Communication wire

• US 7,214,880 B2
• Filed: 03/14/2003
• Issued: 05/08/2007
• Est. Priority Date: 09/24/2002
• Status: Expired due to Fees

• Current Assignee: Commscope Emea Limited (CommScope Holding Company, Inc.), CommScope Technologies, LLC (CommScope Holding Company, Inc.)
• Original Assignee: ADC Incorporated
• Inventors: Kenny, Robert, Johnston, Fred, Wiekhorst, David, Stutzman, Spring, Dickman, Jim L., Juengst, Scott, Stutzman, Jeff
• Primary Examiner(s): LEE, JINHEE J
• Application Number:
  US10/389,254
• Publication Number:
  US 20040055779A1
• Time in Patent Office: 1,516 Days
• Field of Search: 174/117.AS, 174/72.A, 174/68.3, 174/97, 174/136
• US Class Current: 174/80
• 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

A wire is disclosed including a component extending along a longitudinal axis and including at least one first channel extending generally along the longitudinal axis. The component is selected from a conductor, insulation, a jacket or combinations thereof to form a channeled component. Where the channeled component consists of insulation, an outer peripheral surface of the conductor forms one side of the at least one first channel. The at least one first channel is configured to provide at least improved electrical characteristics for communications along the wire.

Claims

1. A wire comprising a component extending along a longitudinal axis and including at least one first channel extending generally along the longitudinal axis,

wherein the component is selected from a conductor, insulation, a jacket or combinations thereof to form a channeled component wherein the channeled component includes at least a channeled conductor,

insulation extending along the longitudinal axis, wherein the insulation surrounds the channeled conductor to form an insulated, channeled conductor,

a channeled insulation, a channeled jacket or combinations thereof,

providing that where the channeled component consists of said insulation, an outer peripheral surface of said conductor forms one side of the at least one first channel.

2. The wire of claim 1, wherein the channeled component includes at least a channeled jacket.

3. The wire of claim 2, further comprising a core element extending along the longitudinal axis, wherein the channeled jacket surrounds the core element to form an isolated core.

4. The wire of claim 3, wherein the isolated core has an overall dielectric constant of less than 3.0.

5. The wire of claim 3, wherein the at least one first channel contains a material that has a dielectric constant that differs from a dielectric constant of the jacket.

6. The wire of claim 5, wherein the at least one first channel contains air.

7. The wire of claim 3, wherein the jacket includes a plurality of channels.

8. The wire of claim 7, wherein no one of the plurality of channels has a cross-sectional area greater than about 30% of a cross-sectional areas of the jacket.

9. The wire of claim 3, wherein the core element forms one side of the at least one first channel.

10. The wire of claim 3, wherein the jacket fully surrounds the at least one first channel.

11. The wire of claim 3, wherein the core element forms one side of at least a first channel and the jacket fully surrounds at least one second channel.

12. The wire of claim 3, wherein the at least one first channel has a cross-sectional area of at least 2.0×

10<sup>−

5</sup> in².

13. The wire of claim 3, wherein the isolated core has a diameter of less than about 0.25 in.

14. The wire of claim 13, wherein the jacket has a thickness of less than about 0.030 in.

15. The wire of claim 3, wherein a shape of the at least one first channel is selected from the group consisting of rectangular, trapezoidal and arched.

16. The wire of claim 3, wherein the core element is selected from the group consisting of a copper conductor, a fiber optic conductor, an insulated conductor, a twisted pair, insulation, a shield, a separator and combinations thereof.

17. The wire of claim 16, wherein the core element includes a channeled insulation, a channeled conductor, or combinations thereof.

18. The wire of claim 16, wherein the core element includes a plurality of twisted pairs.

19. The wire of claim 18, wherein delay skew is no greater than 15 ns between the individual twisted pairs.

20. The wire of claim 3, wherein the isolated core passes a test selected from the group consisting of The National Fire Prevention Association 255, The National Fire Prevention Association 259, The National Fire Prevention Association 262 or combinations thereof.

21. The wire of claim 20, wherein the isolated core passes all of The National Fire Prevention Association 255, The National Fire Prevention Association 259 and The National Fire Prevention Association 262.

22. The wire of claim 3, wherein the isolated core generates at least 10% less smoke when burned according to a Underwriters Laboratories 910 Steiner Tunnel test than when compared to an isolated core without channels in its jacket.

23. The wire of claim 3, wherein the isolated core spreads flame at a rate at least 10% slower when burned according to a UL 910 Steiner Tunnel test when compared to an isolated core without channels in its jacket.

24. The wire of claim 3, wherein the jacket has a first portion with a first signal speed and a second portion with a second signal speed, wherein the first signal speed is significantly faster than the second signal speed.

25. The wire of claim 24, wherein the first portion includes the at least one first channel.

26. The wire of claim 24, wherein the first signal speed is at least about 5% faster than the second signal speed.

27. The wire of claim 26, wherein the first signal speed is at least about 10% faster than the second signal speed.

28. The wire of claim 1, wherein the at least one first channel contains a material that has a dielectric constant that differs from a dielectric constant of the insulation.

29. The wire of claim 28, wherein the at least one first channel contains air.

30. The wire of claim 28, wherein the conductor includes a plurality of channels.

31. A wire comprising:

a conductor defining a plurality of conductor channels located at an exterior of the conductor, the conductor channels having lengths that run along a length of the conductor; and

insulation surrounding the conductor, the insulation defining a plurality of insulation channels having lengths that run along the length of the conductor.

32. The wire of claim 31, wherein at least some of the conductor channels are in fluid communication with at least some of the insulation channels.

33. The wire of claim 31, wherein the insulation channels include open sides that expose the insulation channels to the exterior of the conductor.

34. The wire of claim 31, wherein the conductor and insulation channels contain air.

35. The wire of claim 31, wherein the insulation is less than about 0.01 inches thick.

36. The wire of claim 31, wherein the conductor includes exterior ridges between which the conductor channels are defined, wherein the insulation includes inwardly projecting legs between which the insulation channels are defined, and wherein the legs contact at least some of the ridges.