HIGH PERFORMANCE DATA CABLE

• US 20100096160A1
• Filed: 12/23/2009
• Published: 04/22/2010
• Est. Priority Date: 04/09/1996
• Status: Active Grant

• Current Assignee: Belden Inc.
• Original Assignee: Belden Technologies, LLC (Belden Inc.)
• Inventors: Vanderlaan, Paul Z., Gareis, Galen Mark
• Granted Patent: US 7,977,575 B2
• Time in Patent Office: Days
• US Class Current: 174/113.00C
• CPC Class Codes: H01B 11/02 Cables with twisted pairs or quads
• CPC Class Codes: H01B 11/06 with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens

Abstract

The present invention is for a high performance data cable which has an interior support or star separator. The star separator or interior support extends along the longitudinal length of the data cable. The star separator or interior support has a central region. A plurality of prongs or splines extend outward from the central region along the length of the central region. Each prong or spline is adjacent with at least two other prongs or splines. The prongs or splines may be helixed or S-Z shaped as they extend along the length of the star separator or interior support. Each pair of adjacent prongs or splines defines grooves which extend along the longitudinal length of the interior support. At least two of the grooves have disposed therein an insulated conductor. The interior support can have a first material and a different second material. The different second material forms an outer surface of the interior support.

Claims

1. An unshielded data cable comprising:

a plurality of twisted pair conductors;

a non-conductive interior support having a surface that defines a plurality of channels within which the plurality of twisted pair conductors are individually disposed; and

an outer jacket longitudinally enclosing the plurality of twisted pair conductors and the non-conductive interior support, the outer jacket being formed of a non-conductive material;

wherein the outer jacket in combination with the non-conductive interior support maintains the plurality of twisted pair conductors within the channels defined by the surface of the non-conductive interior support; and

wherein the unshielded data cable does not include a shield or any additional layers between the outer jacket and the twisted pair conductors and the non-conductive interior support.

2. The unshielded data cable as claimed in claim 1, wherein non-conductive interior support comprises a longitudinally extending central portion and a plurality of projections extending radially outward from the longitudinally extending central portion to at least an outer boundary defined by an outer dimension of the twisted pair conductors.

3. The unshielded data cable as claimed in claim 2, wherein the plurality of channels are defined by the plurality of projections.

4. The unshielded data cable as claimed in claim 3, wherein each projection of the plurality of projections is adjacent two other projections of the plurality of projections, the plurality of projections forming a plurality of pairs of adjacent projections;

and

wherein each channel of the plurality of channels is defined by one pair of adjacent projections of the plurality of adjacent projections.

5. The unshielded data cable as claimed in claim 3, wherein the plurality of projections consists of four projections;

and

the plurality of channels consists of four channels; and

the plurality of twisted pair conductors consists of four twisted pair conductors.

6. The unshielded data cable as claimed in claim 5, wherein each projection of the four projections extends radially outward from the central portion at approximately right angles to at least one other projection of the four projections.

7. The unshielded data cable as claimed in claim 1, wherein the non-conductive interior support is formed of a copolymer.

8. The unshielded data cable as claimed in claim 1, wherein each twisted pair conductor of the plurality of twisted pair conductors comprises two electrical conductors, each insulated with a copolymer, which are helically twisted together to form the twisted pair conductor.

9. The unshielded data cable as claimed in claim 1, wherein the plurality of twisted pair conductors and the non-conductive interior support are twisted together about a common axis to close the cable.

10. The unshielded data cable as claimed in claim 9, wherein the plurality of twisted pair conductors and the non-conductive interior support are twisted together with one of a helical twist and an S-Z twist.

11. The unshielded data cable as claimed in claim 1, wherein the non-conductive interior support is a one-piece plastic interior support which is solid beneath the surface.

12. A data cable comprising:

four twisted pair conductors;

a non-conductive interior support having a surface that defines four channels, one twisted pair conductor of the four twisted pairs of conductors respectively disposed in each of four channels; and

an outer jacket longitudinally enclosing the four twisted pair conductors and the non-conductive interior support, the outer jacket consisting of one or more non-conductive materials;

wherein the outer jacket in combination with the non-conductive interior support maintains the four twisted pair conductors within the four channels defined by the surface of the non-conductive interior support

13. The data cable as claimed in claim 12, wherein the non-conductive interior support comprises a longitudinally extending central portion and four projections extending radially outward from the central portion to at least an outer boundary defined by an outer dimension of the twisted pair conductors;

wherein the four channels are defined by adjacent pairs of the four projections.

14. The data cable as claimed in claim 13, wherein each projection of the four projections extends radially outward from the central portion at approximately right angles to at least one other projection of the four projections.

15. The data cable as claimed in claim 12, wherein the non-conductive interior support is a one-piece plastic interior support formed of a copolymer.

16. The data cable as claimed in claim 15, wherein the non-conductive interior support is solid beneath the surface.

17. The data cable as claimed in claim 12, wherein the four twisted pair conductors and the non-conductive interior support are twisted together about a common axis to close the cable.

18. The data cable as claimed in claim 17, wherein the four twisted pair conductors and the non-conductive interior support are twisted together with one of a helical twist and an S-Z twist.

19. The data cable as claimed in claim 12, wherein the outer jacket comprises polyvinyl chloride.

20. A data cable consisting of:

four twisted pair conductors;

a non-conductive interior support comprising a longitudinally extending central portion and four projections extending radially outward from the central portion to at least an outer boundary defined by an outer dimension of the twisted pair conductors; and

an outer jacket longitudinally enclosing the four twisted pair conductors and the non-conductive interior support, the outer jacket being formed of a non-conductive material;

wherein the four projections form four adjacent pairs of projections that define four channels in which the four twisted pair conductors are individually disposed;

wherein the outer jacket in combination with the non-conductive interior support maintains the four twisted pair conductors within the four channels defined by the four adjacent pairs of projections; and

wherein the four twisted pair conductors and the non-conductive interior support are twisted together about a common axis to close the cable.