High performance, multi-media cable support-separator facilitating insertion and removal of conductive media

• US 7,473,850 B2
• Filed: 04/21/2006
• Issued: 01/06/2009
• Est. Priority Date: 04/25/2005
• 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.
• Primary Examiner(s): Mayo, III; William H
• Application Number:
  US11/408,451
• Publication Number:
  US 20060237218A1
• Time in Patent Office: 991 Days
• Field of Search: 174/36, 174/110.R, 174/113.R, 174/113.C, 174/120.R, 174/115, 174/116, 174/70.R, 174/72.R, 174/72.C, 138/111, 138/113, 138/114, 138/115
• 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

The present invention includes a high performance communication cable support-separator that includes one or more core support-separators having various shaped profiles which define and maintain a spacing between transmission media or transmission media pairs. The cable channels have longitudinal gaps that allow for insertion and removal of conductive transmission media to aid in terminating and connecting the transmission media. The cable support-separator channel intermediary may be additionally separated from each other.

Claims

1. A single high performance, multi-media communications cable support-separator structure comprising;

hollow support structures including a gap which remains open, extending along a longitudinal length of said high performance, multi-media communications cable support-separator, an interior support section of said support-separator having a central region, said central region comprising a hollow portion extending in combination with said hollow support structures along said longitudinal length of said interior support section and said communications cable;

said interior support section comprising one or more radial and axial surfaces that may be removably attached wherein said hollow support surfaces are partially defined by said central region, and wherein each of said hollow support structures comprises said gap that extends longitudinally along said central region such that said gap allows for insertion and removal of conductive or non-conductive media into and out of said hollow support structures.

2. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said hollow support structures directed longitudinally along said central region with said gap allows for said conductive or non-conductive media to be inserted into said hollow support structures and wherein said hollow support structures may be individually peelably removed and/or said conductive or non-conductive media may also be peelably removed through said gap.

3. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said hollow support structures may be located closer together to form one or more smaller said central regions allowing for reduction of overall size of said cable support-separator wherein said cable support-separator may be used primarily for installations in constrained spaces or for reducing mass thereby reducing smoke and flame spread.

4. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator and said hollow support structures may be equally or non-equally spaced, extruded or molded or adhered or otherwise attached integrally to said central region, each having said gap allowing for said insertion, containment and removal of said conductive or non-conductive media comprising twisted pair, co-axial, WIFI antennae, power, and/or fiber optic conductors in advance of, during, or after installation and wherein any or all said hollow support structures may be left empty.

5. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may comprise as many as six or more said hollow support structures equally or non-equally spaced and said hollow support structures may be individually constructed of various diameters and/or thicknesses to contain and support said conductive media of varying diameters, and said hollow support structures may include within said central region a longitudinal hollow region and said hollow region may be of any shape or form useful in providing primarily randomness to further mitigate pair-to-pair coupling thereby improving any crosstalk performance, including alien crosstalk.

6. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said hollow support structures comprise a thicker shell which may act as a strength member or as a drain wire and wherein said hollow support structures with said thicker shell may be used for insertion, containment or removal of said conductive or non-conductive media or may remain empty.

7. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said hollow support structures each or separately comprising variable radial and axial diameters and wherein said hollow support structures may be filled and either solid or foamed or foamed with a solid skin layer and wherein said hollow support structures may be of various shapes of random diameter and size along said longitudinal length thereby varying said cable support-separator overall diameter thereby improving the conductive and/or insulative nature of said cable support-separator.

8. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may be helically wound, around another cable support-separator or internal to said high performance, multi-media communications cable, with variable patterns and of variable tensions and may be wrapped or jacketed with conventional wrapping or jacketing materials and processes.

9. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said hollow support structures are customizable via extrusion or molding ensuring sufficient space between said conductive media thereby reducing crosstalk including alien crosstalk and whereby said hollow support structures are removeably attached to said central region wherein a knife or other sharp object provides removability of said conductive or non-conductive media or said hollow support structures.

10. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may be conductive, semi-conductive, or non-conductive, filled and either solid or foamed or foamed with a solid skin layer, metal, conductive or non-conductive polymer media, providing electrical grounding or earthing, or primarily of organic or inorganic polymers or combinations of inorganic and organic polymer blends.

11. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may be a combination of inorganic fillers or additives with inorganic and/or organic polymers or combinations including inorganic and organic polymer blends, homo and copolymers of ethylene, propylene, 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, TiO₂, MgOH, and ATH (ammonium tetrahydrate), calcium molybdates, ammonium octyl molybdate and may also be employed as nano-sized particles including tube shaped particles, and wherein any and all combinations may be utilized to provide polymer blends, and wherein said cable support-separator and/or conductive media insulation utilizing nanotubes of C₆₀ in the form of fibers or substituted/unsubstituted fullerenes or fullerene compounds, nano-composites or both and wherein said nano-composites or both are imbedded in said cable support-separator.

12. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may be comprised of, separately or in combination, of 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.

13. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may also be comprised of compounds such as acid gas scavengers that scavenge gasses such as hydrogen chloride and hydrogen fluoride or other halogenated gasses occurring during combustion of said cable support-separator.

14. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator may be comprised of organic and/or inorganic polymers that each may include the use of recycled or reground thermoplastics in an amount up to 100%.

15. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator comprises 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 fluorinated or otherwise halogenated polymers or copolymers to ethylene or vinyl chloride polymers or copolymers or foamed polymer blends including a nucleating agent of polytetrafluoroethylene, carbon black, color concentrate, or boron nitride, boron triflouride, direct injection of air or gas into an extruder, chioroflurocarbons (CFCs), or more environmentally acceptable alternatives such as pentane or other acceptable nucleating or blowing agents.

16. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator comprises solid, partially solid, or partially or fully foamed organic or inorganic dielectric materials, wherein said dielectric materials may include a solid skin surface with any one of a number of said dielectric materials and wherein said cable support-separator may include an adhesive surface.

17. The high performance, multi-media communications cable support-separator structure as in claim 1, wherein said high performance multi-media communications cable and said cable support-separator are comprised of a sealant coated dimensionally heat-recoverable dual layer of said high performance, multi-media communications cable or said cable support-separator comprising selecting a first polymer composition comprising a cross-linkable polymer;

forming a second polymer composition by admixing a thermoplastic component and a rubber-like component in proportions such that a composition comprises 30 to 95% of said thermoplastic component and 5 to 70% of said rubber-like component with said second polymer composition being convertible to a sealant composition.

18. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said separator comprises extruding a first and second polymer composition to form a unitary dual layer, wherein said second polymer composition forms an outer tubular layer formed from a crosslinkable polymer composition disposed concentrically around an inner tubular layer and being in a first configuration at a temperature below the crystalline melt temperature of said first polymer composition whereby exposing said conduit tubes or said jacketing to a source of energy initiates formation of chemical bonds between adjacent polymer chains in said first composition, and induces a chemical change in said second composition, thereby converting said second composition from a melt processable composition to a sealant composition and rendering said first composition recoverable in that said sealant composition is more easily recoverable upon subsequent heating.

19. The high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator is capable of providing for said conductive media transmitting data up to and greater than 10 Gbit/second while substantially mitigating or completely eliminating all forms of crosstalk, including alien crosstalk.

20. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator comprises a conductive or non-conductive substrate such as metallized thermoplastic film at a nominal 50 ohms per square (50Ω

/cm²) resistance and are attached, laminated, molded, extruded or co-extruded to said cable support-separator surface and where said surface itself may be comprised of imbedded non-conductive or conductive substrate such as said metallized thermoplastic film at a nominal 50 ohms per square (50Ω

/cm²) resistance, where said metallized thermoplastic film may include a drain wire of a preferred AWG or a braided shield in contact with said metallized film.

21. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said cable support-separator surface provides either a shielded or unshielded internal EME/RFI (electromagnetic emissions/radio frequency interference) barrier surfaces directed toward a center of said cable support-separator and also provides for a barrier from external EME/RFI, and where a ground wire in contact with said cable support-separator shielded or unshielded surfaces may provide additional EMI/RFI (electromagnetic interference/radio frequency interference) protection.

22. The single high performance, multi-media communications cable support-separator structure as in claim 1, wherein said high performance, multi-media communications cable and said cable support-separator is comprised of polyolefin or other thermoplastic based polymers and blends thereof capable of meeting specific flammability and smoke generation requirements as defined by UL 910, NFPA 255, 259 or 262, and EN 50266-2-x, class B test specifications as well as NFPA 72 test criteria for circuit integrity, wherein said test criteria is met by said high performance, multi-media communications cable and said cable support-separator(s).

23. A single high performance, multi-media communications cable support separator structure comprising;

hollow support structures including a gap which remains open, extending along a longitudinal length of said high performance, multi-media communications cable support-separator, an interior support section of said support-separator having a central region, said central region comprising a hollow portion extending in combination with said hollow support structures along said longitudinal length of said interior support section and said communications cable;

said interior support section comprising one or more radial and axial surfaces that may be removably attached wherein said surfaces are partially defined by said central region, and wherein each of said hollow support structures comprises said gap that extends longitudinally along said central region such that said gap allows for insertion and removal of conductive or non-conductive media into and out of said hollow support structures;

wherein said cable support-separator and said hollow support structures with said gap may comprise corrugated or rifled inner surfaces and/or a corrugated or rifled outer surfaces for the installation of said conductive or non-conductive media and said cable support-separator may be comprised of metal or conductive or non-conductive polymer for electrical grounding or earthing media.

24. A method for making a high performance, multi-media communications cable single support separator structure comprising;

hollow support structures comprising a gap which remains open, extending along a longitudinal length of said high performance, multi-media communications cable support-separator, an interior support section also having a central region, said central region comprising a hollow portion also extending along said longitudinal length of said interior support section and said communications cable;

said interior support section comprising radial and axial surfaces defined by said central region, wherein each of said hollow support structures comprising said gap is longitudinally removably attached to said central region wherein said gap allows for insertion and removal of conductive or non-conductive media into and out of said hollow support structures wherein said hollow support structures are also removable from said central region.

25. The method for making a high performance, multi-media communications cable single support separator structure as in claim 24, wherein said cable support-separator extends along said longitudinal length of said high performance, multi-media communications cable where pulling of said cable support-separator from a reel or cobb into a closing die mates said cable support-separator hollow support structures with said gap with one or more twisted pair or other conductive or non-conductive media through said gap and whereby said conductive or non-conductive media provides for nesting and shielding as necessary, such that said one or more twisted pair or said conductive or non-conductive media are providing single or double twisted bunching which may include a binder for holding twisted bunching with or without shielding, or may include a single or two-step process followed by use of said binder for holding said twist bunching in place and jacketed via extrusion or wrapping or both or neither with a final take up on a final take-up reel, wherein implementation of said method provides for completion of said high performance, multi-media communications cable.

26. The method for making a high performance, multi-media communications cable single support separator structure as in claim 24, comprising a method for binding or wrapping said jacketing or both, wherein said wrapping may include one or more of several methods including single tape winding such as a cigarette tape wrap, spiral wrapping such as a notebook binder with a tighter or looser configuration or varying tensions or where said binder method may simply comprise extruding a thin skin thermoplastic or a thicker skin thermoplastic or thermoset or the like over said high performance, multi-media communications cable.

27. The method for making a high performance, multi-media communications cable single support separator structure as in claim 24, wherein said binder can be a corrosive and/or chemical resistant barrier protecting said high performance, multi-media communications cable and said conductive or non-conductive media from severe environments.