Electrical cable apparatus and method for making

• US 6,506,976 B1
• Filed: 09/14/1999
• Issued: 01/14/2003
• Est. Priority Date: 09/14/1999
• Status: Expired due to Term

• Current Assignee: Commscope Inc of North Carolina (CommScope Holding Company, Inc.)
• Original Assignee: Avaya Technology Corporation Miami Lakes FLA US
• Inventors: Neveux, Paul Emilien Jr.
• Primary Examiner(s): Reichard, Dean A.
• Assistant Examiner(s): Mayo, III, William H.
• Application Number:
  US09/396,682
• Time in Patent Office: 1,218 Days
• Field of Search: 174/36, 174/113.R, 174/113.A, 174/113.AS, 174/113.C, 174/27
• US Class Current: 174/113.00R
• CPC Class Codes: H01B 11/06 with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens

Abstract

Embodiments of the invention include an electrical cable apparatus and method for making. The electrical cable apparatus includes a plurality of paired conductive elements, a dielectric jacket formed around the plurality of paired conductive elements, and at least one dielectric film separating the pairs of conductive elements within the dielectric jacket. For example, for an arrangement having four twisted pair of copper wires within an electrically insulating jacket, two dielectric films surround alternating pairs of individually insulated conductor elements. The dielectric film is made of one or more of the following materials: ethylchlorotrifluoroethylene (ECTFE or HALAR®), poly(vinyl chloride) (PVC), polyolefins, and fluoropolymers including fluorinated ethylene-propylene (FEP or TEFLON®), perfluoroalkoxy polymers of tetrafluoroethylene and either perfluoropropyl ether (PFA) or perfluoromethylvinyl ether (MFA). Alternatively, the dielectric film is made of woven glass yarn tape such as KAPTON®. The dielectric film has a width, e.g., of approximately 0.125 to 0.250 inch and a thickness, e.g., of approximately 2 to 20 mils (0.002 to 0.020 inch). Alternatively, a dielectric film is positioned between individual conductive elements within the conductor pairs. The method for making an electrical cable includes providing a plurality of the paired conductive elements, forming the dielectric film around one or more of the conductor pairs and/or forming the dielectric film between the individual conductors within one or more conductor pairs, and forming the dielectric jacket around the conductor pairs. The thin dielectric film provides separation between conductor pairs and/or between individual conductors within conductor pairs to reduce crosstalk therebetween.

Claims

1. An electrical cable, comprising:

a plurality of paired conductive elements;

a dielectric jacket formed around the plurality of paired conductive elements;

at least tow dielectric films each formed around at least one pair in the plurality of paired conductive elements in order to separate the pairs of conductive elements within the dielectric jacket, wherein each of the at least two dielectric films does not form an enclosed space; and

at least one dielectric film separating the conductive elements within at least one of the plurality of paired conductive elements.

2. The electrical cable, comprising:

a plurality of pairs of conductive elements;

a dielectric jacket formed around the plurality of pairs of conductive elements; and

a plurality of dielectric films corresponding to the plurality of pairs of conductive elements, wherein each dielectric film separates the conductive elements within its corresponding pair of conductive elements.

3. The method for making an electrical cable;

said method comprising the steps of;

providing a plurality of paired condictive elements;

forming a dielectric jacket around the plurality of paired conductive elements;

forming at least two dielectric films each formed around at least one pair in the plurality of paired conductive elements in order to separate the pairs of conductive elements within the dielectric jacket, wherein each of the at least two dielectric films does not form an enclosed space; and

forming a dielectric film between the conductive elements in at least one pair of the plurality of paired conductive elements.

4. A method for making an electrical cable, said method comprising the steps of:

providing a plurality of pairs of conductive elements;

forming a dielectric jacket around the plurality of pairs of conductive elements;

providing a plurality of dielectric films corresponding to the plurality of conductive elements; and

forming a dielectric film from the plurality of dielectric films helically beteween each of the conductive elements in the corresponding pair of conductive elements.

5. An electrical cable, comprising:

a plurality of paired conductive elements;

a dielectric jacket formed around the plurality of paired conductive elements;

at least one dielectric film separating the pairs of conductive elements within the dielectric jacket, wherein at least one dielectric film has a width within the range of approximately 0.125 inch to approximately 0.190 inch and a thickness within the range from approximately 0.0005 to approximately 0.020 inch; and

at least one dielectric film separating the conductive elements within at least one of the plurality of paired conductive elements.

6. A method for making an electrical cable, said method comprising the steps of:

providing a plurality of paired conductive elements;

forming a dielectric jacket around the plurality of paired conductive elements;

forming at least one dielectric film around at least one pair of conductive elements to separate the pairs of conductive elements within the dielectric jacket wherein the at least one dielectric film has a width the range of approximately 0.125 inch to approximately 0.190 inch and a thickness within the range of approximately 0.005 to approximately 0.020 inch; and

forming at least one dielectric film between the conductive elements in at least one pair of conductive elements.