Multiple conductor electrical cable with minimized crosstalk

• US 6,378,283 B1
• Filed: 05/25/2000
• Issued: 04/30/2002
• Est. Priority Date: 05/25/2000
• Status: Expired due to Fees

• Current Assignee: General Cable Technologies Corporation (General Cable Corporation)
• Original Assignee: Helix/HiTemp Cables, Inc.
• Inventors: Barton, John A.
• Primary Examiner(s): Calvert, John J.
• Assistant Examiner(s): Hurley, Shaun R
• Application Number:
  US09/578,289
• Time in Patent Office: 705 Days
• Field of Search: 57/584.9, 57/585.2, 57/586.3, 57/586.5, 57/587, 57/587.2, 57/588.1, 57/59, 57/60, 57/61, 57/62, 57/63, 57/64, 57/66, 573/14
• US Class Current: 57/58.52
• CPC Class Codes: H01B 11/04 with pairs or quads mutually positioned to reduce cross-talk
• CPC Class Codes: H01B 13/0257 being a perforated disc
• CPC Class Codes: H01B 13/0292 After-treatment

Abstract

A process and apparatus for manufacturing multiple conductor cable having improved transmission parameters. The apparatus includes a rotatable alignment die having a plurality of apertures. At least one strand of the multiple conductor cable is caused to traverse an aperture of the rotatable alignment die. A rotation motor causes the strand to rotate about its elongate axis, and a translation motor causes the strand, or the cable, to traverse along its elongate axis. The multiple conductors are brought into a predetermined mutual mechanical alignment that is calculated to produce a cable having at least one improved transmission parameter. The cable can additionally include a support member adapted to maintain the conductors in the mutual mechanical alignment. A binder is applied to the cable to maintain the conductors in the predetermined mutual alignment. Tests performed on cable manufactured using the principles of the invention demonstrate improved transmission characteristics as compared to cable made without using the principles of the invention.

Claims

1. An apparatus for manufacturing a multiple conductor cable from a plurality of elongate conductors, comprising:

a rotatable aligning die including a plurality of apertures;

an applicator adapted to apply a binder to at least two of said plurality of conductors; and

one or more motors that cause;

at least one of said plurality of elongate conductors to traverse along its elongate axis, and

at least one of said plurality of elongate conductors to rotate substantially about its elongate axis;

whereby at least one of said plurality of elongate conductors is caused to traverse at least one of said apertures of said rotatable aligning die, said plurality of elongate conductors are brought into a defined mutual mechanical alignment, and said plurality of elongate conductors are retained in said mutual mechanical alignment at least partially by the application of said binder, producing said multiple conductor cable.

2. The apparatus of claim 1, further comprising:

a support situated substantially along a rotation axis of said die, said support stabilizing said mutual mechanical alignment of at least two of said plurality of elongate connectors.

3. The apparatus of claim 2, wherein said support is a consumable mechanical alignment component that is incorporated into the cable that is manufactured.

4. The apparatus of claim 1, further comprising:

a support fixture adapted to adjustably position said applicator relative to the position where said elongate conductors are brought into mutual mechanical alignment.

5. The apparatus of claim 1, wherein said applicator comprises an applicator that dispenses a heated binder material adapted to bind at least two of said plurality of conductors.

6. The apparatus of claim 1, wherein the rotatable aligning die comprises:

a rotatable body including a circular periphery and including a plurality of apertures therethrough, each of said plurality of apertures adapted to receive one or more elongate electrical conductors;

a fixing collar adapted to be adjustably attached to said apparatus for manufacturing a multiple conductor cable; and

at least one bearing situated at the circular periphery of said rotatable body and supporting said rotatable body within said fixing collar;

said body capable of rotating relative to said fixing collar, said apertures aligned in said body substantially transversely to a plane defined by said circular periphery of said body.

7. A rotatable aligning die for the manufacture of multiple conductor electrical cable, comprising:

a rotatable body including a circular periphery and including a plurality of apertures therethrough, each of said plurality of apertures adapted to receive one or more elongate electrical conductors;

a fixing collar adapted to be adjustably attached to said apparatus for manufacturing a multiple conductor cable; and

at least one bearing situated at said circular periphery of said rotatable body and supporting said rotatable body within said fixing collar;

said body capable of rotating relative to said fixing collar, said apertures aligned in said body substantially transversely to a plane defined by said circular periphery of said body and oriented at an angle non-parallel to a rotation axis of said rotatable body;

whereby the application of rotational force to at least one of said electrical conductors causes the rotation of the rotatable body.

8. A process for manufacturing a multiple conductor cable from a plurality of elongate conductors, comprising the steps of:

providing a rotatable aligning die including a plurality of apertures;

providing an applicator adapted to apply a binder to at least two of said plurality of conductors;

advancing at least one of said plurality of elongate conductors through at least one of said apertures of said rotatable aligning die;

rotating at least one of said plurality of elongate conductors about its elongated axis;

bringing said plurality of elongate conductors into a defined mutual mechanical alignment; and

retaining at least two of said plurality of elongate conductors in said mutual mechanical alignment at least partially by the application of said binder.

9. The process of claim 8, further comprising the step of:

providing a consumable mechanical alignment component that is incorporated into said cable to stabilize said mutual mechanical alignment of at least two of said plurality of conductors.

10. The process of claim 8, further comprising the step of:

providing a support member disposed substantially along a rotation axis of said rotatable aligning die to stabilize the mutual mechanical alignment of at least two of said plurality of conductors, said support member not being incorporated into said cable.

11. A multiple conductor cable comprising a plurality of elongate conductors produced by the process of claim 8.