Communication wire

• US 20080066944A1
• Filed: 05/03/2007
• Published: 03/20/2008
• Est. Priority Date: 09/24/2002
• Status: Active Grant

• Current Assignee: CommScope Technologies, LLC (CommScope Holding Company, Inc.)
• Original Assignee: ADC Incorporated (CommScope Holding Company, Inc.)
• Inventors: Dickman, Jim, Kenny, Robert, Johnston, Fred, Wiekhorst, David, Stutzman, Spring, Juengst, Scott, Stutzman, Jeff
• Granted Patent: US 7,560,648 B2
• Time in Patent Office: Days
• US Class Current: 174/106R
• CPC Class Codes: H01B 11/002 Pair constructions
• CPC Class Codes: H01B 11/12 Arrangements for exhibiting specific transmission characteristics
• CPC Class Codes: H01B 7/0233 Cables with a predominant gas dielectric
• CPC Class Codes: H01B 7/0275 comprising one or more extruded layers of insulation

Abstract

The present invention relates to an improved isolated core or insulated conductor with a low dielectric constant and reduced materials costs. Apparatuses and methods of manufacturing the improved isolated core or insulated conductor are also disclosed.

Claims

1-48. -48. (canceled)

49. A twisted wire pair comprising:

a first wire and a second wire, the first and second wires being twisted about one another;

the first wire including a first conductor, the first wire also including a first polymeric insulator surrounding the first conductor, the first polymeric insulator defining a plurality of first insulator channels having lengths that run along the length of the first conductor, each of the plurality of first insulator channels having an open side that faces toward the first conductor, each of the plurality of first insulator channels including a first material therein that has a dielectric constant that is lower than the dielectric constant of the first polymeric insulator; and

the second wire including a second conductor, the second wire also including a second polymeric insulator surrounding the second conductor, the second polymeric insulator defining a plurality of second insulator channels having lengths that run along the length of the second conductor, each of the plurality of second insulator channels having an open side that faces toward the second conductor, each of the plurality of second insulator channels including a second material therein that has a dielectric constant that is lower than the dielectric constant of the second polymeric insulator.

50. The twisted wire pair of claim 49, wherein the first and second polymeric insulators include a polyolefin material.

51. The twisted wire pair of claim 49, wherein the first and second polymeric insulators includes a fluoropolymer material.

52. The twisted wire pair of claim 51, wherein the fluoropolymer material includes foamed fluoropolymer.

53. The twisted wire pair of claim 49, wherein an overall dielectric constant of each of the first and second wires is less than about 2.

54. The twisted wire pair of claim 49, wherein the first and second polymeric insulators are each less than about 0.01 inches thick.

55. The twisted wire pair of claim 49, wherein open inner sides of the first insulator channels are bounded by a first outer peripheral surface of the first conductor, and wherein open inner sides of the second insulator channels are bounded by a second outer peripheral surface of the second conductor.

56. The twisted wire pair of claim 49, wherein the first and second materials within the first and second insulator channels include a gas.

57. The twisted wire pair of claim 49, wherein the gas within the first and second insulator channels includes air.

58. The twisted wire pair of claim 49, wherein the first and second materials within the first and second insulator channels include a polymer.

59. The twisted wire pair of claim 49, wherein a first outer peripheral surface of the first conductor is exposed to the first material within the first insulator channels and a second outer peripheral surface of the second conductor is exposed to the second material within the second insulator channels.

60. A twisted wire pair according to claim 49, wherein at least one of the first and second conductors has a diameter of less than about 0.042 inches.

61. A telecommunications cable comprising:

a first wire and a second wire, the first and second wires being twisted about one another; and

the first and second wires each including;

a conductor extending along a longitudinal axis; and

a polymeric insulation surrounding the conductor, the polymeric insulation defining a plurality of channels that extend generally along the longitudinal axis, the channels being circumferentially spaced relative to one another about the conductor, the channels having an open side that faces toward the conductor, the channels containing a channel material,

wherein at least one of the polymeric insulation and the channel material includes foamed construction.

62. A telecommunications cable according to claim 61, wherein the channels contain gas and the conductor includes an exterior surface that is exposed to the gas within the channels.

63. A telecommunications cable according to claim 61, wherein the polymeric insulation includes foamed construction.

64. A telecommunications cable according to claim 61, wherein the polymeric insulation includes a fluoropolymer material.

65. A telecommunications cable according to claim 61, wherein the conductor has a diameter of less than about 0.042 inches.

66. A telecommunications cable according to claim 61, wherein the polymeric insulation is less than about 0.01 inches thick.

67. A telecommunications cable according to claim 61, wherein a shape of at least one of the channels is selected from the group consisting of rectangular, trapezoidal and arched.

68. A telecommunications cable according to claim 61, wherein the cable includes an outer jacket surrounding the first and second wires twisted about one another, the outer jacket including channels.