Subdivided separation fillers for use in cables

• US 9,363,935 B1
• Filed: 03/15/2013
• Issued: 06/07/2016
• Est. Priority Date: 08/11/2006
• Status: Active Grant

• Current Assignee: Superior Essex International IP
• Original Assignee: Superior Essex Communications LP (LS Corporation)
• Inventors: Gebs, Bernhart A, McNutt, Christopher W, Cook, Thomas Christopher
• Primary Examiner(s): Nguyen, Chau N
• Application Number:
  US13/835,800
• Time in Patent Office: 1,180 Days
• Field of Search: 174/113.R, 174/113.C
• US Class Current: 1/1
• CPC Class Codes: H01B 11/08 Screens specially adapted for reducing cross-talk
• CPC Class Codes: H01B 11/1008 Features relating to screening tape per se
• CPC Class Codes: H01B 13/26 by winding, braiding or longitudinal lapping
• CPC Class Codes: H05K 9/0098 for shielding electrical cables

Abstract

Cables incorporating discontinuous separators or separation fillers are described. A cable may include a plurality of twisted pairs of individually insulated electrical conductors, and a separator may be disposed between at least two of the plurality of twisted pairs. The separator may include a plurality of discrete sections respectively positioned along a longitudinal length of the cable and each section may optionally include electrically conductive material. A jacket may be formed around the plurality of twisted pairs and the separator.

Claims

1. A cable, comprising:

a plurality of twisted pairs of individually insulated electrical conductors;

a separator disposed between at least two of the plurality of twisted pairs and having a cross-sectional shape comprising one of (i) a cross shape, (ii) a T-shape, (iii) a Y-shape, (iv) an L-shape, (v) a J-shape, or (vi) a diamond shape or (vii) a rod shape, the separator comprising a plurality of discrete sections respectively positioned along a longitudinal length of the cable, each section comprising electrically conductive material, wherein the separator does not include any components that extend along the longitudinal length to connect two or more of the discrete sections; and

a jacket formed around the plurality of twisted pairs and the separator.

2. The cable of claim 1, wherein each section of the separator comprises:

a first end comprising dielectric material; and

a second end longitudinally opposite the first end and comprising dielectric material,

wherein the electrically conductive material is positioned between the first end and the second end.

3. The cable of claim 1, wherein the electrically conductive material comprises one of (i) electrically conductive material formed on a dielectric material, (ii) electrically conductive material embedded in a dielectric material, (iii) electrically conductive material impregnated into a dielectric material, or (iv) substantially solid electrically conductive material.

4. The cable of claim 1, wherein the electrically conductive material associated with each section comprises at least one patch of electrically conductive material.

5. The cable of claim 4, wherein each patch of electrically conductive material has a length between approximately one meter and approximately three meters.

6. The cable of claim 1, wherein a respective gap is formed between each set of adjacent discrete sections of the separator.

7. The cable of claim 1, wherein each discrete section of the separator has a common longitudinal length.

8. The cable of claim 1, wherein a first discrete section of the separator has a first longitudinal length and a second discrete section of the separator has a second longitudinal length different than the first longitudinal length.

9. The cable of claim 1, wherein each discrete section of the separator has a longitudinal length of approximately three meters or less.

10. The cable of claim 1, further comprising:

a shield layer disposed between at least one of the plurality of twisted pairs and the jacket, wherein the shield layer comprises a plurality of patches of electrically conductive material.

11. The cable of claim 10, wherein the shield layer is circumferentially wrapped around all of the plurality of twisted pairs.

12. The cable of claim 10, wherein the electrically conductive material associated with each section of the separator comprises at least one patch of electrically conductive material,

wherein first spaces are formed between adjacent patches of the electrically conductive material along a longitudinal length of the separator, and

wherein second spaces corresponding to the first spaces are formed between adjacent patches of electrically conductive material along a longitudinal length of the shield layer.

13. A cable comprising:

a plurality of individually insulated electrical conductors;

a flexible member comprising an X-shaped cross-section disposed between at least two of the conductors and extending along a longitudinal length, the flexible member consisting of a plurality of disconnected portions that each have a respective length that is less than the longitudinal length, the plurality of portions comprising a first portion and a second portion separate from the first portion, wherein the first and second portions are positioned adjacent to one another in a longitudinal direction of the cable; and

a jacket formed around the plurality of conductors and the flexible member.

14. The cable of claim 13, wherein the first portion is formed from a first material and the second portion is formed from a second material different from the first material.

15. The cable of claim 13, wherein a gap is formed in the longitudinal direction between the first portion and the second portion.

16. The cable of claim 13, wherein each of the first portion and the second portion comprise electrically conductive material.

17. A cable comprising:

a plurality of twisted pairs of individually insulated electrical conductors;

a separator positioned between at least two of the plurality of twisted pairs and having a cross-sectional shape comprising one of (i) a cross shape, (ii) a T-shape, (iii) a Y-shape, (iv) an L-shape, (v) a J-shape, or (vi) a diamond shape or (vii) a rod shape, the separator comprising a plurality of discrete sections respectively positioned along a longitudinal length of the cable with no component of the separator connecting any of the discrete sections, each section comprising first electrically conductive material;

a shield layer formed around the plurality of twisted pairs, the shield layer comprising second electrically conductive material; and

a jacket formed around the plurality of twisted pairs and the separator.

18. The cable of claim 17, wherein the first electrically conductive material comprises first discontinuous patches of electrically conductive material having respective first gaps formed between adjacent patches, and

wherein the second electrically conductive material comprises second discontinuous patches of electrically conductive material having respective second gaps formed between adjacent patches and corresponding to the first gaps.

19. The cable of claim 18, wherein each of the first discontinuous patches and the second discontinuous patches has a length between approximately one meter and approximately three meters.

20. The cable of claim 17, wherein the shield layer is disposed between the plurality of twisted pairs and the jacket.