein one or more central regions of said support-separator sections are optionally hollow and optionally jacketed to complete said cable by;

passing a plurality of transmission conductors within said optionally hollow central regions 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 optionally hollow central region portions of said interior support-separator where said hollow central ring portions maintain a spatial relationship between each of said transmission conductors by optionally;

jacketing said interior support containing each of said conductors within said hollow central regions and;

optionally pulling each of said transmission conductors through said hollow central regions or said support-separators either before, during or after initial installation.

90. The method of producing a cable of claim 89, by omitting the step of jacketing said cable.

91. The method of producing a cable of claim 89, wherein jacketing and/or support-separator extrusion line speeds are significantly improved compared with conventional line speeds when said polymer blends are not utilized.

93. The high performance communications cable of claim 91, wherein said cable meets as a minimum the EIA/TIA CAT 5e as well as CAT 6, and CAT 6e electrical performance requirements and wherein conductors within said cable or interior support-separator acting as said cable achieves significantly reduced near-end cross talk (NEXT), power sum near end cross talk (PSNEXT), equal level far end cross talk (ELFEXT) and power sum equal level far end cross talk (PSELFEXT) and alien cross-talk values and wherein said cable also passes flammability and smoke generation requirements as defined by UL 910, UL 2424, NAPA 262, 259, 255, and EN 50266-2-x, class B test specifications.

92. 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 polymer blend based materials capable of meeting specific flammability and smoke generation requirements as defined by UL 910, UL 2424, NAPA 262, 259, 255, and EN 50266-2-x, class B test specifications.