Communication cables incorporating separator structures

• US 9,928,943 B1
• Filed: 08/03/2016
• Issued: 03/27/2018
• Est. Priority Date: 08/03/2016
• Status: Active Grant

• Current Assignee: Superior Essex International IP
• Original Assignee: Superior Essex International Lp (LS Corporation)
• Inventors: McNutt, Christopher W., Sekhavat, Amir
• Primary Examiner(s): Mayo, III, William H
• Application Number:
  US15/227,365
• Time in Patent Office: 601 Days
• Field of Search: 174110 R, 174113 R, 174113 C, 174115, 174116
• CPC Class Codes: H01B 11/005 Quad constructions
• CPC Class Codes: H01B 11/04 with pairs or quads mutually positioned to reduce cross-talk
• CPC Class Codes: H01B 11/1008 Features relating to screening tape per se
• CPC Class Codes: H01B 11/1016 composed of a longitudinal lapped tape-conductor

Abstract

A cable may include a plurality of twisted pairs of individually insulated conductors and a separator positioned between the plurality of twisted pairs. The separator may include a first longitudinally extending tape structure having a first longitudinal fold formed between its widthwise edges and a second longitudinally extending tape structure having a second longitudinal fold formed between its widthwise edges. Additionally, the first tape structure and the second tape structure may be bonded together along a longitudinally extending line proximate to the first and second longitudinal folds. A jacket may be formed around the plurality of twisted pairs and the separator.

Claims

1. A cable comprising

four twisted pairs of individually insulated electrical conductors that extend along a longitudinal direction;

a separator positioned between the twisted pairs, the separator comprising only two tape structures, wherein;

a first of the two tape structures comprises electromagnetic shielding material and has a first width in a width dimension perpendicular to the longitudinal direction, a first longitudinally extending widthwise edge, and a second longitudinally extending widthwise edge opposite the first edge; and

a second of the two tape structures comprises electromagnetic shielding material and has a second width in the width dimension, a third longitudinally extending widthwise edge, and a fourth longitudinally extending widthwise edge opposite the third edge,

the first tape structure and the second tape structure are bonded together along a longitudinally extending line positioned between the first and second edges of the first tape structure and between the third and fourth edges of the second tape structure,

the first tape structure extends from the longitudinally extending line in a first direction between a first and a second of the four twisted pairs and in a second direction between the first and a third of the four twisted pairs without extending between the second and a fourth of the four twisted pairs or between the third and a fourth of the four twisted pairs, and

the second tape structure extends from the longitudinally extending line in a third direction between the second and the fourth of the four twisted pairs and in a fourth direction between the third and the fourth of the four twisted pairs without extending between the first and the second of the four twisted pairs or between the first and the third of the four twisted pairs; and

a jacket formed around the twisted pairs and the separator.

2. The cable of claim 1, wherein the first tape structure comprises a first longitudinally extending fold, the second tape structure comprises a second longitudinally extending fold, and the longitudinally extending line is proximate to the first and second longitudinally extending folds.

3. The cable of claim 1, wherein the first tape structure and the second tape structure each comprise a base layer of dielectric material and a layer of electrically conductive material formed on the base layer.

4. The cable of claim 3, wherein the layer of electrically conductive material comprises a plurality of discontinuous patches of electrically conductive material.

5. The cable of claim 1, wherein the first and second tape structures comprise substantially flat tape structures.

6. The cable of claim 1, wherein at least one of the first tape structure or the second tape structure is further wrapped around an outer periphery of the four twisted pairs.

7. The cable of claim 6, wherein both the first and second tape structures are wrapped around the outer periphery such that each of the widthwise edges contacts one of the first or second tape structure.

8. A cable comprising:

a plurality of twisted pairs of individually insulated conductors;

a separator positioned between the plurality of twisted pairs, the separator comprising;

a first longitudinally extending tape structure comprising electromagnetic shielding material and having a first longitudinal fold between its widthwise edges; and

a second longitudinally extending tape structure comprising electromagnetic shielding material and having a second longitudinal fold between its widthwise edges,

wherein the first tape structure and the second tape structure are bonded together only along a longitudinally extending line positioned between the plurality of twisted pairs and proximate to the first and second longitudinal folds; and

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

9. The cable of claim 8, wherein the first tape structure extends from the longitudinally extending bonding line between a first and second set of adjacent twisted pairs and the second tape structure extends from the longitudinally extending bonding line between a third and fourth set of adjacent twisted pairs.

10. The cable of claim 8, wherein the separator comprises an approximately cross-shaped cross-section.

11. The cable of claim 8, wherein the first tape structure and the second tape structure each comprise a base layer of dielectric material and a layer of electrically conductive material formed on the base layer.

12. The cable of claim 11, wherein the layer of electrically conductive material comprises a plurality of discontinuous patches of electrically conductive material.

13. The cable of claim 8, wherein at least one of the first tape structure or the second tape structure is further wrapped around an outer periphery of the plurality of twisted pairs.

14. The cable of claim 13, wherein both the first and second tape structures are wrapped around the outer periphery such that each of the widthwise edges contacts one of the first or second tape structure.

15. A cable comprising:

a plurality of twisted pairs of individually insulated conductors;

a separator positioned between the plurality of twisted pairs and having an approximately cross-shaped cross-section, the separator comprising;

two tape structures that are longitudinally bonded together only at a position between the plurality of twisted pairs,

wherein each tape structure comprises electromagnetic shielding material and extends from the bonding position between two respective sets of twisted pairs.

16. The cable of claim 15, wherein each of the tape structures comprises a longitudinally extending fold positioned proximate to a line along which the two tape structures are bonded together.

17. The cable of claim 15, wherein each of the tape structures comprise a base layer of dielectric material and a layer of electrically conductive material formed on the base layer.

18. The cable of claim 17, wherein the layer of electrically conductive material comprises a plurality of discontinuous patches of electrically conductive material.

19. The cable of claim 15, wherein at least one of the two tape structures is further wrapped around an outer periphery of the plurality of twisted pairs.

20. The cable of claim 19, wherein both of the tape structures are wrapped around the outer periphery such that each of their respective widthwise edges contacts one of the two tape structures.