U.S. patent application number 12/945388 was filed with the patent office on 2011-11-24 for flame retardant and smoke suppressant composite high performance support-separators and conduit tubes.
This patent application is currently assigned to Cable Components Group, LLC. Invention is credited to Charles A. Glew.
Application Number | 20110284287 12/945388 |
Document ID | / |
Family ID | 34921923 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110284287 |
Kind Code |
A1 |
Glew; Charles A. |
November 24, 2011 |
Flame Retardant and Smoke Suppressant Composite High Performance
Support-Separators and Conduit Tubes
Abstract
The present invention includes a high performance communications
cable exhibiting reduced cross-talk between transmission media with
one or more core support-separators having various shaped profiles
defining a clearance that maintains spacing between transmission
media. The core is formed of a conductive or insulative material to
further reduce cross-talk and improve other electrical properties
in addition to reducing flame and smoke spread. The cable and
separators are comprised of polymer blends that include olefin
and/or fluoropolymer and/or chlorofluoropolymer based resins with
and without inorganic additives including nano-clay composites. The
core support-separators have both a central region and a plurality
of shaped sections that extend outward from the central region and
are solid, or partially solid, foamed, or foamed with a solid skin
surface. In addition, the invention includes the incorporation of
hollow ducts used to provide a pathway for conductor media before,
during, or after installation of the cable.
Inventors: |
Glew; Charles A.;
(Charlestown, RI) |
Assignee: |
Cable Components Group, LLC
Pawcatuck
CT
|
Family ID: |
34921923 |
Appl. No.: |
12/945388 |
Filed: |
November 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11030436 |
Jan 6, 2005 |
7202418 |
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12945388 |
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60534646 |
Jan 7, 2004 |
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Current U.S.
Class: |
174/99R ;
29/825 |
Current CPC
Class: |
Y10T 29/49117 20150115;
H02G 3/0412 20130101; G02B 6/4429 20130101; G02B 6/4459 20130101;
H01B 13/06 20130101; H01B 7/185 20130101; H02G 3/0481 20130101;
H01B 7/295 20130101; G02B 6/4435 20130101; H01B 7/292 20130101 |
Class at
Publication: |
174/99.R ;
29/825 |
International
Class: |
H02G 3/00 20060101
H02G003/00; H01R 43/00 20060101 H01R043/00 |
Claims
1. An interior support-separator for a communications cable
extending along a longitudinal length of a communications cable,
comprising, along its cross-section a maltese-cross shaped
configuration with two arm members such that said maltese-cross
shaped configuration is skewed along one arm member with an axis
along said arm member providing a length along one axis of said arm
member that is longer than along any other axis and providing
larger blunt tipped ends at both ends of said arm member than blunt
tipped ends at both ends of an arm member with a length shorter
than another longer arm member and a hollow orifice in a center
region of a central portion of said interior support-separator.
2. An interior support-separator for a communications cable as in
claim 1, wherein said maltese-cross shaped configuration is a
cross-section along the length of said cable and said cross-section
includes step-like sections along a perimeter of said
support-separator providing small interstitial sectional grooves
along an inner circumferential portion of clearance channels
provided by said support-separator and a hollow orifice in said
center region of said central portion of said interior
support-separator.
3. An interior support-separator for a communications cable as in
claim 2, extending along a longitudinal length of a communications
cable, comprising along its cross-section a central region of a
diamond shaped configuration with a hollow orifice in said center
region of said central portion of said interior
support-separator.
4. The interior support-separator for a communications cable as in
claim 3, comprising within said cross-section, two hollow
triangular orifices in said central region of said interior
support-separator, said two hollow triangular orifices shaped as
equilateral triangles, wherein one triangular orifice faces upright
and the other triangular orifice faces downward such that a peak of
each triangular orifice is facing in opposite directions.
5. The interior support-separator for a communications cable as in
claim 4, comprising within said cross-section, and a diamond shaped
orifice in said central region of said interior
support-separator.
6. The interior support-separator for a communications cable as in
claim 5, comprising within said cross-section, a center slot
orifice in said central region of said interior
support-separator.
7. A method for producing a high performance communications cable
by using organic or organic/inorganic polymer blends to fabricate
an interior support-separator section or sections with a
longitudinal length that is provided within said cable and where
external radial and axial surfaces of said separator having a
central region extending along said longitudinal length of said
interior support-separator define one or more clearance channels
within said support-separator introduced into a jacket of said
cable by; passing a plurality of transmission conductors within
said clearance channels of said interior support-separator through
a first die that aligns the plurality of transmission conductors
with surface features of said internal support-separator allowing
for intentional twisting of said conductors, forcing each of said
plurality of conductors into a proper clearance channel of said
interior support-separator where said clearance channels are closed
by single or double flap-tops, thereby maintaining a spatial
relationship between each of said transmission conductors by use of
a second die, heating said second die allowing for closing of said
exterior surface of said channels, taping and twisting said
interior support-separator allowing for closing of said exterior
surface of said channels, and; jacketing said interior
support-separator containing each of said conductors within said
clearance channels.
8. The method of producing a cable of claim 7, by omitting the step
of heating.
9. The method of producing a cable of claim 7, by omitting the use
of a second die.
10. The method of producing a cable of claim 7, by including the
use of a metal ring for forcing said conductors into a proper
clearance channel and forcing closure of said double or single
flap-tops.
11. The method of producing a cable of claim 7, by omitting the
step of taping and twisting.
12. The method of producing a cable of claim 7, by omitting the
step of jacketing said cable.
13. A method for producing a high performance communications cable
by introducing an interior support-separator section or sections
composed of organic and/or inorganic polymer blends with a
longitudinal length and external radial and axial surfaces having a
central region extending along said longitudinal length of said
interior support-separator wherein one or more central regions of
said support-separator has sections that are hollow and wherein
said separator is jacketed to complete said cable by; passing a
plurality of transmission conductors within said hollow central
regions of said interior support-separator through a first die that
aligns the plurality of transmission conductors with surface
features of said internal support allowing for intentional twisting
of said conductors, forcing each of said plurality of conductors
into said hollow central region portions of said interior
support-separator where said hollow central ring portions maintain
a spatial relationship between each of said transmission conductors
by; jacketing said interior support containing each of said
conductors within said hollow central regions and; pulling each of
said transmission conductors through said hollow central regions or
said support-separators either before, during or after initial
installation.
14. The method of producing a cable of claim 13, by omitting the
step of jacketing said cable.
15. The method of producing a cable of claim 13, wherein jacketing
and/or support-separator extrusion line speeds are significantly
improved compared with conventional line speeds when said polymer
blends are not utilized.
16. A high performance communications cable comprising; an interior
support-separator with an external radial and axial surface,
extending along a longitudinal length and within said
communications cable, said interior support also having a central
region, said central region also extending along a longitudinal
length of said interior support and said communications cable; said
support comprised of polymer blend based materials capable of
meeting specific flammability and smoke generation requirements as
defined by UL 910, UL 2424, NAPA 262, 259, 255, and EN 50266-2-x
class B test specifications.
17. The high performance communications cable of claim 15, wherein
said cable meets as a minimum test specification the E1A/T1A CAT 5e
as well as CAT 6, and CAT 6e electrical performance requirements
and wherein conductors within said cable or interior
support-separator acting as said cable, achieves significantly
reduced near-end cross talk (NEXT), power sum near end cross talk
(PSNEXT), equal level far end cross talk (ELFEXT) and power sum
equal level far end cross talk (PSELFEXT) and alien cross-talk
values and wherein said cable also passes flammability and smoke
generation requirements as defined by UL 910, UL 2424, NAPA 262,
259, 255, and EN 50266-2-x, class B test specifications.
18. A method for producing a high performance communications cable
comprising: an interior support-separator with an external radial
and axial surface, said interior support-separator extending along
a longitudinal length of said communications cable, said interior
support-separator also having a central region, outwardly extended
protrusions, and at least one conduit tube, said central region
also extending along a longitudinal length of said interior
support-separator of said communications cable;
19. A method for producing a high performance communications cable
comprising: said interior support-separator, said central region,
said outwardly extended protrusions, and said at least one conduit
tube are comprised of a composition of inorganic and organic
polymers; said composition including: fluorinated ethylene
propylene, fluorinated ethylene, chlorinated ethylene propylene,
fluorochlorinated ethylene, perfluoroalkoxy, fluorochlorinated
propylene, a copolymer of tetrafluoroethylene and
perfluoromethylvinylether (MFA), or a copolymer of ethylene and
chlorotrifluoroethylene (ECTFE); and homo or copolymers of ethylene
or propylene with fluorinated ethylene or polyvinylidene fluoride
(PVDF); and blends of polyvinyl chloride, polyvinylidene chloride,
nylons, polyesters, polyurethanes; and nano-composites of clay
including unsubstituted or substituted fullerenes primarily
comprised of C.sub.60 molecules; and nano-sized particles of ZnO or
TiO.sub.2, wherein between a first node and a second node remote
from said communications cable comprising said interior
support-separator; said interior support-separator comprising also
at least one symmetrical core with an central circular ring region
with extending protrusions each extending in a preferred degree of
separation from each of any other extending protrusions, wherein
said central circular ring portion includes a hollow region acting
as a ductlet extending from said first node to said second node and
a duct containing a first transmission line which extends between
said first and said second nodes, the method comprising the steps
of: attaching a supply of compressed gas to said duct at said first
node; flowing gas from said supply of compressed gas along said
duct from said first node to said second node to cause viscous drag
forces to act on said first transmission line, and withdrawing said
first transmission line from said duct under the action of said
viscous drag forces; introducing a second transmission line into
said duct at one of said nodes, supplying compressed gas to said
duct at said first node to cause a flow of gas between said first
node and said second node; and advancing said second transmission
line from said first node to said second node under said action of
viscous drag forces caused by action on said second transmission
line by gas flowing from said first node towards said second
node.
20. The method as in claim 18, wherein said first transmission line
comprises at least one multimode optical fiber and said second
transmission line comprises at least one single mode optical
fiber.
21. The method as in claim 19, wherein said first transmission line
includes at least one electrical conductor and said second
transmission line includes at least one optical fiber.
22. The method as claimed in claim 20, wherein said at least one
optical fiber is a single mode optical fiber.
23. The method as claimed in claim 18, wherein said transmission
line can include any transmission type media.
Description
CLAIM TO PRIORITY
[0001] This utility application is a further continuation of U.S.
application Ser. No. 11/030,436 filed Jan. 6, 2005, issued as U.S.
Pat. No. 7,202,418 that takes priority from U.S. Provisional
Application No. 60/534,646 filed Jan. 7, 2004 entitled "FLAME
RETARDANT AND SMOKE SUPPRESSANT COMPOSITE HIGH PERFORMANCE
SUPPORT-SEPARATORS AND CONDUIT TUBES" the initial continuation of
which was filed on Feb. 28, 2007 as a continuation application with
Ser. No. 11/712,532, also entitled "FLAME RETARDANT AND SMOKE
SUPPRESSANT COMPOSITE HIGH PERFORMANCE SUPPORT-SEPARATORS AND
CONDUIT TUBES". The above claim of priority is also submitted
herewithin on form PTO/SB/14 entitled Application Data Sheet 37 CFR
1.76 in the section listed as Domestic Benefit/National Stage
Information. The continuation application as presented here within
contains no new matter as defined in 35 USC 132.
BACKGROUND OF THE INVENTION
[0002] Many communication systems utilize high performance cables
normally having four pairs or more that typically consist of two
twisted pairs transmitting data and two receiving data as well as
the possibility of four or more pairs multiplexing in both
directions. A twisted pair is a pair of conductors twisted about
each other. A transmitting twisted pair and a receiving twisted
pair often form a subgroup in a cable having four twisted pairs.
High-speed data communications media in current usage includes
pairs of wire twisted together to form a balanced transmission
line. Optical fiber cables may include such twisted pairs or
replace them altogether with optical transmission media (fiber
optics).
[0003] When twisted pairs are closely placed, such as in a
communications cable, electrical energy may be transferred from one
pair of a cable to another. Energy transferred between conductor
pairs is undesirable and referred to as crosstalk. The
Telecommunications Industry Association and Electronics Industry
Association have define standards for crosstalk, including
TIA/EIA-568 A, B, and C including the most recent edition of the
specification. The International Electrotechnical Commission has
also defined standards for data communication cable crosstalk,
including ISO/IEC 11801. One high-performance standard for 100 MHz
cable is ISO/IEC 11801, Category 5. Additionally, more stringent
standards are being implemented for higher frequency cables
including Category 6 and Category 7, which includes frequencies of
200 and 600 MHz, respectively and the most recent proposed
industrial standard raising the speeds to 10 Gbit over copper with
Ethernet or other cable designs. Industry standards cable
specifications and known commercially available products are listed
in Table 1 and a set of updated standards for Category 6, including
alien crosstalk proposals are included in Tables 2 A G.
TABLE-US-00001 TABLE 1 INDUSTRY STANDARD CABLE SPECIFICATIONS
ANIXTER ANIXTER XP6 XP7 TIA CAT 6 R3.00XP R3.00XP ALL DATA AT TIA
CAT DRAFT 10 November November 100 MHz 5e Nov. 15, 2001 2000 2000
MAX TEST 100 MHz 250 MHz 250 MHz 350 MHz FREQUENCY ATTENTUATION
22.0 db 19.8 db 21.7 db 19.7 db POWER SUM 32.3 db 42.3 db 34.3 db
44.3 db NEXT ACR 13.3 db 24.5 db POWER SUM 10.3 db 22.5 db 12.6 db
23.6 db ACR POWER SUM 20.8 db 24.8 db 23.8 db 25.8 db ELFEXT RETURN
LOSS 20.1 db 20.1 db 21.5 db 22.5 db
TABLE-US-00002 TABLE 2A Return Loss Requirements for Category 6
Cable Return loss @ 20.degree. C. .+-. 3.degree. C. (68.degree. F.
.+-. 5.5.degree. F.), worst pair for a length of 100 m (328 ft)
Frequency MHz Category 6 dB 1 .ltoreq. f .ltoreq. 10 20 + 5 log (f)
10 .ltoreq. f .ltoreq. 20 25 20 .ltoreq. f .ltoreq. 250 25 - 7 log
(f/20)
TABLE-US-00003 TABLE 2B Insertion Loss Requirements for Category 6
Cable Insertion loss @ 20.degree. C. .+-. 3.degree. C. (68.degree.
F. .+-. 5.5.degree. F.), worst pair for a length of 100 m (328 ft)
Frequency MHz Category 6 dB .772 1.8 10.0 6.0 250.0 32.8
TABLE-US-00004 TABLE 2C Near End Crosstalk Requirements For
Category 6 Cable Horizontal cable NEXT loss @ 20.degree. C. .+-.
3.degree. C. (68.degree. F. .+-. 5.5.degree. F.), worst
pair-to-pair, for a length of 100 m (328 ft) Frequency MHz Category
6 dB 0.150 86.7 10.0 59.3 250.0 38.3
TABLE-US-00005 TABLE 2D Power Sum Near End Crosstalk Requirements
for Category 6 Cable PSNEXT loss @ 20.degree. C. .+-. 3.degree. C.
(68.degree. F. .+-. 5.5.degree. F.), for a length of 100 m (328
ft)
TABLE-US-00006 TABLE 2E Equal Level Near End Crosstalk Requirements
for Category 6 Cable ELNEXT loss @ 20.degree. C. .+-. 3.degree. C.
(68.degree. F. .+-. 5.5.degree. F.), worst pair-to-pair, for a
length of 100 m (328 ft) Frequency MHz Category 6 dB .772 70.0 10.0
47.8 250.0 19.8
TABLE-US-00007 TABLE 2F Power Sum Equal Level Near End Crosstalk
Requirements for Category 6 Cable PSELNEXT loss @ 20.degree. C.
.+-. 3.degree. C. (68.degree. F. .+-. 5.5.degree. F.), for a length
of 100 m (328 ft) Frequency MHz Category 6 dB .772 67.0 10.0 44.8
250.0 16.8
TABLE-US-00008 TABLE 2G Proposed Requirements for Alien Near-end
Cross-talk for Category 6 Cable Proposed Requirement for Channel
Power Sum Alien Near-End Cross-talk Frequency Category 6 dB PSANEXT
.gtoreq. 60 - 10 log(f) 1 .ltoreq. f .ltoreq. 100 MHz PSANEXT
.gtoreq. 60 - 15 log(f) 100 .ltoreq. f .ltoreq. 625 MHz
[0004] In conventional cable, each twisted pair of conductors for a
cable has a specified distance between twists along the
longitudinal direction. That distance is referred to as the pair
lay. When adjacent twisted pairs have the same pair lay and/or
twist direction, they tend to lie within a cable more closely
spaced than when they have different pair lays and/or twist
direction. Such close spacing increases the amount of undesirable
cross-talk that occurs. Therefore, in many conventional cables,
each twisted pair within the cable has a unique pair lay in order
to increase the spacing between pairs and thereby to reduce the
cross-talk between twisted pairs of a cable. Twist direction may
also be varied. Along with varying pair lays and twist directions,
individual
TABLE-US-00009 Frequency MHz Category 6 dB 0.150 84.7 10.0 57.3
250.0 36.3
solid metal or woven metal air shields can be used to
electro-magnetically isolate pairs from each other or isolate the
pairs from the cable jacket.
[0005] Shielded cable, although exhibiting better cross-talk
isolation, is more difficult, time consuming and costly to
manufacture, install, and terminate. Individually shielded pairs
must generally be terminated using special tools, devices and
techniques adapted for the job, also increasing cost and
difficulty.
[0006] One popular cable type meeting the above specifications is
Unshielded Twisted Pair (UTP) cable. Because it does not include
shielded pairs, UTP is preferred by installers and others
associated with wiring building premises, as it is easily installed
and terminated. However, UTP fails to achieve superior cross-talk
isolation such as required by the evolving higher frequency
standards for data and other state of the art transmission cable
systems, even when varying pair lays are used.
[0007] Some cables have used supports in connection with twisted
pairs. These cables, however, suggest using a standard "X", or "+"
shaped support, hereinafter both referred to as the "X" support.
Protrusions may extend from the standard "X" support. The
protrusions of these prior inventions have exhibited substantially
parallel sides.
[0008] The document, U.S. Pat. No. 3,819,443, hereby incorporated
by reference, describes a shielding member comprising laminated
strips of metal and plastics material that are cut, bent, and
assembled together to define radial branches on said member. It
also describes a cable including a set of conductors arranged in
pairs, said shielding member and an insulative outer sheath around
the set of conductors. In this cable the shielding member with the
radial branches compartmentalizes the interior of the cable. The
various pairs of the cable are therefore separated from each other,
but each is only partially shielded, which is not so effective as
shielding around each pair and is not always satisfactory.
[0009] The solution to the problem of twisted pairs lying too
closely together within a cable is embodied in three U.S. Pat. Nos.
6,150,612 to Prestolite, 5,952,615 to Filotex, and 5,969,295 to
CommScope incorporated by reference herein, as well as an earlier
similar design of a cable manufactured by Belden Wire & Cable
Company as product number 1711A. The prongs or splines in the
Belden cable provide superior crush resistance to the protrusions
of the standard "X" support. The superior crush resistance better
preserves the geometry of the pairs relatives to each other and of
the pairs relative to the other parts of the cables such as the
shield. In addition, the prongs or splines in this invention
preferably have a pointed or slightly rounded apex top which easily
accommodates an overall shield. These cables include four or more
twisted pair media radially disposed about a "+"-shaped core. Each
twisted pair nests between two fins of the "|"-shaped core, being
separated from adjacent twisted pairs by the core. This helps
reduce and stabilize crosstalk between the twisted pair media. U.S.
Pat. No. 5,789,711 to Belden describes a "star" separator that
accomplishes much of what has been described above and is also
herein incorporated by reference.
[0010] However, these core types can add substantial cost to the
cable, as well as excess material mass which forms a potential fire
hazard, as explained below, while achieving a crosstalk reduction
of typically 3 dB or more. This crosstalk value is based on a cable
comprised of a fluorinated ethylene-propylene (FEP) conductors with
PVC jackets as well as cables constructed of FEP jackets with FEP
insulated conductors. Cables where no separation between pairs
exist will exhibit smaller cross-talk values. When pairs are
allowed to shift based on "free space" within the confines of the
cable jacket, the fact that the pairs may "float" within a free
space can reduce overall attenuation values due to the ability to
use a larger conductor to maintain 100 ohm impedance. The trade-off
with allowing the pairs to float is that the pair of conductors
tend to separate slightly and randomly. This undesirable separation
contributes to increased structural return loss (SRL) and more
variation in impedance. One method to overcome this undesirable
trait is to twist the conductor pairs with a very tight lay. This
method has been proven impractical because such tight lays are
expensive and greatly limits the cable manufacturer's throughput
and overall production yield. An improvement included by the
present invention to structural return loss and improved
attenuation is to provide grooves within channels for conductor
pairs such that the pairs are fixedly adhered to the walls of these
grooves or at least forced within a confined space to prevent
floating simply by geometric configuration. This configuration is
both described here within and referenced in U.S. Pat. No.
6,639,152 filed Aug. 25, 2001 as well as PCT/US02/13831 filed at
the United States Patent and Trademark Office on May 1, 2002.
[0011] A "rifling" or "ladder-like" separator design also
contributes to improved attenuation, power sum NEXT (near end cross
talk), power sum ACR (attenuation cross-talk ratio) and ELFEXT
(equal level far end cross-talk) by providing for better control of
spacing of the pairs, adding more air-space, and allowing for
"pair-twinning" at different lengths. Additional benefits include
reduction of the overall material mass required for conventional
spacers, which contributes to flame and smoke reduction.
[0012] In building designs, many precautions are taken to resist
the spread of flame and the generation of and spread of smoke
throughout a building in case of an outbreak of fire. Clearly, the
cable is designed to protect against loss of life and also minimize
the costs of a fire due to the destruction of electrical and other
equipment. Therefore, wires and cables for building installations
are required to comply with the various flammability requirements
of the National Electrical Code (NEC) in the U.S. as well as
International Electrotechnical Commission (EIC) and/or the Canadian
Electrical Code (CEC).
[0013] A broad range of electrical conductors and electrical cables
are installed in modern buildings for a wide variety of uses. Such
uses include data transmission between computers, voice
communications, as well as control signal transmission for building
security, fire alarm, and temperature control systems. These cable
networks extend throughout modern office and industrial buildings,
and frequently extend through the space between the dropped ceiling
and the floor above. Ventilation system components are also
frequently extended through this space for directing heated and
chilled air to the space below the ceiling and also to direct
return air exchange. The space between the dropped ceiling and the
floor above is commonly referred to as the plenum area. Electrical
conductors and cables extending through plenum areas are governed
by special provisions of the National Electric Code ("NEC").
[0014] Cables intended for installation in the air handling spaces
(i.e. plenums, ducts, etc.) of buildings are specifically required
by NEC/CEC/IEC to pass the flame test specified by Underwriters
Laboratories Inc. (UL), UL-910, or its Canadian Standards
Association (CSA) equivalent, the FT6. The UL-910, FT-6, and the
NFPA 262 represent the top of the fire rating hierarchy established
by the NEC and CEC respectively. Also important are the UL 1666
Riser test and the IEC 60332-3C and D flammability criteria. Cables
possessing these ratings, generically known as "plenum" or "plenum
rated" or "riser" or "riser rated", may be substituted for cables
having a lower rating (i.e. CMR, CM, CMX, FT4, FTI or their
equivalents), while lower rated cables may not be used where plenum
or riser rated cables are required.
[0015] In 1975, the NFPA recognized the potential flame and smoke
hazards created by burning cables in plenum areas, and adopted in
the NEC a standard for flame retardant and smoke suppressant
cables. This standard, commonly referred to as "the Plenum Cable
Standard", permits the use of cable without conduit, so long as the
cable exhibits low smoke and flame retardant characteristics. The
test method for measuring these characteristics is commonly
referred to as the Steiner Tunnel Test. The Steiner Tunnel Test has
been adapted for the burning of cables according to the following
test protocols: NFPA 262, Underwriters Laboratories (U.L.) 910, or
Canadian Standards Association (CSA) FT-6. The test conditions for
each of the U.L. 910 Steiner Tunnel Test, CSA FT-6, and NFPA 262
are as follows: a 300,000 BTU/hour flame is applied for 20 minutes
to ten 24-foot lengths of test cables mounted on a horizontal tray
within a tunnel. The criteria for passing the Steiner Tunnel Test
are as follows: [0016] A. Flame spread--flame travel less than 5.0
feet. [0017] B. Smoke Generation: [0018] 1. Maximum optical density
of smoke less than 0.5. [0019] 2. Average optical density of smoke
less than 0.15.
[0020] Because of concerns that flame and smoke could travel along
the extent of a plenum area in the event the electrical conductors
and cable were involved in a fire, the National Fire Protection
Association ("NFPA") has developed a standard to reduce the amount
of flammable material incorporated into insulated electrical
conductors and jacketed cables. Reducing the amount of flammable
material would, according to the NFPA, diminish the potential of
the insulating and jacket materials from spreading flames and
evolving smoke to adjacent plenum areas and potentially to more
distant and widespread areas throughout a building.
[0021] The products of the present invention have also been
developed to support the evolving NFPA standard referenced as NFPA
255 entitled "Limited Combustible Cables" with less than 50 as a
maximum smoke index and/or NFPA 259 entitled "Heat of Combustion"
which includes the use of an oxygen bomb calorimeter that allows
for materials with less than 3500 BTU/lb. for incorporation into
the newer cable (and conductors and separators within these cables)
designs. The proposed materials of the present invention are for
inclusion with high performance support separators and conduit
tubes designed to meet the new and evolving standards proposed for
National Electrical Code (NEC) adoption in 2005. Table 4 below
provides the specific requirements for each of the
[0022] Cables conforming to NEC/CEC/IEC requirements are
characterized as possessing superior resistance to ignitability,
greater resistant to contribute to flame spread and generate lower
levels of smoke during fires than cables having lower fire ratings.
Often these properties can be anticipated by the use of measuring a
Limiting Oxygen Index (LOI) for specific materials used to
construct the cable. Conventional designs of data grade
telecommunication cable for installations in plenum chambers have a
low smoke generating jacket material, e.g. of a specially filled
PVC formulation or a fluoropolymer material, surrounding a core of
twisted conductor pairs, each conductor individually insulated with
a fluorinated insulation layer. Cable produced as described above
satisfies recognized plenum test requirements such as the "peak
smoke" and "average smoke" requirements of the Underwriters
Laboratories, Inc., UL910 Steiner tunnel test and/or Canadian
Standards Association CSA-FT6 (Plenum Flame Test) while also
achieving desired electrical performance in accordance with
EIA/TIA-568 A, B, and C for high frequency signal transmission.
[0023] The newer standards are forcing industrial "norms" to change
and therefore require a new and unique set of materials that will
be required to achieve new standards. These materials are the
subject of the present invention and include nano-composites of
clay and other inorganics such as ZnO and TiO.sub.2 both also as
nano-sized particles. In addition, the use of insulative or
semi-conductive Buckminster fullerenes and doped fullerenes of the
C.sub.60 family and the like are part of the present invention and
offer unique properties that allow for maintaining electrical
integrity as well as providing the necessary reduction in flame
retardance and smoke suppression.
[0024] While the above described conventional cable, due in part to
their use of fluorinated polymers; meets all of the above design
criteria, the use of fluorinated polymers is extremely expensive
and may account for up to 60% of the cost of a cable designed for
plenum usage. A solid core of these communications cables
contributes a large volume of fuel to a potential cable fire.
Forming the core of a fire resistant material, such as with FEP
(fluorinated ethylene-propylene), is very costly due to the volume
of material used in the core, but it should help reduce flame
spread over the 20 minute test period. Reducing the mass of
material by redesigning the core and separators within the core is
another method of reducing fuel and thereby reducing smoke
generation and flame spread. For the commercial market in Europe,
low smoke fire retardant polyolefin materials have been developed
that will pass the EN (European Norm) 502666-Z-X Class B relative
to flame spread, total heat release, related heat release, and fire
growth rate. Prior to this inventive development, standard cable
constructions requiring the use of the aforementioned expensive
fluorinated polymers, such as FEP, would be needed to pass this
rigorous test. Using low smoke fire retardant polyolefins for
specially designed separators used in cables that meet the more
stringent electrical requirements for Categories 6 and 7 and also
pass the new norm for flammability and smoke generation is a
further subject of this invention. Tables 3A, 3B, and 4 indicates
categories for flame and smoke characteristics and associated test
methods as discussed above.
TABLE-US-00010 TABLE 3A International Classification and Flame Test
Methodology for Communications Cable Class Test Methods
Classification Criteria Additional Classification A.sub.ca EN ISO
1716 PCS .ltoreq. 2.0 MJ/kg (1) and PCS .ltoreq. 2.0 MJ/kg (2)
B.sub.1ca FIPEC.sub.20 FS .ltoreq. 1.75 m and Smoke production (3,
7) Scenario 2 (6) THR.sub.1200 .ltoreq. 10 MJ and and Flaming
droplets/ and Peak HRR .ltoreq. 20 kW and particles (4) and Acidity
(5) FIGRA .ltoreq. 120 Ws.sup.-1 EN 50285-2-1 H .ltoreq. 425 mm
C.sub.ca FIPEC.sub.20 FS .ltoreq. 2.0 m and Smoke production (3, 8)
Scenario 1 (6) THR.sub.1200 30 MJ and and Flaming droplets/ and
Peak HRR .ltoreq. 60 kW and particles (4) and Acidity (5) FIGRA
.ltoreq. 300 Ws.sup.-1 EN 50285-2-1 H .ltoreq. 425 mm D.sub.ca
FIPEC.sub.20 THR.sub.1200 .ltoreq. 70 MJ and Smoke production (3,
8) Scenario 1 (6) Peak HRR .ltoreq. 400 kW and and Flaming
droplets/ and FIGRA .ltoreq. 1300 Ws.sup.-1 particles (4) and
Acidity (5) EN 50285-2-1 H .ltoreq. 425 mm Eca EN 50285-2-1 H
.ltoreq. 425 mm Acidity (5) Fca No Performance Determined (1) For
the product as a whole, excluding metallic materials. (2) For any
external component (ie. Sheath) of the product. (3) S1 =
TSP.sub.1200 .ltoreq. 50M.sup.2 and peak SPR .ltoreq. 0.25
m.sup.2/s S2 = TSP.sub.1200 .ltoreq. 400M.sup.2 and peak SPR
.ltoreq. 1.5 m.sup.2/s S3 = Not S1 or S2 (4) For FIPEC.sub.20
Scenarios 1 and 2: d0 = No flaming droplets/particles within 1200 s
d1 = No flaming droplets/particles persisting longer than 10 s
within 1200 s d3 = not d0 or d1 (5) EN 50285-2-1: (?) A1 =
conductivity <2.5 .mu.S/mm and pH >4.3 A2 = conductivity
<10 .mu.S/mm and pH >4.3 A3 = not A1 or A2 No declaration =
No Performance Determined (6) Airflow into chamber shall be set to
8000 +/- 800 1/min. FIPEC.sub.20 Scen. 1 = prEN50399-2-1 with
mounting and fixing according to Annex 2 FIPEC.sub.20 Scen. 2 =
prEN50399-2-2 with mounting and fixing according to Annex 2 (7) The
smoke class declared in class B1ca cables must originate from the
FIPEC.sub.20 Scen.2 test (8) The smoke class declared in class B2ca
cables must originate from the FIPEC.sub.20 Scen.1 test
TABLE-US-00011 TABLE 3B International Classification and Test
Methodology for Communications Cable (cont). Pending CPD
Euro-Classes for Cables PCS = gross calorific potential FIGRA =
fire growth rate FS = flame spread (damaged length) TSP = total
smoke production THR = total het release SPR = smoke production
rate HRR = heat release rate H = flame spread Pending CPD
Euro-Classes for Communications & Energy Cables [A1] EN ISO
1716 Mineral Filled Circuit Integrity Cables [B1] FIPEC Sc.2/EN
50265-2-1 LCC/HIFT-type LAN Comm. Cables [B2] FIPEC Sc.1/EN
50265-2-1 Energy Cables [C] FIPEC Sc.1/EN 50265-2-1 High
FR/Riser-type Cables [D] FIPEC Sc.1/EN 50265-2-1 IEC 332.3C type
Cables [E] EN 50265-2-1 IEC 332.1/VW1 type Cables [F] No
Requirement
TABLE-US-00012 TABLE 4 Flammability Test Methods and Level of
Severity for Wire and Cable Test Method Ignition Source Output
Airflow Duration UL2424/NFPA 8 MJ/kg -- -- 259/255/UL723 (35,000
BTU/lb.) Steiner Tunnel 88 kW (300k BTU/hr.) 73 m/min. 20 min. UL
910/NFPA 262 (240 ft/min.) forced RISER 154 kW (527K BTU/hr.) Draft
30 min. UL2424/NFPA 259 Single Burning Item 30 kW (102k BTU/hr.) 36
m.sup.3/min. 30 min. (20 min burner) Modified IEC 60332-3 30 kW
(102k BTU/hr.) 8 m.sup.3/min. 20 min. (Backboard behind ladder
(heat impact)) IEC 60332-3 20.5 kW (70k BTU/hr.) 5 m.sup.3/min. 20
min Vertical Tray 20.5 kW (70k BTU/hr.) Draft 20 min IEC
60332-1/ULVW-1 Bunsen Burner -- 1 min (15 sec. Flame) Evolution of
Fire Performance (Severity Levels) ##STR00001##
[0025] Table 5 indicates requirements for wire and cable that can
meet some of the test method criteria as provided in Table 4. "Low
smoke and flame compound A" is a fluoropolymer based blend that
includes inorganics known to provide proper material properties
such that NFPA 255 and NFPA 259 test protocols may be met.
TABLE-US-00013 TABLE 5 Material Requirements and Properties for
Plenum, Riser, and Halogen Free Cables Low Smoke and LSFR PVC
(Halogen Free) (Halogen Free) Flame Compound A HIFT/NFPA 262 IEC
332.2C IEC 332.1 Properties NFPA 255/259 LC Euro Class B1 Class C/D
Euro Class E Specific Gravity 2.77 g/cc 1.65 g/cc 1.61 g/cc 1.53
g/cc Durometer D Aged, 69/61 72/63 59/49 53/47 Inst/15 sec. Tensile
Strength. 2,250 psi/15.5 Mpa 2,500 psi/17.2 Mpa 1,750 psi/12.1 Mpa
1,750 psi/12.1 Mpa 20''/min. Elongation, 20''/min. 250% 180% 180%
170% Oxygen Index. 100+% 53% 53% 35% (0.125'') Brittle point. deg
C. -46 -5 -22 -15 Flexural Modulus, 202000 psi/1400 Mpa 56000
psi/390 Mpa 41000 psi/280 Mpa 49000 psi/340 Mpa 0.03''/min. UL Temp
Rating, 125+ 60 90 75 dec C. Dielectric Constant, 2.92 3.25 3.87
3.57 100 MHz Dissipation Factor, 0.012 0.014 0.015 0.014 100 MHz
4pr UTP Jkt 9-11 mils/.23-.28 mm 15-17 mils/.38-.43 mm 30-40
mils/.76-1.02 mm 20-24 mils/.50-.60 mm Thickness
[0026] Table 6 is provided as an indicator of low acid gas
generation performance for various materials currently available
for producing wire and cable and cross-web designs of the present
invention. The present invention includes special polymer blends
that are designed to significantly reduce these values to levels to
those shown for low smoke and flame Compound A listed above in
Table 5.
TABLE-US-00014 TABLE 6 Acid Generation Values for Wire and Cable
Insulation Materials Material % Acid PH FEP 27.18 1.72 ECTFE 23.890
1.64 PVDF 21.48 2.03 LSFR PVC 13.78 1.90 Low Smoke and Flame
Compound A 1.54 3.01 48% LOI HFFR 0.35 3.42 34% LOI HFFR .024
3.94
[0027] Solid flame retardant/smoke suppressed polyolefins may also
be used in connection with fluorinated polymers. Commercially
available solid flame retardant/smoke suppressed polyolefin
compounds all possess dielectric properties inferior to that of FEP
and similar fluorinated polymers. In addition, they also exhibit
inferior resistance to burning and generally produce more smoke
than FEP under burning conditions. A combination of the two
different polymer types can reduce costs while minimally
sacrificing physio-chemical properties. An additional method that
has been used to improve both electrical and flammability
properties includes the irradiation of certain polymers that lend
themselves to crosslinking. Certain polyolefins are currently in
development that have proven capable of replacing fluoropolymers
for passing these same stringent smoke and flammability tests for
cable separators, also known as "cross-webs". Additional advantages
with the polyolefins are reduction in cost and toxicity effects as
measured during and after combustion. The present invention
utilizes blends of fluoropolymers with primarily polyolefins as
well as the use of "additives" that include C.sub.60 fullerenes and
compounds that incorporate the fullerenes and substituted
fullerenes as well as inorganic clays and metal oxides as required
for insulative or semi-conductive properties in addition to the
flame and smoke suppression requirements. The use of fluoropolymer
blends with other than polyolefins is also a part of the present
invention and the incorporation of these other "additives" will be
included as the new compounds are created. Reduction of acid gas
generation is another key feature provided by the use of these
blends as shown in Table 6 and another important advantage
presented in the use of the cables and separators of the present
invention. Price and performance characteristics for the separators
and conduit tubes will determine the exact blend ratios necessary
for these compounds.
[0028] A high performance communications data cable utilizing
twisted pair technology must meet exacting specification with
regard to data speed, electrical, as well as flammability and smoke
characteristics. The electrical characteristics include
specifically the ability to control impedance, near-end cross-talk
(NEXT), ACR (attenuation cross-talk ratio) and shield transfer
impedance: A method used for twisted pair data cables that has been
tried to meet the electrical characteristics, such as controlled
NEXT, is by utilizing individually shielded twisted pairs (ISTP).
These shields insulate each pair from NEXT. Data cables have also
used very complex lay techniques to cancel E and B (electric and
magnetic fields) to control NEXT. In addition, previously
manufactured data cables have been designed to meet ACR
requirements by utilizing very low dielectric constant insulation
materials. Use of the above techniques to control electrical
characteristics have inherent problems that have lead to various
cable methods and designs to overcome these problems. The blends of
the present invention are designed such that these key parameters
can be met.
[0029] Recently, as indicated in Tables 1, 2A and 2B, the
development of "high-end" electrical properties for Category 6 and
7 cables has increased the need to determine and include power sum
NEXT (near end crosstalk) and power sum ELFEXT (equal level far end
crosstalk) considerations along with attenuation, impedance, and
ACR values. These developments have necessitated the development of
more highly evolved separators that can provide offsetting of the
electrical conductor pairs so that the lesser performing electrical
pairs can be further separated from other pairs within the overall
cable construction.
[0030] Recent and proposed cable standards are increasing cable
maximum frequencies from 100 200 MHz to 250 700 Mhz. Recently, 10
Gbit over copper high speed standards have been proposed. The
maximum upper frequency of a cable is that frequency at which the
ACR (attenuation/cross-talk ratio) is essentially equal to 1. Since
attenuation increases with frequency and cross-talk decreases with
frequency, the cable designer must be innovative in designing a
cable with sufficiently high cross-talk. This is especially true
since many conventional design concepts, fillers, and spacers may
not provide sufficient cross-talk at the higher frequencies.
Proposed limits for alien crosstalk have also been added to the
present standards as shown in Table 2G. Such limits in many cases
can only be met using the separators of the present invention.
[0031] Current separator designs must also meet the UL 910 flame
and smoke criteria using both fluorinated and non-fluorinated
jackets as well as fluorinated and non-fluorinated insulation
materials for the conductors of these cable constructions. In
Europe, the trend continues to be use of halogen free insulation
for all components, which also must meet stringent flammability
regulations. The use of the blends of the present invention for
both separators and tube conduits will allow for meeting these
requirements.
[0032] In plenum applications for voice and data transmission,
electrical conductors and cables should exhibit low smoke
evolution, low flame spread, and favorable electrical properties.
Materials are generally selected for plenum applications such that
they exhibit a balance of favorable and unfavorable properties. In
this regard, each commonly employed material has a unique
combination of desirable characteristics and practical limitations.
Without regard to flame retardancy and smoke suppressant
characteristics, olefin polymers, such as polyethylene and
polypropylene, are melt extrudable thermoplastic materials having
favorable electrical properties as manifested by their very low
dielectric constant and low dissipation factor.
[0033] Dielectric constant is the property of an insulation
material which determines the amount of electrostatic energy stored
per unit potential gradient. Dielectric constant is normally
expressed as a ratio. The dielectric constant of air is 1.0, while
the dielectric constant for polyethylene is 2.2. Thus, the
capacitance of polyethylene is 2.2 times that of air. Dielectric
constant is also referred to as the Specific Inductive Capacity or
Permittivity.
[0034] Dissipation factor refers to the energy lost when voltage is
applied across an insulation material, and is the cotangent of the
phase angle between the voltage and current in a reactive
component. Dissipation factor is quite sensitive to contamination
of an insulation material. Dissipation factor is also referred to
as the Power Factor (of dielectrics).
[0035] Fluorinated ethylene/propylene polymers exhibit electrical
performance comparable to non-halogenated to olefin polymers, such
as polyethylene, but are over 15 times more expensive per pound.
Polyethylene also has favorable mechanical properties as a cable
jacket as manifested by its tensile strength and elongation to
break. However, polyethylene exhibits unfavorable flame and smoke
characteristics.
[0036] Limiting Oxygen Index (ASTM D-2863) ("LOI") is a test method
for determining the percent concentration of oxygen that will
support flaming combustion of a test material. The greater the WI,
the less susceptible a material is to burning. In the atmosphere,
there is approximately 21% oxygen, and therefore a material
exhibiting an LOI of 22% or more cannot burn under ambient
conditions. As pure polymers without flame retardant additives,
members of the olefin family, namely, polyethylene and
polypropylene have an LOI of approximately 19. Because their LOI is
less than 21, these olefins exhibit disadvantageous properties
relative to flame retardancy in that they do not self-extinguish
flame, but propagate flame with a high rate of heat release.
Moreover, the burning melt drips on the surrounding areas, thereby
further propagating the flame.
[0037] In the U.S. and Canada, the standards for flame retardancy
for voice communication and data communication cables are
stringent. The plenum cable test (U.L. 910/CSA FT-6) and riser
cable test U.L. 1666 are significantly more stringent than the
predominantly used international fire test IEC 332-3, which is
similar to the IEEE 383/U.L. 1581 test. Table 4 already summarizes
the standards required for various U.L. (Underwriters Laboratories
and CSA (Canadian Standards Authority) cable designations.
[0038] As indicated above, current separator designs must also meet
the UL 910 flame and smoke criteria using both fluorinated and
non-fluorinated jackets as well as fluorinated and non-fluorinated
insulation materials for the conductors of these cable
constructions. The UL 910 criteria has been included in the
recently adopted NFPA 262 criteria and extended with more severity
in the NFPA 255 and 259 test criteria. To ensure that the test
criteria is met, the use of the separators of the current invention
is not only useful but often necessary. For meeting the NFPA 72
test criteria for circuit integrity cable, the support-separators
and the materials from which they will be produced is an integral
part of the present invention.
[0039] The reduction in material loading (lbs/NIFT) as shown in
Table 7 can be an essential aspect in meeting this demand.
Substantial reduction of this load by the use of separators can be
achieved. The use of the polymer blends of the present invention
for both separators and conduit tubes will allow for meeting the
requirements for not only current circuit integrity cables but also
for cables that must meet the newer more stringent requirements in
the future.
TABLE-US-00015 TABLE 7 Insulation Material Criteria For Circuit
Integrity Cable Number Insula- Jacket Cable of tion Thick- Di-
Approximate Nominal Con- AWG Thickness ness ameter Weight Cable Lay
ductors size (mils) (mils) (in) (lbs/MFT) (in./twist) 2 16 35 40
.34 59 3.7 2 14 35 40 .36 75 4.0 2 12 35 50 .42 106 4.4
[0040] Principal electrical criteria can be satisfied based upon
the dielectric constant and dissipation factor of an insulation or
jacketing material. Secondarily, the electrical criteria can be
satisfied by certain aspects of the cable design such as, for
example, the insulated twisted pair lay lengths. Lay length, as it
pertains to wire and cable, is the axial distance required for one
cabled conductor or conductor strand to complete one revolution
about the axis of the cable. Tighter and/or shorter lay lengths
generally improve electrical properties.
[0041] Individual shielding is costly and complex to process.
Individual shielding is highly susceptible to geometric instability
during processing and use. In addition, the ground plane of
individual shields, 360 degree in ISTP's--individually shielded
twisted pairs is also an expensive process. Lay techniques and the
associated multi-shaped anvils of the present invention to achieve
such lay geometries are also complex, costly and susceptible to
instability during processing and use. Another problem with many
data cables is their susceptibility to deformation during
manufacture and use. Deformation of the cable geometry, such as the
shield, also potentially severely reduces the electrical and
optical consistency.
[0042] Optical fiber cables exhibits a separate set of needs that
include weight reduction (of the overall cable), optical
functionality without change in optical properties and mechanical
integrity to prevent damage to glass fibers. For multi-media cable,
i.e. cable that contains both metal conductors and optical fibers,
the set of criteria is often incompatible. The use of the present
invention, however, renders these often divergent set of criteria
compatible. Specifically, optical fibers must have sufficient
volume in which the buffering and jacketing plenum materials (FEP
and the like) covering the inner glass fibers can expand and
contract over a broad temperature range without restrictions, for
example -40 C to 80 C experienced during shipping. It has been
shown by Grune, et. al., among others, that cyclical compression
and expansion directly contacting the buffered glass fiber causes
excess attenuation light loss (as measured in dB) in the glass
fiber. The design of the present invention allows for designation
and placement of optical fibers in clearance channels provided by
the support-separator having multiple shaped profiles. It would
also be possible to place both glass fiber and metal conductors in
the same designated clearance channel if such a design is required.
In either case the forced spacing and separation from the cable
jacket (or absence of a cable jacket) would eliminate the
undesirable set of cyclical forces that cause excess attenuation
light loss. In addition, fragile optical fibers are susceptible to
mechanical damage without crush resistant members (in addition to
conventional jacketing). The present invention addresses this
problem by including the use of both organic and inorganic polymers
as well as inorganic compounds blended with fluoropolymers to
achieve the necessary properties.
[0043] The need to improve the cable and cable separator design,
reduce costs, and improve both flammability and electrical
properties continues to exist.
OBJECTIVE OF THE INVENTION
[0044] An objective is to provide a high performance communications
cable where an interior support, a central region, and outwardly
extended portions and optional conduit tubes are capable of
shielding conductors that transmit data at 10 Gbit while
substantially mitigating or eliminating alien crosstalk.
[0045] An objective of the invention is a high performance
communications cable with an interior support, a central region,
and outwardly extended portions and optional conduit tubes that are
comprised of organic blends including homo and copolymers of
ethylene or polyvinyl chloride with fluorinated ethylene propylene,
fluorinated ethylene, chlorinated ethylene propylene,
fluorochlorinated ethylene, perfluoroalkoxy, fluorochlorinated
propylene, a copolymer of tetrafluoroethylene and
perfluoromethylvinylether (MFE), a copolymer of ethylene and
chlorotrifluoroethylene (ECTFE), as well as homo and copolymers of
ethylene and/or propylene with fluorinated ethylene propylene,
fluorinated ethylene, chlorinated ethylene propylene,
fluorochlorinated ethylene, perfluoroalkoxy, fluorochlorinated
propylene, as well as blends of polyvinyl chloride, polyvinylidene
chloride, unsubstituted or substituted fullerenes primarily
comprised of C.sub.60 molecules, nylons, polyesters, polyurethanes;
and nano-composites of clay including; and nano-sized particles of
ZnO or TiO and the like.
[0046] Another objective is the high performance communications
cable separator or conduit tube where the interior support, the
central region, and outwardly extended portions and optional
conduit tubes are comprised of compounds such as acid gas
scavengers that scavenge gasses such as hydrogen chloride and
hydrogen fluoride and other halogenated gasses.
[0047] Additionally, the high performance communications cable
separator or conduit tube where the interior support, central
region, and outwardly extended portions and optional conduit tubes
are comprised of a foamed polymer blend ratio of halogenated
polymers or copolymers to ethylene or vinyl chloride polymers or
copolymers of from 0.1% to up to 99.9% of the halogenated polymers
to ethylene or vinyl chloride polymers or copolymers and where the
foam polymer blend includes a nucleating agent of
polytetrafluoroethylene, carbon black, color concentrate or boron
nitride or other acceptable nucleating or blowing agent.
[0048] Another objective is a high performance communications cable
separator or conduit tube comprising an interior support with an
external radial and axial surface, extending along a longitudinal
length of a communications cable the interior support also having a
central region, the central region also extending along a
longitudinal length of the interior support of the communications
cable; the interior support comprising one or more outwardly
extended shaped portions and optional conduit tubes extended from
the central region wherein the central region and outwardly
extended portions are comprised of organic polymer blends.
[0049] Additionally, anvil-shaped core support-separator sections
comprise channel walls defining one or more clearance channels and
where the clearance channels are defined by a semi-circular
geometry such that there remains a 180 degree opening along the
external radial and axial surface of the interior support.
[0050] In addition, each anvil-shaped core support-separator
sections comprises clearance walls defined by a semi-closed
semi-circular geometry such that there remains less than a 160
degree opening along the exterior radial and axial surface, but
more than a 10 degree opening along the external surface of the
interior support of the clearance channels.
[0051] In another objective the flap-top is comprised of a
press-fit arrangement that is hinged allowing for opening and
closing the exterior radial and axial surfaces of the channel walls
of the clearance channels.
[0052] Additionally the flap-top is sealed by use of heat, tape,
interlocking, or by skin extrusion of the hinged press-fit
arrangement.
[0053] An additional objective is anvil-shaped core
support-separator sections comprising clearance walls defined by a
fully closed circular geometry that remain closed but optionally
includes an interlocking double flap-top, where the double flap-top
is adhered to or adjoined with a surface on each side of the
clearance walls for opening or closing the exterior radial and
axial surfaces of the channel walls of the clearance channels.
[0054] Another objective is that the channel walls comprise
interior surfaces that are corrugated including internal axial
grooves separated by a sufficient distance such that individual
conductors or conductor pairs maintain required electrical
integrity and such that the conductor or conductor pairs are forced
against an edge of the grooves or sections of the channel
walls.
[0055] In addition, the metal conductors are copper with or without
metallic shielding or aluminum with or without metallic
shielding.
[0056] Additionally, at least one anvil shaped support-separator
section comprises rounded edges at an outer radial end of the anvil
shaped sections sufficient to reduce overall weight and size of the
support-separator and subsequently the cable.
[0057] An additional objective is at least one anvil shaped
support-separator sections comprising minimized dual lobes at an
outer radial end of the multi-anvil shaped sections sufficient to
minimize and reduce overall weight and size of the
support-separator and subsequently the cable.
[0058] Additionally the anvil shaped core support-separator
sections themselves are twisted to a specified lay length.
[0059] An additional objective is an interior support-separator for
a communications cable extending along a longitudinal length of a
communications cable comprising along the support-separator's
cross-section a pendulum shaped configuration with two ends with a
pendant shaped section comprising triangular shaped pendants with
apexes that face in opposite directions along a horizontal plane in
a central region of the pendulum shaped separator comprising a
diamond-like shape and an optional hollow orifice in a center
region of the central portion of the interior
support-separator.
[0060] Additionally the triangular shaped pendants may be nearer
either end of the central region of the pendulum shaped separator
than near the central region.
[0061] Another objective of the present disclosure is an interior
support-separator for a communications cable extending along a
longitudinal length of a communications cable, comprising, along
its cross-section, a dual-lobed shaped pendulum-like configuration
with curved elongated lobed end portions along a top portion and a
bottom portion of the pendulum-like separator creating at least two
clearance channels for conductors or conductor pairs and an
optional hollow orifice in a center region of the central portion
of the interior support-separator.
[0062] In addition is an interior support-separator for a
communications cable extending along a longitudinal length of a
communications cable, comprising at least two symmetrical or
asymmetrical intersecting arms that intersect in a cross-like
manner along an essentially horizontal and vertical axis; the
intersecting arms provided with ladder-like steps evenly spaced
along each arm and along a complete length of the arm whereby each
arm with the ladder-like steps forms a rifle-like pattern along the
horizontal and vertical axes the intersecting arms providing four
or more separate clearance channels and the arms are comprised of
solid or foamed material.
[0063] Another objective is an interior support-separator for a
communications cable extending along a longitudinal length of a
communications cable, comprising at least two intersecting arms
that intersect in a cross-like manner along an essentially
horizontal and vertical axis with the intersecting arms optionally
providing ladder-like steps evenly spaced along each arm and along
a complete length of the arm whereby each arm with the ladder-like
steps forms a rifle-like saw-tooth pattern along the horizontal and
vertical axes and a central portion of the intersection of the
arms, with the central portion comprising a solid predetermined
shaped member that includes step-like portions cut away from the
central solid member and an optional hollow orifice in a center
region of the central portion of the interior support-separator
where the central region is void of a saw-tooth member along at
least one or more of the horizontal and vertical axes.
[0064] Additionally is an interior support-separator for a
communications cable extending along a longitudinal length of a
communications cable comprising at least two spatial quadrants
defined by a horizontal arm member of a support including a two
sided drill-bit-like shaped central member with geometrically
symmetric sections in opposite quadrants and; each drill-bit-like
shape a mirror image of the other drill-bit-like shape in the other
quadrant and the support in sum appears to be shaped as a mirrored
battleship and an optional hollow orifice in a center region of the
central portion of the interior support-separator.
[0065] Another objective is an interior support-separator for a
communications cable extending along a longitudinal length of a
communications cable, comprising at least two intersecting arms
that intersect in a cross-like manner comprising a cross-like
support separator along an essentially horizontal and vertical
axis; the intersecting arms optionally provided with ladder-like
steps evenly spaced along each arm and along a complete length of
the arm whereby each arm with the ladder-like steps forms a
rifle-like saw-tooth pattern along the horizontal and vertical axes
and a central portion of the intersection of the arms, with the
central portion comprising an optional hollow center wherein the
vertical and horizontal intersecting arms are initially wide or
narrow along a horizontal or vertical axis and become finally
narrow or wide along the horizontal or vertical axis such that the
cross-like support separator comprises an asymmetric pattern.
[0066] Additionally an objective is an interior support-separator
for a communications cable extending along a longitudinal length of
a communications cable comprising at least two spatial quadrants
defined by two horizontal members with two sides of the support
connected by a vertical member with two sides such that the
complete support appears as a symmetric or skewed angle iron with a
z-like shape and where each of the members may be longer, shorter
or the same length as each of the other two members.
[0067] An additional objective of this disclosure is an interior
support providing a specified lay length by implementing a twisting
of the clearance channels thereby providing a lay length twist into
the support-separator during manufacturing of the final
communications cable assembly.
[0068] Additionally an objective is a high performance
communications cable comprising an interior support-separator with
an external radial axial surface extending along a longitudinal
length of the communications cable with the interior support also
having a central region and the central region also extending along
a longitudinal length of the interior support and the
communications cable. The cable comprises 24 pair of electrical
conductors and a twenty fifth pair of electrical conductors where
the twenty fifth pair is placed within an orifice within the
central region of the interior support-separator.
[0069] An objective also is a high performance communications cable
where the interior support, the central region, and the outwardly
extended sections and optional conduit tubes comprise solid,
partially solid, or foamed organic or inorganic dielectric
materials either solid or partially solid, foamed or foamed with a
solid skin surface.
[0070] An objective also is a high performance communications cable
separator or conduit tube where the interior support, the central
region, and the outwardly extended sections and optional conduit
tubes comprise solid, partially solid, or foamed organic or
inorganic dielectric materials either solid or partially solid,
foamed or foamed with a solid skin surface.
[0071] Additionally, there is an objective of a the high
performance communications cable where the interior support, the
central region and the anvil shaped core support-separator sections
comprises solid, partially solid, or foamed thermoplastic or
thermosetting dielectric materials.
[0072] In addition an objective is to provide a high performance
communications cable where each of the anvil shaped core-support
sections are optionally singularly filled with individual or paired
metal or optionally coaxial electrical transmitting conductors or
optical fiber light transmitting conductors, or filled with a
combination of the individually or paired metal or optical
conductors along the longitudinal length of the support and the
cable.
[0073] Another objective is a high performance communications cable
where the cable comprises one or more axial strength members and
the axial strength members optionally lie parallel to the interior
support inside the communications cable jacket or within the hollow
portion of the interior support along the longitudinal direction of
the support and the cable.
[0074] An additional objective is a high performance communications
cable comprising an interior support with an external radial and
axial surface extending along a longitudinal length of the
communications cable, where the interior support also has a central
region and the central region also extends along a longitudinal
length of the interior support and the communications cable. The
interior support comprises a hollow four-petal daisy shaped
arrangement with a central core that may or may not be hollow with
each of the hollow petals separated by 90 degrees along an axial
plane that extends along a complete length of the communications
cable allowing for individual or paired conductors to be placed
within the hollow petals.
[0075] Additionally an objective is an interior support-separator
for a communications cable comprising an interior support with an
external radial and axial surface extending along a longitudinal
length of the communications cable with the interior support also
having a central region also extending along a longitudinal length
of the interior support and the communications cable. The interior
support comprises a hollow four-petal daisy shaped arrangement with
a central core that may or may not be hollow with each of the
hollow petals separated by 90 degrees along an axial plane that
extends along a complete length of the communications cable
allowing for individual or paired conductors to be placed within
the hollow petals or within hollow sections of otherwise solid
petals.
[0076] An additional objective is a high performance communications
cable comprising an interior support with an external radial and
axial surface extending along a longitudinal length of the
communications cable with the interior support also having a
central region also extending along a longitudinal length of the
interior support and the communications cable. The interior support
comprises an inner cross-like separator section with rifled
sections extending outward into four quadrants away from the
central region with the quadrants defined by 90 degree right angles
formed by an intersection of the extended cross-like rifled
separator sections encased within an outer insulated layer which is
itself shaped in an identical cross-like pattern as the cross-like
separator section so that dimensions of the outer insulated layer
forms a cross-like pattern larger than the rifled inner cross and
functions as a skin for the inner cross-like pattern.
[0077] An additional objective is a high performance communications
cable comprising an interior support with an external radial and
axial surface extending along a longitudinal length of the
communications cable with the interior support also having a
central region also extending along a longitudinal length of the
interior support and the communications cable. The interior support
comprises a cross-like separator section with zig-zag sections
extending outward into four quadrants away from the central region,
the quadrants defined by 90 degree right angles formed by an
intersection of the extended cross-like zig-zag separator
sections.
[0078] Additionally an objective is a high performance
communications cable comprising an interior support with an
external radial and axial surface extending along a longitudinal
length of the communications cable with the interior support also
having a central region also extending along a longitudinal length
of the interior support and the communications cable. The interior
support comprises a cross-like separator section with zig-zag
sections that have sickle-like ends at each of the sections zig-zag
sections and extend outward into four quadrants away from the
central region, the quadrants defined by 90 degree right angles
formed by an intersection of the extended cross-like zig-zag
separator sections with the sickle-like ends.
[0079] Another objective is an interior support-separator for a
communications cable extending along a longitudinal length of a
communications cable comprising, along its cross-section, a
maltese-cross shaped configuration with two arm members such that
the maltese-cross shape is optionally skewed along one arm member
with an axis along the arm member providing a length along one axis
of the arm member that is longer than along any other axis and
providing larger blunt tipped ends at both ends of the arm member.
Blunt tipped ends at both ends of an arm member with a length
shorter are smaller than the other longer arm member and have an
optional hollow orifice in a center region of the central portion
of the interior support-separator.
[0080] Additionally an objective is an interior support-separator
for a communications cable where the maltese-cross shaped
cross-sectional configuration along the cross-section includes
step-like sections along a perimeter of the support-separator
providing small interstitial sectional grooves along an inner
circumferential portion of clearance channels provided by the
support-separator and an optional hollow orifice in a center region
of the central portion of the interior support-separator.
[0081] Another objective is an interior support-separator
comprising within a cross-section, two hollow triangular orifices
in the central region of the interior support-separator, where the
hollow triangular orifices are shaped as equilateral triangles, one
of the triangular orifice facing upright and the other triangular
orifice facing downward such that that a peak of each triangular
orifice is facing opposite directions.
[0082] Additionally an objective is an interior support-separator
comprising within the cross-section, a diamond shaped orifice in
the central region of the interior support-separator.
[0083] Another object is an interior support-separator comprising
within the cross-section, a center slit orifice in the central
region of the interior support-separator.
[0084] Additionally an objective is a method for producing a high
performance communications cable by introducing an interior
support-separator section or sections with a longitudinal length
and the external radial and axial surfaces having a central region
extending along a longitudinal length of the interior support with
the one or more clearance channels into a jacket of the cable. This
is accomplished by passing a plurality of transmission conductors
within the clearance channels of the interior support-separator
through a first die that aligns the plurality of transmission
conductors with surface features of the internal support allowing
for intentional twisting of the conductors. Each of the plurality
of conductors are forced into a proper clearance channel of the
interior support-separator where the clearance channels are
optionally closed by single or double flap-tops maintaining a
spatial relationship between each of the transmission conductors.
Heating a second die allows for closing of the exterior surface of
the channels. Additionally, taping and twisting of the interior
support allows for closing of the exterior surface of the channels
and allows for jacketing the interior support containing each of
the conductors within the clearance channels.
[0085] Additionally an objective is a method for producing a high
performance communications cable by introducing an interior
support-separator section or sections with a longitudinal length
and the external radial and axial surfaces having a central region
extending along a longitudinal length of the interior support with
one or more hollow central ring portions optionally jacketed to
complete the cable. Another step is passing a plurality of
transmission conductors within the hollow central ring portions of
the interior support-separator through a first die that aligns the
plurality of transmission conductors with the surface features of
the internal support allowing for intentional twisting of the
conductors, forcing each of the plurality of conductors into the
hollow central ring portions of the interior support-separator
where the hollow central ring portions maintain a spatial
relationship between each of the transmission conductors by
optionally shielding and jacketing the interior support containing
each of the conductors within the hollow central ring portions and
optionally pulling each of the transmission conductors through the
hollow central ring portion(s) or the support-separators either
before, during or after initial installation.
[0086] An additional objective is a high performance communications
cable comprising an interior support-separator with an external
radial and axial surface extending along a longitudinal length of
the communications cable with the interior support also having a
central region also extending along a longitudinal length of the
interior support and the communications cable. The support is
comprised of a polyolefin based material capable of meeting
specific flammability and smoke generation requirements as defined
by UL 910, NAPA 262, and EN 50266-2-x, class B test
specifications.
[0087] An additional objective is a high performance communications
cable comprising an interior support-separator with an external
radial and axial surface extending along a longitudinal length of
the communications cable with the interior support also having a
central region also extending along a longitudinal length of the
interior support and the communications cable. The support is
comprised of a thermoplastic based material capable of meeting
specific flammability and smoke generation requirements as defined
by UL 910, NAPA 262, and EN 50266-2-x, class B test
specifications.
SUMMARY OF THE INVENTION
[0088] This invention provides a lower cost communications cable,
conductor separator, and in some cases a conduit tube exhibiting
improved electrical, flammability, and optionally, optical
properties. The cable has an interior support and in some cases a
conduit tube extending along the longitudinal length of the
communications cable. The interior support has a central region
extending along the longitudinal length of the interior support. In
the preferred configuration, the cable includes a geometrically
symmetrical core support-separator with a plurality of either solid
or foamed multi-shaped, rifled and ladder sections that extend
radially outward from the central region along the longitudinal or
axial length of the cable's central region. The core
support-separator is optionally foamed and has an optional hollow
center. These various shaped sections of the core support-separator
may be helixed as the core extends along the length of the
communications cable. Each of the adjacent shaped sections defines
a clearance which extends along the longitudinal length of the
multi-shaped core support-separators. The clearance provides a
channel for each of the conductors/optical fibers or conductor
pairs used within the cable as well as for the optional conduit
tubes that may be initially empty so that conductors can be later
placed there within. The clearance channels formed by the various
shaped core support-separators extend along the same length of the
central portion. The channels are either semi-circular, fully
circular, or stepped in a circular-like manner shaped cross-section
with completely closed surfaces in the radial direction toward the
center portion of the core and optionally opened or closed surfaces
at the outer radial portion of the same core. Adjacent channels are
separated from each other to provide a chamber for at least a pair
of conductors or an optical fiber or optical fibers. Conduit
channels of various shapes may be used in addition to or in lieu of
the adjacent channels.
[0089] The various shaped core support-separators of this invention
provides a superior crush resistance to the protrusions of the
standard "X" or other similar supports. A superior crush resistance
is obtained by the arch-like design for the anvil-shaped separators
that provide clearance channels for additional support to the outer
section of the cable. The various shaped cores better preserves the
geometry of the pairs relative to each other and of the pairs
relative to the other parts of the cables, such as the possible use
of a shield or optical fibers. The anvil-shape provides an exterior
surface that essentially establishes the desired roundness for
cable manufacturers. The exterior roundness ensures ease of die
development and eventual extrusion. The rounded surface of the core
also allows for easy accommodation of an overall external
shield.
[0090] The rifled shape separators with ladder-like sections
provide similar crush resistance to the standard "X" supports with
the additional feature that the center portion of the separator may
have solid sections that can be adjusted in step-like increments
such that conductor spacing can be controlled with a degree of
precision. Specifically, the conductors can be set apart so that
individual or sets of pairs can be spaced closer or farther from
one another, allowing for better power sum values of equal level
far end and near end crosstalk. This "offsetting" between conductor
pairs in a logical, methodological pattern to optimize electrical
properties is an additional benefit associated with the rifled
shaped separators with ladder-like sections.
[0091] According to one embodiment, the cable includes a plurality
of transmission media with metal and/or optical conductors that are
individually disposed; and an optional outer jacket maintaining the
plurality of data transmission media in proper position with
respect to the core. The core is comprised of a support-separator
having a multi-anvil shaped profile that defines a clearance to
maintain a spacing between transmission media or transmission media
pairs in the finished cable. The core may be formed or a conductive
or insulative material to further reduce cross-talk, impedance, and
attenuation. It may be solid, foamed, foamed with a solid skin, and
composed of a blend of non-halogenated as well as halogenated
polymers that also include inorganic fillers as described
above.
[0092] Accordingly, the present invention provides for a
communications cable, conductor separator and in some cases a
conduit tube, with a multi-shaped support-separator, that meets the
exacting specifications of high performance data cables and/or
fiber optics or the possibility of including both transmission
media in one cable, has a superior resistance to deformation during
manufacturing and use, allows for control of near-end cross-talk,
controls electrical instability due to shielding, is capable of 200
and 1 Ghz (categories 6 and 7 and beyond) transmission with a
positive attenuation to cross-talk ratio (ACR ratio) of typically 3
to 10 dB.
[0093] Moreover, U.S. Pat. No. 6,639,152 provides a separator so
that jacket material (which normally has inferior electrical
properties as compared with the conductor material) is actually
pushed away from the electrical conductor, thus acting to again
improve electrical performance (ACR, etc.) over the life of the use
of the cable. The anvil-shaped separator, by simple geometric
considerations is also superior to the "X" type separator in that
it increases the physical distance between the conductor pairs
within the same cable configuration, as shown in FIGS. 2 and 3.
[0094] Additionally, it has been known that the conductor pair may
actually have physical or chemical bonds that allow for the pair to
remain intimately bound along the length of the cavity in which
they lie. U.S. Pat. No. 6,639,152 describes a means by which the
conductor pairs are adhered to or forced along the cavity walls by
the use of grooves. This again increases the distance, thereby
increasing the volume of air or other dielectrically superior
medium between conductors in separate cavities. As discussed above,
spacing between pairs, spacing away from jackets, and balanced
spacing all have an effect on final electrical cable
performance.
[0095] It is an object of the present invention to provide a
data/multi-media cable that has a specially designed interior
support that accommodates conductors with a variety of AWG's,
impedances, improved crush resistance, controlled NEXT, controlled
electrical instability due to shielding, increased breaking
strength, and allows the conductors, such as twisted pairs, to be
spaced in a manner to achieve positive ACR ratios using
non-conventional composite compound blends that include halogenated
and non-halogenated polymers together with optional inorganic and
organic additives that include inorganic salts, metallic oxides,
silica and silicon oxides as well as any number of substitute and
unsubstantiated fullerenes.
[0096] It is still another object of the invention to provide a
cable that does not require individual shielding and that allows
for the precise spacing of conductors such as twisted pairs and/or
fiber optics with relative ease. In the present invention, the
cable would include individual glass fibers as well as conventional
metal conductors as the transmission medium that would be either
together or separated in clearance channel chambers provided by the
anvil-shaped sections of the core support-separator or could be
placed either immediately or at a later time into conduit
tubes.
[0097] Another embodiment of the invention includes having a
multi-shaped core support-separator with a central region that is
either solid or partially solid. Again this support-separator and
any conduit tube would be comprised of the special composite
compound blends described in detail above. This again includes the
use of a foamed core and/or the use of a hollow center of the core,
which in both cases significantly reduces the material required
along the length of the finished cable. The effect of foaming
and/or producing a support-separator with a hollow center portion
should result in improved flammability of the overall cable by
reducing the amount of material available as fuel for the UL 910
test, improved electrical properties for the individual non-optical
conductors, and reduction of weight of the overall cable.
[0098] A further embodiment includes the fully opened surface
sections defining the core clearance channels which extend along
the longitudinal length of the multi-anvil shaped core
support-separator as provided in U.S. Pat. No. 6,639,152. This
clearance provides half-circular channel walls for each of the
conductors/optical fibers or conductor pairs used within the cable.
A second version of this embodiment includes a semi-closed or
semi-opened surface section defining the same core clearance
channel walls. These channel walls would be semi-circular to the
point that at least 200 degrees of the potential 360 degree wall
enclosure exists. Typically, these channels walls would include and
opening of 0.005 inches to 0.011 inches wide. A third version of
this embodiment includes either a fully closed channel or an almost
fully closed channel of the anvil-shaped core support-separator
such that this version could include the use of a "flap-top"
initially providing an opening for insertion of conductors or
fibers and thereafter providing a covering for these same
conductors or fibers in the same channel. The flap-top closure can
be accomplished by a number of manufacturing methods including heat
sealing during extrusion of the finished cable product. Other
methods include a press-fit design, taping of the full assembly, or
even a thin skin extrusion that would cover a portion of the
multi-anvil shaped separator. All such designs could be substituted
either in-lieu of a separate cable jacket or with a cable jacket,
depending on the final property requirements. All such designs of
the present invention would incorporate the use if the special
composite compound blends as previously described.
[0099] Yet another embodiment provided in U.S. Pat. No. 6,639,152
that is included in the present invention allows for interior
corrugated clearance channels provided by the multi-shaped sections
of the core support-separator. This corrugated internal section has
internal axial grooves that allow for separation of conductor pairs
from each other or even separation of single conductors from each
other as well as separation of optical conductors from conventional
metal conductors. Alternatively, the edges of said grooves may
allow for separation thus providing a method for uniformly locating
or spacing the conductor pairs with respect to the channel walls
instead of allowing for random floating of the conductor pairs.
[0100] Each groove can accommodate at least one twisted pair. In
some instances, it may be beneficial to keep the two conductors in
intimate contact with each other by providing grooves that ensure
that the pairs are forced to contact a portion of the wall of the
clearance channels. The interior support provides needed structural
stability during manufacture and use. The grooves also improve NEXT
control by allowing for the easy spacing of the twisted pairs. The
easy spacing lessens the need for complex and hard to control lay
procedures and individual shielding. Other significant advantageous
results such as: improved impedance determination because of the
ability to precisely place twisted pairs: the ability to meet a
positive ACR value from twisted pair to twisted pair with a cable
that is no larger than an ISTP cable; and an interior support which
allows for a variety of twisted pair and optical fiber
dimensions.
[0101] Still another related embodiment includes the use of an
exterior corrugated or convoluted design such that the outer
surface of the support-separator has external radial grooves along
the longitudinal length of the cable. This exterior surface can
itself function as a jacket if the fully closed anvil-shaped
version of the invention as described above is utilized.
Additionally, the jacket may have a corrugated, smooth or ribbed
surface depending on the nature of the installation requirements.
In raceways or plenum areas that are new and no previous wire or
cable has been installed, the use of corrugated surfaces can
enhance flex and bending mechanical strength. For other
installations, a smooth surface reduces the possibility of high
friction when pulling cable into areas where it may contact
surfaces other than the raceway or plenum. Mechanical integrity
using an outer jacket such as depicted in FIG. 2a, 2b, or 2c may be
essential for installation purposes.
[0102] Alternatively, depending on manufacturing capabilities, the
use of a tape or polymeric binding sheet may be necessary in lieu
of extruded thermoplastic jacketing. Taping or other means may
provide special properties of the cable construction such as
reduced halogen content or cost and such a construction is found in
FIG. 2c.
[0103] Yet another related embodiment includes the use of a
strength member together with, but outside of the multi-anvil
shaped core support-separator running parallel in the longitudinal
direction along the length of the communications cable. In a
related embodiment, the strength member could be the core
support-separator itself, or in an additional related embodiment,
the strength member could be inserted in the hollow center-portion
of the core.
[0104] According to another embodiment of the invention, the
multi-anvil shaped core support-separator optionally includes a
slotted section allowing for insertion of an earthing wire to
ensure proper and sufficient electrical grounding preventing
electrical draft.
[0105] It is possible to leave the multi-anvil shaped separator
cavities empty in that the separator itself or within a jacket
would be pulled into place and left for future "blown fiber" or
other conductors along the length using compressed air or similar
techniques such as use of a pulling tape or the like
[0106] Additional embodiments to the invention include the use of
rifled shape separators with ladder-like sections to provide
similar crush resistance to the standard "X" supports. These rifled
sections, however, have the additional feature that the center
portion of the separator may include solid sections that can be
adjusted in step-like increments such that conductor spacing can be
controlled with a degree of precision. Specifically, the conductors
can be set apart so that individual pairs or sets of pairs can be
spaced closer or farther from one another, allowing for better
power sum values of equal level far end and near end cross-talk.
This "offsetting" between conductor pairs in a logical,
methodological pattern to optimize electrical properties, is an
additional benefit associated with the rifled shaped separators
with ladder-like sections.
[0107] It is to be understood that each of the embodiments above
could include a flame-retarded, smoke suppressant version and that
each could include the use of recycled or reground thermoplastics
in an amount up to 100%.
[0108] A method of producing the communications cable, introducing
any of the multi-shaped core separators as described above, into
the cable assembly, is described as first passing a plurality of
transmission media and a core through a first die which aligns the
plurality of transmission media with surface features of the core
and prevents or intentionally allows twisting motion of the core.
Next, the method bunches the aligned plurality of transmission
media and core using a second die which forces each of the
plurality of the transmission media into contact with the surface
features of the core which maintain a spatial relationship between
each of plurality of transmission media. Finally, the bunched
plurality of transmission media and core are optionally twisted to
close the cable, and the closed cable optionally jacketed.
[0109] Other desired embodiments, results, and novel features of
the present invention will become more apparent from the following
drawings and detailed description and the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0110] FIG. 1a is a top-right view of one embodiment of the cable
and separator that includes solid or foamed polymeric smooth
internal and external surfaces.
[0111] FIG. 1b is a top-right view of one embodiment of the cable
and separator that includes solid or foamed polymeric grooved
internal and external surfaces.
[0112] FIG. 1c is a top-right view of one embodiment of the cable
and separator that includes solid or foamed polymeric corrugated
internal and external surfaces.
[0113] FIG. 2a is a top-right view of one embodiment of the cable
and separator that includes an anvil-shaped separator and a
smooth/ribbed jacket.
[0114] FIG. 2b is a top-right view of another embodiment of the
cable and separator that includes a ribbed, corrugated jacket.
[0115] FIG. 2c is a top-right view of another embodiment of the
cable and separator that includes a taped or polymer binder sheet
jacketing configuration.
[0116] FIG. 3a is a cross-section end view of the interior support
or anvil-shaped separator taken along the horizontal plane of the
interior support anvil-shaped separator.
[0117] FIG. 3b is a cross-section end view of the single flap,
flap-top embodiment of the interior support or anvil-shaped
separator taken along the horizontal plane of the interior support
anvil-shaped separator when the flap is open.
[0118] FIG. 3c is a cross-section end view of the single flap,
flap-top embodiment of the interior support or anvil-shaped
separator taken along the horizontal plane of the interior support
anvil-shaped separator when the flap is closed.
[0119] FIG. 3d is an enlarged detailed version of the closed
single-flap, flap-top embodiment of the anvil-shaped separator.
[0120] FIG. 3e is a cross-section end view of the single flap,
flap-top embodiment of the interior support or anvil-shaped
separator taken along the horizontal plane of the interior support
anvil-shaped separator when the flap is closed.
[0121] FIG. 3f is an enlarged detailed version of the closed
single-flap, flap-top embodiment of the anvil-shaped separator.
[0122] FIG. 4a is a cross-section end view of the double flap,
flap-top embodiment of the interior support or anvil-shaped
separator taken along the horizontal plane of the interior support
or anvil-shaped separator when the flaps are open.
[0123] FIG. 4b is a cross-section end view of the double flap,
flap-top embodiment of the interior support or anvil-shaped
separator taken along the horizontal plane of the interior support
or anvil-shaped separator when the flaps are closed.
[0124] FIG. 4c is an enlarged detailed version of the closed
double-flap, flap-top embodiment of the anvil-shaped separator.
[0125] FIG. 5 is a cross-section end view of a flap-top embodiment
of the interior support anvil-shaped separator taken along the
horizontal plane of the interior support anvil-shaped separator
where the separator may contain one or more optical fibers in each
of four channels.
[0126] FIG. 6 is a cross-section end view of a cable containing an
anvil shaped separator and four smaller anvil-shaped separators
taken along the horizontal plane of the cable.
[0127] FIG. 7a is a cross-section end view of a cable containing
six anvil-shaped separators taken along the horizontal plane of the
cable with six rifled cross, symmetrically-even shaped separators
(as shown in FIG. 18) with a hollow core feature.
[0128] FIG. 7b is a cross-section end view of a cable containing
six anvil-shaped separators taken along the horizontal plane of the
cable with six anvil-shaped separators with a center core with
conductive wires.
[0129] FIG. 8a is a cross-section end view of an anvil-shaped
separator where both outer sharp edged ends of the anvil have been
replaced with rounded regions to reduce weight and provide a larger
opening for each channel defined by the anvil-shaped separator.
[0130] FIG. 8b is also a cross-section end view of an anvil-shaped
separator where both outer sharp edged ends of each anvil section
are replaced with rounded regions and each anvil section includes a
channel for a drain wire.
[0131] FIG. 9 is a cross-section end view of an anvil-shaped
separator where dual lobed anvil sections are minimized in size to
provide the greatest possible channel girth and opening while still
maintaining an anvil-like shape and each dual lobed section
includes a channel for a drain wire.
[0132] FIG. 10 is a cross-section end view of a relatively large
cable for conductor separation with six (6) anvil shaped sections
and an adjacent section for a fifth conductor pair.
[0133] FIG. 11 is a cross-section end view of a skewed
maltese-cross type separator for "worst" pair spacing.
[0134] FIG. 12a is a cross-section end view of a rifled and
(optionally) skewed maltese-cross type separator.
[0135] FIG. 12b is an enlarged detailed version of the
cross-section end view of a rifled and (optionally) skewed
maltese-cross type separator.
[0136] FIG. 13a is a cross-section end view of a diamond shaped
separator.
[0137] FIG. 13b is a cross-section end view of a diamond shaped
separator with a center circular orifice.
[0138] FIG. 13c is a cross-section end view of a diamond shaped
separator with equilateral triangular slots.
[0139] FIG. 13d is a cross-section end view of a diamond shaped
separator with a diamond shaped center orifice or slot.
[0140] FIG. 14 is a cross-section end view of a pendulum-like
shaped separator with a circular disc pendant near its center
[0141] FIG. 15 is a cross-section end view of a pendulum-like
shaped separator with an elliptical-disc pendant near its
center
[0142] FIG. 16 is a cross-section end view of a pendulum-like
shaped separator with a diamond-disc shaped pendant near its
center
[0143] FIG. 17 is a cross-section end view pendulum-like dual lobed
shaped separator with a diamond-disc shaped pendant near its
center
[0144] FIG. 18 is a cross-section end view of a rifled cross,
symmetrically-even shaped separator.
[0145] FIG. 19 is a cross-section end view of a mirrored
battleship-shaped and inverted separator with top-side and
bottom-side key-way shaped sections.
[0146] FIG. 20 is a cross-section end view of a staggered and
rifled symmetrical cross shaped separator.
[0147] FIG. 21a is a cross-sectional view of an asymmetric
cross-shaped separator.
[0148] FIG. 21b is a cross-sectional view of an asymmetric
cross-shaped separator with rifled or "saw-blade" like members.
[0149] FIG. 22 is a cross-sectional view of a saw-blade horizontal
member-type separator.
[0150] FIG. 23a is a cross-sectional view of a symmetrical "Z" or
angle-iron shaped type separator.
[0151] FIG. 23b is a cross-sectional view of a symmetrical "Z" or
angle-iron shaped type separator with rifled or "saw-blade" like
members.
[0152] FIG. 24a is a cross-section view of one embodiment of the
cable support-separator that includes a symmetrical core with a
central circular ring region with four extending rifled protrusions
each extending in a preferred 90 degree separation from each other
for optimum pair separation. The central ring portion optionally
includes a hollow region to act as an air blown fiber (ABF) duct
which is available for filling with optical fiber which is
comprised of solid, semi-solid, foamed or hollow polymeric smooth
internal and external surfaces.
[0153] FIG. 24b is a cross-section view of a second embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a, but also
includes a second inner ring within the hollow region comprised of
a different material than the outer ring for either increasing
lubricity or friction with four extending rifled protrusions each
extending in a preferred 90 degree separation from each other for
optimum pair separation.
[0154] FIG. 24c is a cross-section view of a third embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a, but also
includes a second inner ring within the hollow region comprised of
a different material than the outer ring for either increasing
friction utilizing rifled inter spatially arranged sections with
four extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation.
[0155] FIG. 24d is a cross-section view of a third embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24c, but also
includes the optional use of a organic or inorganic fibers
including a polyamide (for example Kevlar.RTM.) filing and an
optional strength member within the second inner ring within the
hollow region comprised of a different material than the outer ring
as well as allowing for multiple separate multimode or single mode
fiber optic units also contained within the same hollow region with
four extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation.
[0156] FIG. 24e is a cross-section view of a fifth embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24b and also
includes an inner pull tape for attaching optical fibers or
metallic conductors wherein the tape optionally itself incorporates
a grip or for which a grip is provided for future pulling of those
communication media through the hollow region at some future time
or during an installation with four extending rifled protrusions
each extending in a preferred 90 degree separation from each other
for optimum pair separation.
[0157] FIG. 24f is a cross-section view of a sixth embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24b but also two
individual conductors (which may be twisted) inside the second
inner ring which is smooth instead of rifled within the hollow
region and comprised of a different material than the outer ring as
well as allowing for multiple separate multimode or single mode
fiber optic units also contained within the same hollow region with
four extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation.
[0158] FIG. 24g is a cross-section view of a seventh embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a with four
extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation, but
also includes the optional addition of one or more coaxial
conductors contained in the center hollow region.
[0159] FIG. 25a is a cross-section view of an another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a but possesses 6
instead of 4 rifled protrusions each extending in a preferred
degree separation from each other for optimum pair separation.
[0160] FIG. 25b is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25a but with an
inner rifled ring section with as few as two and as many as six
extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation.
[0161] FIG. 25c is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25a but with an
inner smooth ring section with as few as two and as many as six
extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation that optionally includes the addition of one or more
conductors including optionally organic or inorganic fibers such as
polyamide (for example Kevlar.RTM.) filling and an optional
strength member within the second inner ring.
[0162] FIG. 25d is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25c with an inner
smooth ring section with as few as two and or as many as six
extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation that optionally includes the addition of one or more
conductors including optionally organic or inorganic fibers such as
polyamide (for example Kevlar.RTM.) filing and an optional strength
member within the second inner ring. Also, between as few as one
and as many as six of the extending projections, additional
daisy-like spacers (as shown in FIG. 28a) are placed which
themselves allow for spacing of individual conductors or conductor
pairs.
[0163] FIG. 25e is a cross-section view of another embodiment of
the cable support separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25c with an inner
smooth ring section with as few as two and as many as six extending
protrusions each extending in a preferred degree separation along
the outer ring from each other for optimum pair separation that
optionally includes the addition of one or more conductors
including optionally organic or inorganic fibers such as polyamide
(for example Kevlar.RTM.) filling and an optional strength member
within the second inner ring. Also, between as few as one and as
many as six of the extending projections are shown without the
additional daisy-like spacers (as shown in FIG. 28a).
[0164] FIG. 25f is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25c with an inner
smooth ring section with as few as two and as many as six extending
protrusions each extending in a preferred degree separation along
the outer ring from each other for optimum pair separation that
optionally includes the addition of one or more conductors
including optionally organic or inorganic fibers such as polyamide
(for example Kevlar.RTM.) filling and an optional strength member
within the second inner ring. Also, between as few as one and as
many as six of the extending projections, additional spacers
comprised of a region which includes rounded lobes in a symmetric
diamond-like geometry that defines as many as four separate regions
for pairs that are properly separated in the final (often jacketed)
cable design (as shown in FIG. 29a) are placed which themselves
allow for spacing of individual conductors of conductor pairs.
[0165] FIG. 26a is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending smoother
protrusions, each protrusion extending less than those of FIGS. 24a
through 25f, each again extending in a preferred 90 degree
separation from each other for optimum pair separation. The central
ring portion optionally includes a hollow region to act as an air
blown fiber (ABF) duct which is available for filling with optical
fiber which is comprised of solid, semi-solid, foamed or hollow
polymeric smooth internal and external surfaces.
[0166] FIG. 26b is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending smooth
protrusions, each protrusion extending less than those of FIGS. 24a
through 25f, each again extending in a preferred 90 degree
separation from each other for optimum pair separation and also
includes a second inner ring within the hollow region comprised of
a different material than the outer ring for either increased
lubricity or friction. The central ring portion optionally includes
a hollow region to act as an air blown fiber (ABF) duct which is
available for filling with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smoother internal and
external surfaces.
[0167] FIG. 26c is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending smooth protrusions
each protrusion extending less than those of FIGS. 24a through 25f,
each again extending in a preferred 90 degree separation from each
other for optimum pair separation and also includes a second inner
ring within the hollow region comprised of a different material
than the outer ring for increasing friction utilizing rifled inner
spatially arranged sections. The central ring portion optionally
includes a hollow region to act as an air blown fiber (ABF) duct
which is available for filling with optical fiber which is
comprised of solid, semi-solid, foamed or hollow polymeric smooth
internal and external surfaces.
[0168] FIGS. 26d and 26e are cross-section views of another
embodiment of the cable support-separator that includes a
symmetrical core with a central circular ring region with as few as
two and as many as six extending smoother protrusions, each
protrusion extending less than those of the series of FIGS. 24a
through 25f, each again extending in a preferred separation from
each other for optimum pair separation and also includes also
includes a an optional second inner ring within the hollow region
comprised of a different material than the outer ring for
increasing friction utilizing rifled inner spatially arranged
sections. The central ring portion optionally includes a hollow
region to act as an air blow fiber (ABF) duct which is available
for filling with optical fiber which is comprised of solid,
semi-solid, foamed or hollow polymeric smooth internal and external
surfaces.
[0169] FIG. 26f is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with no extending protrusions that
includes also an optional second inner ring within the hollow
region comprised of a different material than the outer ring for
increasing friction utilizing rifled inner spatially arranged
sections. The central ring portion optionally includes a hollow
region to act as an air blown fiber (ABF) duct which is available
for filling with optical fiber which is comprised of solid,
semi-solid, foamed or hollow polymeric smooth internal and external
surfaces.
[0170] FIG. 27a is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending protrusions each
protrusion extending less than those of FIGS. 24a through 25f and
each with at least a single cross-like section extending outward
from the circular ring section in a preferred 90 degree separation
from each other for optimum pair separation. The central ring
portion optionally includes a hollow region to act as an air blown
fiber (ABF) duct which is available for filling with optical fiber
which is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0171] FIG. 27b is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region and each with at least a single
cross-like section extending from the circular ring section, each
protrusion extending less than those of FIGS. 24a through 25f, each
again extending in a preferred 90 degree separation from each other
for optimum pair separation and also includes a second inner ring
within the hollow region comprised of a different material than the
outer ring for either increasing lubricity or friction. The central
ring portion optionally includes a hollow region to act as an air
blown fiber (ABF) duct which is available for filling with optical
fiber which is comprised of solid, semi-solid, foamed or hollow
polymeric smooth internal and external surfaces.
[0172] FIG. 27c is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region and each with at least a single
cross-like section extending from the circular ring section, each
protrusion extending less than those of FIGS. 24a through 25f, each
again extending in a preferred 90 degree separation from each other
for optimum pair separation and also includes a second inner ring
within the hollow region comprised of a different material than the
outer ring for either increasing lubricity or friction. The inner
portion of the hollow ring region here is optionally filled with
inorganic or organic fibers such as polyamide fiber (Kevlar.RTM.)
and at least four single or multimode fiber optic units.
[0173] FIGS. 27d and 27e include a cross-section view of another
embodiment of the cable support-separator that includes a
symmetrical core with a central circular ring region with as few as
two and as many as six extending protrusions each with at least a
single cross-like section, each protrusion extending less than
those in of FIGS. 24e through 25f, each again extending in a
preferred separation from each other for optimum pair separation
and also includes also includes an optional second inner ring
within the hollow region comprised of a different material than the
outer ring for increasing friction utilizing rifled inner spatially
arranged sections. The central ring portion optionally includes a
hollow region to act as an air blown fiber (ABF) duct which is
available for filling with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0174] FIG. 27f includes a cross-section view of another embodiment
of the cable support-separator includes a symmetrical core with a
central circular ring region with no extending protrusions that
includes also an optional second inner ring within the hollow
region comprised of a different material than the outer ring for
increasing friction utilizing rifled inner spatially arranged
sections. The central ring portion optionally includes a hollow
region to act as an air blown fiber (ABF) duct which is available
for filling with optical fiber which is comprised of solid,
semi-solid, foamed or hollow polymeric smooth internal and external
surfaces.
[0175] FIG. 28a is a cross-section view of another embodiment of
the cable support-separator that includes a hollow four-petal or
"daisy" shaped arrangement with a central core that may or may not
be hollow. If the central region is hollow, the possibility again
exists for that region to act as an air blown fiber (ABF) duct
which is available for filling with optical fiber. Coaxial or
twisted pair conductors may also be introduced in that region.
[0176] FIG. 28b is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that may or may not
be hollow. Each "petal" contains two hollow sections for additional
optical or metallic conductor media. The central region is hollow
allowing for the possibility that this region may act as an air
blown fiber (ABF) duct which is available for filling with optical
fiber. Coaxial or twisted pair conductors may also be introduced in
that region.
[0177] FIG. 28c is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that may or may not
be hollow. Each "petal" contains three hollow sections of differing
diameters for additional optical or metallic conductor media. The
central region is solid.
[0178] FIG. 28d is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that may or may not
be hollow. Each "petal" contains three hollow sections of differing
diameters for additional optical or metallic conductor media. In
this case, the center hollow section of each petal is filled with
an optical fiber unit. The central region is solid or optionally
hollow.
[0179] FIG. 28e is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that may or may not
be hollow. In this case, the center hollow section is filled with
an optical fiber unit.
[0180] FIGS. 29a, 29b, 29c are cross-sectional views of another set
of embodiments of the cable support-separator that includes a
circular ring region which is surrounded by rounded lobes in a
symmetric diamond-like geometry that defines as many as four
separate regions for pairs that are properly separated in the final
(often jacketed) cable design. Against the central ring portion can
optionally include a hollow region that may be used as an air blown
fiber (ABF) duct which is available for filling with optical fiber
which is comprised of solid, semi-solid, foamed or hollow polymeric
smoother internal and external surfaces. FIG. 29a has no inner
ring. FIG. 29b has a smooth inner ring with optionally different
material than the outer ring, and FIG. 29c has a an inner ring with
rifled sections. Each can optionally be used for coax or twisted
pair as well as for fiber optic conductors in advance, during or
after installation.
[0181] FIG. 29d is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes the optional addition of one or more
conductors including optionally organic or inorganic fibers such as
a polyamide (for example Kevlar.RTM.) filling and an optional
strength member within the second inner ring (that may or may not
be rifled). Again the central ring portion can optionally include a
hollow region that may be used as an air blown fiber (ABF) duct
which is available for filling with optical fiber which is
comprised of solid, semi-solid, foamed or hollow polymeric smooth
internal and external surfaces.
[0182] FIG. 29e is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes a center portion filled with a fiber
optic unit as well as four separated conductor pairs in each of the
regions defined by the symmetric diamond-like geometry of the cable
support-separator. Again the central ring portion can optionally
include a hollow region that may be used as an air blown fiber
(ABF) duct which is available for filling with optical fiber which
is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0183] FIG. 29f is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes a center portion with a second inner
ring portion filled with a fiber optic unit or other conductors as
well as four cross-like separators (see FIG. 30a) in each of the
regions defined by the symmetric diamond-like geometry of the cable
support-separator within which another, up to four pairs of
conductors are situated and separated by the cross-like separator.
Again the central ring portion can optionally include a hollow
region that may be used as an air blown fiber (ABF) duct which is
available for filling with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0184] FIG. 30a is a cross-section view of another embodiment of
the cable support-separator that includes a more conventional
cross-like separator section with "rifled" sections extending
outward into four quadrants away from the central region and is
encased or covered within an outer insulated layer which is itself
shaped in an identical cross except that the dimensions of this
outer cross is larger than the rifled inner cross and functions as
a "skin". The inner cross-like portion may be metallized by
utilizing electroless or electrolytic plating techniques over a
thermoplastic.
[0185] FIG. 30b is a cross-section view of another embodiment of
the cable support-separator that includes the same more
conventional cross-like separator section as with FIG. 30a except
that this separator contains a shield that extends along the
horizontal axis and optionally also along the vertical axis or both
axes within the horizontal hollow portion of the cross-like
separator. This shield is comprised of aluminum PET film and may be
configured so that it is held within the outer cross-like
separator. The design also allows for shielding exterior to the
separator under a jacketed cable containing the separator.
[0186] FIG. 31a is a cross-section view of another embodiment of
the cable support-separator that includes providing variations on a
cross-like arrangement by adding "zig-zag" extensions that extend
away from the central region. Again the cross-like "zig-zag"
arrangement may be covered within an outer insulated layer which is
itself shaped in an identical cross except that the dimensions of
this outer cross are larger than the rifled inner cross and
functions as a "skin".
[0187] FIG. 31b is a cross-section view of another embodiment of
the cable support-separator that includes providing variations on a
cross-like arrangement by adding "sickle-like" extensions that
extend away from the central region. Again the cross-like and
sickle-like arrangement may be covered within an outer insulated
layer which is itself shaped in an identical cross except that the
dimensions of this outer cross are larger than the rifled inner
cross and functions as a "skin".
[0188] FIG. 32 is a cross-sectional view of another embodiment with
several hollow regions for blown fiber or any transmission media
for present, future, or concurrent installations using the
support-separator alone or in combination with a cable.
[0189] FIGS. 33a and 33b are cross-sectional views of another set
of embodiments of the cable support-separator that includes a
circular ring region which is surrounded by semi-rounded lobes in a
symmetric star-like geometry that defines as many as four separate
regions for pairs that are properly separated in the final (often
jacketed) cable design. Again the central ring portion can
optionally include a hollow region that may be used as an air blown
fiber (ABF) duct which is available for filling with optical fiber
which is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces. FIGS. 33a and 33b include
view of optionally filled inner hollow regions such that each can
optionally be used for coax or twisted pair as well as for fiber
optic conductors (in advance, during or after installation).
DETAILED DESCRIPTION OF THE DRAWINGS
[0190] The following description will further help to explain the
inventive features of the cable and the interior support portion of
the cable.
[0191] FIG. 1a is a top-right view of one embodiment of this
invention. The shown embodiment has an interior support shown as an
anvil-shaped separator (110). The interior support anvil-shaped
separator, shown in more detail in FIGS. 3 and 4, runs along the
longitudinal length on the cable. The interior support anvil-shaped
separator, hereinafter, in the detailed description, referred to as
the "anvil-shaped separator", has a central region (112) extending
along the longitudinal length of the cable. The center region
includes a cavity that runs the length of the separator in which a
strength member (114) may be inserted.
[0192] Channels 120, 122, 124, and 126 extend along the length of
the anvil-shaped separator and provide compartments for conductors
(130).
[0193] A strength member may be added to the cable. The strength
member (114) in the shown embodiment is located in the central
region of the anvil-shaped separator. The strength member runs the
longitudinal length of the anvil-shaped separator. The strength
member is a solid polyethylene or other suitable plastic, textile
(nylon, aramid, etc.), fiberglass flexible or rigid (FGE rod), or
metallic material.
[0194] Conductors, such as the shown insulated twisted pairs, (130)
are disposed in each channel. The pairs run the longitudinal length
of the anvil-shaped separator. While this embodiment depicts one
twisted pair per channel, there may be more than one pair per
channel. The twisted pairs are insulated with a suitable polymer,
copolymer, or dual extruded foamed insulation with solid skin
surface. The conductors are those normally used for optical or
conventional data transmission. The twisted pairs may be bonded
such that the insulation of each conductor is physically or
chemically bound in an adhesive fashion, or an external film could
be wrapped around each conductor pair to provide the same effect.
Although the embodiment utilizes twisted pairs, one could utilize
various types of insulated conductors within the anvil-shaped
separator channels or cavities.
[0195] A metal drain wire may be inserted into a specially
designated slot (140). The drain wire functions as a ground or
earthing wire. It also serves to reduce material content and maybe
applicable to each anvil-type separator.
[0196] FIG. 1b is another embodiment that includes grooves (150) on
either the exterior surface of the separator or within the channels
of the separator or both. The interior grooves within the channels
of this embodiment are specifically designed so that at least a
single conductor of a conductor pair can be forced along the inner
wall of the groove, thereby allowing for specific spacing that
improves electrical properties associated with the conductor or
conductor pair. A cross section of this separator with channeled
grooves is shown and discussed in a later figure.
[0197] FIG. 1c is yet another related embodiment that includes the
use of an exterior corrugated design (160) such that the outer
surface of the support-separator has external radial grooves along
the longitudinal length of the cable. This exterior surface can
itself function as a jacket if the fully closed anvil-shaped
version of the invention as described above is utilized.
Optionally, this corrugated version of FIG. 1c may also include the
channeled grooves shown in FIG. 1b.
[0198] The anvil-shaped separator may be cabled with a helixed
configuration. The helically twisted portions (165) in turn define
helically twisted conductor receiving grooves within the channels
that accommodate the twisted pairs or individual optical
fibers.
[0199] The cable (200), as shown in FIG. 2a is a high performance
cable capable of greater than 600 MHz and easily reaching 2 Ghz or
greater. The cable has an optional outer jacket (210) that can be a
thermoplastic, polyvinyl chloride, a fluoropolymer or a polyolefin,
or a thermoset, with or without halogen free material as required
by flammability, smoke generation, corrosivity, or toxicity, and
electrical specifications as detailed above. Additionally, the
jacket may be either corrugated (220) as in FIG. 2b or
smooth/ribbed (210) depending on the nature of the installation
requirements. Mechanical integrity using an outer jacket such as
depicted in FIGS. 2a and 2b, may be essential for installation
purposes.
[0200] FIG. 2b is another embodiment that includes grooves along
the interior channels of the separator. The interior grooves (225)
within the channels of this embodiment are also specifically
designed so that at least a single conductor of a conductor pair
can be forced along the inner wall of the groove, thereby allowing
for specific spacing that improves electrical properties associated
with the conductor or conductor pair.
[0201] Over the anvil shaped separator optional polymer binder
sheet or tape or sheets or tapes (230) that may be non-wovens such
as polyimide, polyether-imide, mica, or other fire retardant
inorganic tapes may be used as shown in FIG. 2c for circuit
integrity cable. The binder is wrapped around the anvil shaped
separator (200) to enclose the twisted pairs or optical fiber
bundles. The binder or tape itself maybe a laminated aluminum
shield or the aluminum shield may also be included under the
polymer binder sheet. The electromagnetic interference and radio
frequency (EMI-RFI) shield is a tape with a foil or metal surface
facing towards the interior of the jacket that protects the signals
carried by the twisted pairs or fiber cables from electromagnetic
or radio frequency distortion. The shield may be composed of a foil
and has a belt-like shield that can be forced into a round, smooth
shape during manufacture. This taped embodiment with shield may be
utilized to control electrical properties with extreme precision.
This shielded version is capable of at least 1 Ghz or higher
frequency signal propagation. Each of the individual conductor
pairs may themselves be individually shielded. A metal drain wire
may be inserted into a specially designated slot (240) that then
can be subsequently wrapped around the shield. The drain wire
within the slot runs the length of the cable. The drain wire
functions as a ground or earthing wire.
[0202] Use of the term "cable covering" refers to a means to
insulate and protect the cable. The cable covering being exterior
to said anvil member and insulated conductors disposed in grooves
provided within the clearance channels. These grooves within
clearance channels allow for proper insertion of conductors. Recent
developments in communications cabling has shown that improvements
in electrical properties can be accomplished if "worst" pair
conductors are spaced such that they are physically further removed
from other "worst pair" conductors. "Worst pair" refers to two
conductors that are physically matched and can be helically twisted
around each other such that electrical properties such as
attenuation, crosstalk, and impedance properties are least
favorable in comparison with other similarly paired conductors.
Inevitably, during cable manufacture, at least one set of paired
conductors exhibit these "worst pair" parameters and a major
attribute of this invention is to space these "worst pairs" far
from the better electrical transmission performing pairs. Parallel
pair conductors with individual shielding can also be used to
achieve the present invention.
[0203] The outer jacket, shield, drain spiral and binder described
in the shown embodiment provide an example of an acceptable cable
covering. The cable covering, however, may simply include an outer
jacket or may include just the exterior surface (corrugated or
convoluted with ribbed or smooth surfaces) of the anvil shaped
interior support member.
[0204] The cable covering may also include a gel filler to fill the
void space (250) between the interior support, twisted pairs and a
portion of the cable covering,
[0205] The clearance channels formed by the anvil shaped interior
support member of the present inventive cable design allows for
precise support and placement of the twisted pairs, individual
conductors, and optical fibers. The anvil shaped separator will
accommodate twisted pairs of varying AWG's and therefore of varying
electrical impedance. The unique circular shape of the separator
provides a geometry that does not easily crush and allows for
maintenance of a cable appearing round in final construction.
[0206] The crush resistance of the inventive separator helps
preserve the spacing of the twisted pairs, and control twisted pair
geometry relative to other cable components. Further, adding a
helical twist allows for improving overall electrical performance
design capability while preserving the desired geometry.
[0207] The optional strength member located in the central region
of the anvil shaped separator allows for the displacement of stress
loads away from the pairs.
[0208] FIG. 3a is a horizontal cross-section of a preferred
embodiment of the anvil-shaped separator. The anvil-shaped
separator can be typically approximately 0.210 inches in diameter.
It includes four channels (300, 302, 304, and 306) that are
typically approximately 0.0638 to 0.0828 inches in diameter. The
channel centers are 90 degrees apart relative to the center of the
separator. Each channel is typically approximately 0.005 inches
from the channel across from it, and each channel is approximately
0.005 0.011 inches apart form its two nearest-neighboring channels
at their closest proximity. Inserted in the channels is one set of
twisted pairs (310, 312, 314, and 316) with the option for adding
twisted pairs to each channel denoted by dashed circles. In a
preferred embodiment, each channel has typically a 0.037-inch
opening along its radial edge that allow for the insertion of the
twisted pairs. This embodiment also includes a cavity in the center
of the anvil-shaped separator for a strength member (320).
Additionally, there is a slot for a drain or earthing wire (330).
The exploded view of FIG. 3a also indicates the use of an interior
slotted rifled section or sections (332) that allows for less bulk
material based on overall depth of the slots of the rifled section,
improves electrical characteristics as described above regarding
worst pair conductors (allowing for more air around each insulated
conductor or pair), and physically binds the pairs together so that
each pair has semi-permanently fixed position. As shown in the
other exploded view (334), the individual conductor may compress
against the solid or foamed slotted rifled surface to ensure the
semi-permanently fixed position.
[0209] FIG. 3b is another embodiment of the anvil-shaped separator.
The anvil-shaped separator includes a single flap-top (340, 342,
344, and 346) that is initially in an open position to allow the
twisted pairs to be inserted into the channels. In FIG. 3c the
flap-tops are in the closed position (350, 352, 354, and 356) where
the flap-top (360) fits into a recessed portion of the separator
(365) for closure. The flap-tops (360) are self-sealing when heat
and/or pressure is applied, such that elements within the channels
can no longer be removed from the separator and such that the
channels containing the twisted pairs are enclosed. The flap-top
(360) is shown in more detail in FIG. 3d.
[0210] FIG. 3e is another embodiment of the anvil-shaped separator.
The anvil-shaped separator includes a single flap-top (380, 382,
384, and 386) that is depicted in the closed position. When in the
closed position, the flap-top (390) overlaps the outer portion
(395) of the separator. The amount of overlap required will depend
on several design and manufacturing factors and the shown
embodiment is only intended as one example of the overlap required.
The flap-tops (390) are self-sealing when heat and/or pressure is
applied, such that the elements within the channels can no longer
be removed or displaced from the separator and such that the
channels containing twisted pairs are enclosed. The flap-top (390)
is shown in more detail in FIG. 3f.
[0211] Another embodiment of FIGS. 3a, 3b and 3c includes all of
the aforementioned features without the drain wire or drain wire
slot (330), but may include the center hole (320) for strength
members. Use of a center hole (320) is also important in that it
reduces the mass required for the spacing. It has been shown and
reported in prior art journals and publications that the total mass
of the organic components of the cable is directly proportional to
flame spread and smoke generation. As mass is reduced, the
probability that the cable will pass more stringent flame testing
(such as U.L. 910/NFPA 262/IEC 60332-3B.sub.1/IEC 60332-3B.sub.2 as
previously described) significantly increases.
[0212] A further embodiment of FIGS. 3a, 3b and 3c includes all the
aforementioned features without the center hole (320) for strength
members and without the drain wire or drain wire slot (330).
[0213] FIG. 4a is a horizontal cross-section of a preferred
embodiment of the anvil-shaped separator that is identical to FIG.
3b but has a pair of overlapping section instead of the single
overlapping section of FIG. 3b and may include optional "stepped"
or "rifled" grooves that exist along the inner circumference of the
clearance channels. These grooves can be larger in diameter than
pictured and used to improve spacing of the "worst pair" conductors
as described earlier. These rifled clearance channels can be used
to "squeeze" the conductors or conductor pairs into the
interstitial openings creating a more permanent positioning that
will enhance the electrical characteristics of the final cable
assembly. If properly positioned during the "twinning" and
subsequent forming of the cable, the forced positioning of the
conductors in the rifled sections will improve signal performance.
The anvil-shaped separator includes double flap-tops (440, 442,
444, and 446) that are initially in an open position to allow the
twisted pairs to be inserted into the channels. In FIG. 4b
(exploded view of FIG. 4c) the flap-tops are in the closed position
(450, 452, 454, and 456). The flap-tops are against self-sealing in
the presence of heat and/or pressure and the channels containing
the twisted pairs are subsequently enclosed. The flap top is shown
in more detail in FIG. 4c. Another embodiment of FIGS. 4a, and 4b
include all of the aforementioned features without the drain wire
or drain wire slot, but includes the center hole for strength
members. A further embodiment of FIGS. 4a, and 4b includes all the
aforementioned features without the center hole for strength
members and without the drain wire or drain wire slot.
[0214] FIG. 3d and FIG. 3f depict the single flap-top in enlarged
detail, and FIG. 4c depicts the double flap-top in enlarged detail.
The single flap-tops (360 and 390) and the double flap-top (410)
enclose the wires or cables within channels created by the
separator. During manufacturing, the flap-top is in the opened
position and closes as either pressure or heat or both are applied
(normally through a circular cavity during extrusion). Optionally,
a second heating die may be used to ensure closure of the flap-top
after initial extrusion of the separator or cable during
manufacture. Another possibility is the use of a simple metal ring
placed in a proper location that forces the flap-top clown during
final separator or cable assembly once the conductors have been
properly inserted into the channels. The metal ring may be heated
to induce proper closure. Other techniques may also be employed as
the manufacturing process will vary based on separator and cable
requirements (i.e. no. of conductors required, use of grounding
wire, alignment within the channels, etc.). In one embodiment the
single flap-top (360) is secured to a recessed portion of one side
of an opening of the cavity of the separator (365), and closure
occurs when the unsecured, physically free end is adjoined to and
adhered with the other end of the outer surface of the channel
wall. In another embodiment the single flap-top (390) is secured by
overlapping and adhering the unsecured end to the outer surface of
the separator (395), thereby, enclosing the channel. The
double-flap top arrangement requires that both flap-top ends
physically meet and eventually touch to secure enclosure of the
existing cavity (460) formed by the separator (470).
[0215] FIG. 5 is a cross-section of another embodiment of the
flap-top anvil-shaped separator. Each channel is enclosed by double
flaps that can be sealed via heat and/or pressure (510, 512, 514,
and 515). Each channel contains at least one fiber (520, 522, 524,
and 526) that runs the length of the cable. More than one fiber may
be included in each channel if necessary. The separator also
includes a slot for a drain or earthing wire (530). For
applications such as multimedia cables, the application may have
one or more twisted pair, one or more fiber optic conductors, or
coaxial cables within the clearance channels of the anvil
separators.
[0216] FIG. 6 is a cross-section of a cable that contains four
anvil-shaped separators (602, 604, 606, and 608) within a larger
anvil-shaped separator (610). The larger separator contains a
cavity in the center of the separator for a strength member (620).
Each of the smaller separators contained within the larger
anvil-shaped separator has four channels (630, 632, 634, and 636).
As shown, each of these channels contains a twisted pair within
this embodiment (640, 642, 644, and 646). This embodiment allows
for a total of sixteen twisted pairs to be included in one
cable.
[0217] FIG. 7a is a cross-section of a cable that contains six
symmetrical rifled cross separators (700, 701, 702, 703, 704, 705)
within a larger anvil shaped separator (710). The larger separator
contains a optional hollow cavity in the center of the separator
for an optional strength member (720). Each of the smaller
separators contained within the larger anvil-shaped separator has
four channels (730, 732, 734, and 736). Within each of these
channels in one twisted pair (740, 742, 744, and 746). This
embodiment allows twenty four twisted pairs to be included in one
cable.
[0218] FIG. 7b are cross-sections of a cable that contains rifled
six anvil-shaped separators (750, 751, 752, 753, 754, and 755)
within a larger anvil-shaped separator (710). The larger separator
contains an optional hollow cavity in the center of the separator
for a either a strength member or an additional conductor pair
(725) which is accessed via a slit (726) which can be forced opened
during manufacture. Each of the smaller separators contained within
the larger anvil-shaped separator has four smooth or rifled
channels (780, 782, 784, and 786). Within each of these channels is
one twisted pair (760, 762, 764, and 766). This embodiment allows
twenty four twisted pairs to be included in one cable. Feature
(750) is an optional wired slot for a drain wire with or without a
shield.
[0219] FIGS. 8a and 8b depict a cross-section and additional
embodiment of an anvil-shaped separator which has been
substantially trimmed such that the each edged end of each anvil is
removed (800 and 802) to reduce weight resulting in enlarged
channel openings (804). FIG. 8b depicts the cross-section with
optional drain wires within each solid and trimmed anvil section
(810, 812, 814, and 816) as well as optional rifled slots (820)
within each clearance channel and optional asymmetric conductor
pair offset due to the skewed elongated axis.
[0220] FIG. 9 is a cross-section and additional embodiments of a
separator where the dual lobed ends of the anvil are minimized (900
and 902) such that an even further reduction in weight, enlarged
channel openings (904) and enlarged channel girth are provided.
FIG. 9 also includes earthing or drain wire slots (910, 912, 914,
and 916).
[0221] FIG. 10 is a cross-sectional end view of a large cable space
separator that itself separates six (6) anvil shaped separators as
described in detail and shown in FIGS. 1 and 2 and very similar to
the design shown as FIGS. 7a and 7b. This separator has an optional
center (1000) orifice that allows for reduction of mass and thereby
reduction of flame spread and smoke generation in, for example UL
910/NFPA 262/IEC 60332-3B.sub.1/IEC 60332-3B.sub.2 and associated
flame testing as previously described. The entire center section
(with the center (1000) orifice or without it) could be either
solid or foamed or a combination using a skimmed solid surface over
a foamed core. This design allows for six solid anvil shaped cores
(1001) with four clearance channels for conductor pairs. In
addition, the large cable spacer separator includes six special "Y"
shaped channel spacings (1002 1007) at the outer edges that allow
for a fifth conductor pair within these channels. The fifth
conductor pairs (1008) are optional in that some or none of the "Y"
shaped channel spacings (1002 1007) may be filled. Each of the
solid anvil cores (1001) also may optionally contain a center
orifice (1009). Each of the conductors consist of an inner solid
metal portion (1011, 1015, 1018, and 1021) and an outer insulation
(1010, 1014, 1017, and 1020) covering the solid and metal portion
of the conductors or conductor pairs that are held within each of
the four clearance channels (1012, 1016, 1019, and 1022) formed by
the six anvil shaped separators cores (1001). In addition to the
clearance channels (1012) provided for the conductors or conductor
pairs, there all exists an optional specially designed slot (1013)
for a metal drain wire that provides proper grounding or earthing
of the conductors within the cable for instances where an aluminum
mylar shield may be used.
[0222] FIG. 11 is a cross-sectional view of a optionally skewed or
asymmetrical "maltese cross-type" cable spacer separator. It is
skewed in the sense that along one axis of symmetry in a
two-dimensional plane, the tip-to-tip length is longer than along
the other. This spacer provides two relatively larger width blunt
tipped ends (1100) and two relatively smaller width tipped blunt
ends (1102). The distance between a larger width blunt end tip and
a smaller width blunt end tip along the longer axis of symmetry
provides two skewed channels (1106) for "worst" pair conductors.
These pairs are the ones determined to have the least desirable
electrical properties and thus are intentionally spaced further
apart form each other. The better performing electrical pairs are
contained in two skewed channels (1104) formed between a larger
width blunt end tip (1100) and a smaller width blunt end tip (1102)
along the shorter axis of symmetry. In this manner the "worst pair"
channels (1106) are adjacent to the "better pair" channels (1104)
so that the influence of the poorest electrical performing
conductors or conductor pairs (1110) are insulated from another
poorest or poorer performing electrical pair (1110). Best or better
conductor pairs (1112) would be provided in the better pair
channels. As previously alluded to, distance, and the presence of
air are the two controllable parameters used in the present
invention to reduce electrical property deterioration due to "worst
pair"-"worst pair" interaction. A center (optional) orifice (1108)
is also provided which would allow for reduction of weight of
material and better flammability and smoke generation properties as
previously described.
[0223] FIG. 12a is a cross-sectional view of an optionally skewed
"maltese cross-type" cable spacer separator with "rifled" sections
along the outer perimeter of the spacer separator. It optionally
skewed in the sense that along one axis of symmetry in a
two-dimensional plane, the top-to-tip length is longer than along
the other. This spacer provides four equi-widthed blunt tipped ends
(1200). The rifled sections as shown in FIG. 12b contain
interstitial stepped optionally rifled spacers (1201) extending
from near the blunt tipped ends toward channels (1205) formed for
single or paired conductors that are provided such that the
conductor or conductor pairs will be "squeezed" into a portion of
the rifled section where some traction or friction within these
interstitial stepped spacer rifled sections will control spacing
and movement during the entire cabling operation. In this manner,
again "worst pair" spacing can be achieved. A center (optional)
orifice (1204) is also provided which would allow for reduction of
weight of material and better flammability and smoke generation
properties as previously described.
[0224] FIG. 13a is a cross-sectional view of a diamond shaped cable
spacer separator that is solid (1300) and provides for four
semi-circular channels (1310) formed by curved surfaces of the
diamond shaped spacer for conductors. The solid diamond shaped
spacer has curved ends that converge at each of four tips (1320)
which designate the beginning or ending of the channels. Individual
conductors (1325) would be preferably placed in each of the
channels for pair separator. Alternatively, conductor pairs could
also be separated using this design and technique.
[0225] FIG. 13b is a cross-sectional view of a diamond shaped cable
spacer separator that has a hollowed center circular orifice
section (1330) and provides for four semi-circular channels (1310)
formed by curved surfaces of the diamond shaped spacer for
conductors. The solid diamond shaped spacer has curved ends that
converge at each of four tips (1320) which designate the beginning
or ending of the channels. Individual conductors would be
preferably placed in each of the channels for pair separator.
Alternatively, conductor pairs could also be separated using this
design and technique.
[0226] FIG. 13c is a cross-sectional view of a diamond shaped cable
spacer separator that has two triangular hollowed center sections,
one of which is an upright equilateral triangular hollowed orifice
(1340) and the other of which is a downward-facing equilateral
triangular orifice (1345) and provides for four semi-circular
channels (1310) formed by curved surfaces of the diamond shaped
spacer for conductors. The solid diamond shaped spacer has curved
ends that converge at each of four tips (1320) which designate the
beginning or ending of the channels. Individual conductors would be
preferably placed in each of the channels for pair separator.
Alternatively, conductor pairs could also be separated using this
design and technique.
[0227] FIG. 13d is a cross-sectional view of a diamond shaped cable
spacer separator that has a diamond shaped hollowed center orifice
section (1350) and provides for four semi-circular channels (1310)
formed by curved surfaces of the diamond shaped spacer for
conductors. The solid diamond shaped spacer has curved ends that
converge at each of four tips (1320) which designate the beginning
or ending of the channels. Individual conductors would be
preferably placed in each of the channels for pair separator.
Alternatively, conductor pairs could also be separated using this
design and technique.
[0228] FIG. 14 is a cross-sectional view of a pendulum-like shaped
cable spacer separator with a circular-disc like pendant portion
(1400) that is either in the center of the pendulum-like shaped
separator or is optionally skewed to an elongated rectangular
shaped end (1410). This separator does not form specific channels
for conductors or conductor pairs, however the circular-disc like
portion (1400) provides a device which allows for proper spacing of
better or worse performing electrical pairs by placing this
circular-disc in a specific location. The circular-disc (1400)
includes an optional center hollow orifice portion (1420), again to
reduce material loading which should enable certain cable
constructions to pass stringent flame and smoke test
requirements.
[0229] FIG. 15 is a cross-sectional view of a pendulum-like shaped
cable spacer separator with an elliptical-disc like pendant portion
(1500) that is either in the center of the pendulum-like shaped
separator or is optionally skewed to an elongated rectangularly
shaped end (1510). This separator also does not form specific
channels for conductors or conductor pairs, however the
elliptical-disc like pendant portion (1500) provides a device which
allows for proper spacing of better or worse performing electrical
pairs by placing this elliptical-disc in a specific location. The
elliptical-disc like pendant portion (1500) includes an optional
center hollow orifice portion (1520), again to reduce material
loading which should enable certain cable constructions to pass
stringent flame and smoke test requirements.
[0230] FIG. 16 is a cross-sectional view of a pendulum-like shaped
cable spacer separator with a diamond-disc like pendant portion
(1600) that is either in the center of the pendulum-like shaped
separator or is optionally skewed to an elongated rectangularly
shaped end (1610). This separator forms more specific channels for
conductors or conductor pairs (1625) than that of FIGS. 14 and 15,
and the diamond-disc like portion (1600) additionally provides a
device which allows for proper spacing of better or worse
performing electrical pairs by placing this diamond-disc in a
specific location. The diamond-disc like portion (1600) includes an
optional center hollow orifice portion (1620), again to reduce
material loading which should enable certain cable constructions to
pass stringent flame and smoke test requirements. The design and
function of the separator of FIG. 16 is similar to that shown in
FIGS. 13a 13d with the additional feature of the horizontal
separator bar that restricts movement of the conductors in the
vertical direction during cabling and subsequent handling.
[0231] FIG. 17 is a cross-sectional view of a pendulum-like,
dual-lobed shaped cable spacer separator with a diamond-shaped
pendant portion in the center that can be optionally skewed to one
end and with lobed end portions (1700). Channels for conductors
(1725) are formed by curved elongated rectangular portions (1710)
of the dual-lobbed pendulum-like shaped separator). This separator
forms more specific channels for conductors or conductor pairs
(1725) than that of FIGS. 14 and 15, similar to that of FIG. 16,
and the diamond-shaped pendant portion additionally provides a
device which allows for proper spacing of better or worse
performing electrical pairs by placing this diamond-shaped pendant
in a specific location. The diamond-shaped pendant section includes
an optional center hollow orifice portion (1720), again to reduce
material loading which should enable certain cable constructions to
pass stringent flame and smoke test requirements.
[0232] FIG. 18 is a cross-sectional view of a rifled and
symmetrically balanced cross cable spacer separator (1800) that is
comprised optionally of a solid, foamed or solid skin over a foamed
core as described earlier in the present specification and again
for FIG. 18. The rifled cross separator also is comprised of four
"tipped" ends that have key-like features (1810). The rifled cross
separator provides clearance channels for conductors or conductor
pairs that may or may not be separately insulated (1825) where each
conductor or conductor pair includes an outer insulation material
(1835) and an inner section portion of the conductor (1830). As for
most of the prior separator constructions, a hollow orifice in the
center (1820) is optional again for the purpose of material
reduction loading.
[0233] FIG. 19 is a cross-sectional view of a dual drill-bit shaped
cable spacer separator (1900) or "mirrored battleship" shape that
is comprised optionally of a solid, foamed or solid skin over a
foamed core as described earlier. If one were to split this
separator along its central horizontal axis, the top and bottom
portions would be mirrored images of each other in that the bottom
portion would appear as a reflection of the top portion in much the
way a battleship would be reflected by floating in a still body of
water. Along the top portion of the separator, there is an
ascending stepped section (1905) upon which exists a key-like
shaped section (1910) that includes a double key-way inward
protruding portion (1911) and a double key-way outward protruding
portion (1912) of the separator. Along the bottom portion of the
separator, there is a symmetrical (with the top portion) descending
stepped section (1905) which includes the same shaped key-like
section (1910) with inward protruding portions (1911) and outward
protruding portions (1912) that exist under the bottom stepped
section (1905).
[0234] This separator again provides at least a four quadrant set
of clearance channels for conductors or conductor pairs with an
optional outer film (1930) and with conductors that have both an
outer insulation material (1940) and an inner conductor material
(1945) for each individual conductor or conductor pair. There is a
center hollow portion (1950) as part of the stepped (1905) portion
that is also shaped in a circular fashion to again achieve material
reduction for cost, flammability and smoke generation benefits.
[0235] FIG. 20 is a cross-sectional view of a "staggered rifled
cross" shaped cable spacer separator (2000) that is comprised
optionally of a solid, foamed or solid skin over a foamed core. As
in the spacer of FIG. 19, there is at least one upward protruding
sections (2005) near the center portion of the staggered rifled
cross separator along the lateral or horizontal direction that are
longer than such subsequent upward protruding sections in the same
direction. There is also at least one laterally protruding section
(2006) near the center portion of the staggered rifled cross
separator along the lateral or horizontal direction that is longer
than any subsequent laterally protruding section in the same
direction. In addition, there are inwardly intruding sections near
the center portion of the spacer (2007) along the vertical and
lateral or horizontal directions of the separator as well as
laterally protruding sections (as many as four) (2008) that may
exist near the center portion of the staggered rifled cross
separator. Inwardly intruding sections are also located near the
tipped portions of the separator (2009)--as many as four may exist.
At the same tipped end portion, there may be inverted ends (2010).
This entire geometry is configured to ensure that "worst pair"
electrical conductors are spaced in a staggered arrangement to
ensure that little or no influence or synergism can occur between
the electrically worst two pairs or electrically worst individual
conductors. The rifled arrangement allows for squeezing the
conductors into the interstices of each of four quadrants with
optional outer jacket or film insulation (2030) for the conductor
pairs which include an outer insulation section (2040) and an inner
conductor sections (2045). The central portion of the separator may
also include a hollow orifice (2020).
[0236] FIG. 21a is a cross-sectional view of an asymmetric cross,
where each of four quadrants formed by the cross to make clearance
channels are formed by either vertical or horizontal sections along
an axis of the cross with varying widths. Here, the left side
horizontal member (2110) is narrower in width than that of the
right side horizontal member (2120). Similarly, the vertical member
(2130) extending in an upward direction is narrower in width than
that of the other vertical member (2140). FIG. 21b is completely
analogous to FIG. 21a except that the asymmetric cross in this
cross-sectional view includes rifled or "saw-blade" like members as
shown previously. In this figure, section (2150) is narrower than
section (2160) along the horizontal axis, and section (2170) is
narrower than section (2180). The "teeth" of the saw-blade are
described in detail with FIG. 22.
[0237] FIG. 22 is a cross-sectional view of a saw-blade type
separator (2200) that may be, in fact, a semi-rigid thermoplastic
or thermoset film with "serrated" or rifled section along the top
and bottom portions of the horizontal axis. The teeth that form
serrated edges may be shaped in several ways, two of which are
shown in the expanded view of the same figure. Along either the top
or bottom portion of the separator blunt undulating sections may be
used (2210) or other shapes such as the "u" or "v" grooved sections
(2220). It should be understood that the teeth may be used in any
combination desired, based on the need of the cable
manufacturer.
[0238] FIG. 23a is a cross-sectional view of a symmetrical "Z" or
angle-iron shaped type separator (2300) that also may be a
semi-rigid thermoplastic or thermoset film. As shown, the separator
is symmetric in that both horizontal sections (2310) and (2320) are
of the same length and evenly spaced apart by the central vertical
section (2330). The separator could also be asymmetric in that
either of the horizontal sections could be extended or shortened
with respect to one another. Also, the vertical section (2330)
length could be adjusted as needed for electrical specification
requirements. This separator is provided primarily for 2 conductor
pair (2340) to be inserted in the clearance channels provided. FIG.
23b is also a symmetrical "Z" or angle-iron shaped type separator
with the addition, in this cross-sectional view, of rifled or
"saw-blade" like members as shown previously. In this figure,
sections (2350) and (2360) along the horizontal axis can be the
same length or arbitrarily different lengths--resulting in an
asymmetric shape. The central vertical section (2370) and
associated saw-blade like teeth can also be lengthened or shortened
as necessary. The "teeth" of the saw-blade are described in detail
in FIG. 22 and the same blunt undulating, "u" or "v" shaped grooves
can be used for this separator as well. This separator is provided
primarily for 2 conductor pair (2380) to be inserted in the
clearance channels provided.
[0239] FIG. 24a is a cross-section view of one embodiment of the
cable support-separator that includes a symmetrical core with a
central circular ring region (100) with four extending rifled
protrusion (2410, 2412, 2414, 2416) each extending in a preferred
90 degree separation from each other for optimum pair separation.
The optimum pair separation is gained by placing pairs between the
four extending rifled protrusions in regions (2420, 2422, 2424,
2426). The central circular ring portion (2400) optionally includes
a hollow region (2430) to act as an air blown fiber (ABF) duct
which is available for filling with optical fiber which is
comprised of solid, semi-solid, foamed or hollow polymeric smooth
internal and external surfaces.
[0240] FIG. 24b is a cross-section view of a second embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a, but also
includes a second inner ring (2440) within the hollow region
comprised of a different material than the outer ring for either
increasing lubricity or friction with four extending rifled
protrusions each extending in a preferred 90 degree separation from
each other for optimum pair separation.
[0241] FIG. 24c is a cross-section view of a third embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a, but also
includes a second inner ring within the hollow region comprised of
a different material than the outer ring for increasing friction
utilizing rifled inner spatially arranged sections (2450) with four
extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation.
[0242] FIG. 24d is a cross-section view of a fourth embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24c, but also
includes the optional use of a organic or inorganic fibers (2460)
including polyamide (for example Kevlar.RTM.) filing and an
optional strength member within the second inner ring within the
hollow region comprised of a different material than the outer ring
as well as allowing for multiple separate multimode or single mode
fiber optic units (2462) also contained within the same hollow
region with four extending rifled protrusions each extending in a
preferred 90 degree separation from each other for optimum pair
separation.
[0243] FIG. 24e is a cross-section view of a fifth embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24b and also
includes an inner pull tape (2470) for attaching optical fibers or
metallic conductors wherein the tape optionally itself incorporates
a grip or for which a grip is provided for future pulling of those
communication media through the hollow region at some future time
or during an installation with four extending rifled protrusions
each extending in a preferred 90 degree separation from each other
for optimum pair separation.
[0244] FIG. 24f is a cross-section view of a sixth embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24b but also two
individual conductors (2480 and 2482) (which may be twisted) inside
the second inner ring which is smooth instead of rifled within the
hollow region and comprised of a different material than the outer
ring as well as allowing for multiple separate multimode or single
mode fiber optic units also contained within the same hollow region
with four extending rifled protrusions each extending in a
preferred 90 degree separation from each other for optimum pair
separation.
[0245] FIG. 24g is a cross-section view of a seventh embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a with four
extending rifled protrusions each extending in a preferred 90
degree separation from each other for optimum pair separation, but
also includes the optional addition of one or more coaxial
conductors (2490) with a tinned copper braided shield (2492).
[0246] FIG. 25a is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 24a but possesses 6
instead of 4 rifled protrusions (2510, 2512, 2514, 2516, 2518,
2520) each extending in a preferred degree separation from each
other for optimum pair separation. The optimum pair separation is
gained by placing pairs between the six extending rifled
protrusions in regions (2530, 2532, 2534, 2536, 2538, and 2540).
The central circular ring portion (2500) optionally includes a
hollow region (2550) to act as an air blown fiber (ABF) duct which
is available for filing with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0247] FIG. 25b is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25a with as few as
two and as many as six extending protrusions each extending in a
preferred degree separation along the outer ring from each other
for optimum pair separation, but also includes a second inner ring
within the hollow region comprised of a different material than the
outer ring for increasing friction utilizing rifled inner spatially
arranged sections (2560).
[0248] FIG. 25c is a cross-section view of another embodiment of
the cable support-separator separator that includes the same
symmetrical core with a central circular ring region as for FIGS.
25a and 25b but with an inner smooth ring section (2570) with as
few as two and as many as six extending protrusions each extending
in a preferred degree separation along the outer ring from each
other for optimum pair separation that optionally includes the
optional addition of one or more conductors (2574) including
optionally organic or inorganic fibers such as polyamide (for
example Kevlar.RTM.) filling and an optional strength member (2572)
within the second inner ring.
[0249] FIG. 25d is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIGS. 25a and 25c but
with an inner smooth ring section with as few as two and as many as
six extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation that optionally includes the optional addition of one or
more conductors including optionally organic or inorganic fibers
such as polyamide (for example Kevlar.RTM.) filing and an optional
strength member within the second inner ring. Also, between as few
as one and as many as six of the extending projections,
additionally daisy-like spacers (2580) (as shown in FIG. 28a) are
placed which themselves allow for spacing of individual conductors
or conductor pairs (2582).
[0250] FIG. 25e is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIGS. 25a and 25c but
with an inner smooth ring section with as few as two and as many as
six extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation that optionally includes the optional addition of one or
more conductors including optionally organic or inorganic fibers
such as polyamide (for example Kevlar.RTM.) filing an optional
strength member within the second inner ring. Also, between as few
as one and as many as six of the extending projections are shown
without (2584) the additional daisy-like spacers (FIG. 28a).
[0251] FIG. 25f is a cross-section view of another embodiment of
the cable support-separator that includes the same symmetrical core
with a central circular ring region as for FIG. 25e but with an
inner smooth ring section with as few as two and as many as six
extending protrusions each extending in a preferred degree
separation along the outer ring from each other for optimum pair
separation that optionally includes the optional addition of one or
more conductors including optionally organic or inorganic fibers
such as polyamide (for example Kevlar.RTM.) filling and an optional
strength member within the second inner ring. Also, between as few
as one and as many as six of the extending projections, additional
spacers (2590) comprised of a circular ring region which is
surrounded by rounded lobes in a symmetric diamond-like geometry
that defines as many as four separate regions for pairs that are
properly separated in the final (often jacketed) cable designed (as
shown in FIG. 29e) are placed which themselves allow for spacing of
individual conductors or conductor pairs.
[0252] FIG. 26a is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region (2600) with four extending smooth
protrusions (2610, 2612, 2614, 2616), each protrusion extending
less than those of FIGS. 24a through 25f, each again extending in a
preferred 90 degree separation from each other for optimum pair
separation. The central region portion optionally includes a hollow
region (2620) to act as an air blown fiber (ABF) duct which is
available for filing with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0253] FIG. 26b is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending smooth
protrusions, each protrusion extending less than those of FIGS. 24a
through 24f, each again extending in a preferred 90 degree
separation from each other for optimum pair separation and also
includes a second inner ring (2630) within the hollow region
comprised of a different material than the outer ring for either
increasing lubricity or friction. The central ring portion
optionally includes a hollow region to act as an air blown fiber
(ABF) duct which is available for filing with optical fiber which
is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0254] FIG. 26c is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with four extending smooth
protrusions, each protrusion extending less than those of FIGS. 24a
through 25f, each against extending in a preferred 90 degree
separation from each other for optimum pair separation and also
includes also includes a second inner ring within the hollow region
comprised of a different material than the outer ring for
increasing friction utilizing rifled inner spatially arranged
sections (2640). The central ring portion optionally includes a
hollow region to act as an air blown fiber (ABF) duct which is
available for filling with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0255] FIGS. 26d and 26e are cross-section views of another
embodiment of the cable support-separator that includes a
symmetrical core with a central circular ring region with as few as
two (2670 and 2672 in FIG. 26e) and as many as six extending smooth
protrusions (2650, 2652, 2654, 2656, 2658, 2660 in FIG. 26d), each
protrusion extending less than those of the series of FIGS. 24a
through 25f, each again extending in a preferred separation from
each other for optimum pair separation and also includes also
includes a an optional second inner ring within the hollow region
comprised of a different material than the outer ring for
increasing friction utilizing rifled inner spatially arranged
sections. The central ring portion optionally includes a hollow
region to act as an air blown fiber (ABF) duct which is available
for filling with optical fiber which is comprised of solid,
semi-solid, foamed or hollow polymeric smooth internal and external
surfaces.
[0256] FIG. 26f is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region with no extending protrusions (2680)
that includes also an optional second inner ring within the hollow
region comprised of a different material than the outer ring for
increasing friction optionally utilizing rifled inner spatially
arranged sections. The central ring portion optionally includes a
hollow region to act as an air blown fiber (ABF) duct which is
available for filing with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smooth internal and
external surfaces.
[0257] FIG. 27a is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region (2700) with four extending protrusions
(2710, 2712, 2714, 2716) each protrusion extending less than those
of FIGS. 24a through 25f and each with at least a single cross-like
section (2720, 2722, 2724, 2726) extending outward from the
circular ring section in a preferred 90 degree separation from each
other for optimum pair separation. The central ring portion
optionally includes a hollow region (2730) to act as an air blown
fiber (ABF) duct which is available for filling with optical fiber
which is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0258] FIG. 27b is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region and each with at least a single
cross-like section extending from the circular ring section, each
protrusion extending less than those of FIGS. 24a through 25f, each
again extending in a preferred 90 degree separation from each other
for optimum pair separation and also includes a second inner ring
(2740) within the hollow region comprised of a different material
than the outer ring for either increasing lubricity or friction.
The central ring portion optionally includes a hollow region to act
as an air blown fiber (ABF) duct which is available for filing with
optical fiber which is comprised of solid, semi-solid, foamed or
hollow polymeric smooth internal and external surfaces.
[0259] FIG. 27c is a cross-section view of another embodiment of
the cable support-separator that includes a symmetrical core with a
central circular ring region and each with at least a single
cross-like section extending from the circular ring section, each
protrusion extending less than those of FIGS. 24a through 25f, each
again extending in a preferred 90 degree separation from each other
for optimum pair separation and also includes a second inner ring
within the hollow region comprised of a different material than the
outer ring for either increasing lubricity or friction. The inner
portion of the hollow ring region here is optionally filled with
inorganic or organic fibers (2750) such as polyamide fiber
(Kevlar.RTM.) and at least four single or multimode finer optic
units (2760, 2762, 2764, and 2766).
[0260] FIGS. 27d and 27e include a cross-section view of another
embodiment of the cable support-separator that includes a
symmetrical core with a central circular ring region with as few as
two (2770 and 2772 in FIG. 27e) and as many as six (2750, 2752,
2754, 2756, 2758, and 2760 in FIG. 27d) extending protrusions each
with at least a single cross-like section, each protrusion
extending less than those of FIGS. 24a through 25f, each again
extending in a preferred separation from each other for optimum
pair separation and also includes an optional second inner ring
within the hollow region comprised of a different material than the
outer ring for increasing friction utilizing rifled inner spatially
arranged sections. The central ring portion optionally includes a
hollow region to act as an air blown fiber (ABF) duct which is
available for filing with optical fiber which is comprised of
solid, semi-solid, foamed or hollow polymeric smoother internal and
external surfaces.
[0261] FIG. 27f includes a cross-section view of another embodiment
of the cable support-separator includes a symmetrical core with a
central circular ring region with no extending protrusions (2780)
that includes also an optional second inner ring which is smoother
within the hollow region comprised of a different material than the
outer ring for increasing friction as well as allowing for multiple
separate multimode or single mode fiber optic units (2785) also
contained within the same hollow region. The central ring portion
optionally includes a hollow region to act as an air blown fiber
(ABF) duct which is available for filling with optical fiber which
is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0262] FIG. 28a is a cross section view of another embodiment of
the cable support-separator that includes a hollow four-petal
(2810, 2812, 2814, and 2816) or "daisy" shaped arrangement with a
central core (2800) that may or may not be hollow (2820 shown
hollow). If the central region is hollow, the possibility again
exists for that region to act as an air blown fiber (ABF) duct
which is available for filling with optical fiber. Coaxial or
twisted pair conductors may also be introduced in that region.
[0263] FIG. 28b is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal (2840,
242, 2844, and 2486) or "daisy" shaped arrangement with a central
core (2830) that may or may not be hollow (2832 shown hollow). Each
"petal" contains two hollow sections (2850 and 2852) for additional
optical or metallic conductor media. The central region (2832) is
hollow allowing for the possibility that this region may act as an
air blown fiber (ABF) duct which is available for filing with
optical fiber. Coaxial or twisted pair conductors may also be
introduced in that region.
[0264] FIG. 28c is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core (2860) that may or
may not be hollow. Each "petal" contains three hollow sections
(2870, 2872, 2874) of differing diameters for additional optical or
metallic conductor media. The central region (2860) is solid.
[0265] FIG. 28d is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that mayor not be
hollow. Each "petal" contains three hollow sections of differing
diameters for additional optical or metallic conductor media. In
this case, the center hollow section of each petal is filled with
an optical fiber unit (2880). The central region is solid or
optionally hollow.
[0266] FIG. 28e is a cross-section view of another embodiment of
the cable support-separator that includes a solid four-petal or
"daisy" shaped arrangement with a central core that mayor may not
be hollow. Each "petal" contains three hollow sections of differing
diameters for additional optical or metallic conductor media. In
this case, the center hollow section of the daisy is filled with an
optical fiber unit (2890). The central region is solid or
optionally hollow.
[0267] FIGS. 29a, 29b, 29c are cross-sectional views of another set
of embodiments of the cable support-separator that includes a
circular ring region (2900) which is surrounded by rounded lobes
(2910, 2912, 2914, 2916) in a symmetric diamond-like geometry that
defines as many as four separate regions for pairs that are
properly separated in the final (often jacketed) cable design.
Again the central ring portion can optionally include a hollow
region (2920) that may be used as an air blown fiber (ABF) duct
which is available for filling with optical fiber which is
comprised of solid, semi-solid, foamed or hollow polymeric smooth
internal and external surfaces. FIG. 29a has no inner ring. FIG.
29b has a smooth inner ring (2930) with optionally different
material than the outer ring, and FIG. 29c has an inner ring (2940)
with rifled sections (2942). Each can optionally be used for coax
or twisted pair as well as for fiber optic conductors in advance,
during, or after installation.
[0268] FIG. 29d is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes the optional addition of one or more
conductors including optionally organic or inorganic fibers such as
polyamide (for example Kevlar.RTM.) filling and an optional
strength member (2950) within the second inner ring (that may or
may not be rifled). Again the central ring portion can optionally
include a hollow region that may be used as an air blown fiber
(ABF) duct which is available for filling with optical fiber (2960,
2962, 2964, 2966) which is comprised of solid, semi-solid, foamed
or hollow polymeric smooth internal and external surfaces.
[0269] FIG. 29e is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes a center portion filled with a fiber
optic unit (2970) as well as four separated conductor pairs (2980,
2982, 2984, 2986) in each of the regions defined by the symmetric
diamond-like geometry of the cable support-separator. Again the
central ring portion can optionally include a hollow region that
may be used as an air blown fiber (ABF) duct which is available for
filling with optical fiber which is comprised of solid, semi-solid,
foamed or hollow polymeric smooth internal and external
surfaces.
[0270] FIG. 29f is a cross-sectional view of another embodiment of
the cable support-separator that includes a circular ring region
which is surrounded by rounded lobes in a symmetric diamond-like
geometry that defines as many as four separate regions for pairs
that are properly separated in the final (often jacketed) cable
design. This design includes a center portion with a second inner
ring portion (2990) filled with a fiber optic unit (2992) or other
conductors as well as four cross-like separators (2994) (see FIG.
18) in each of the regions defined by the symmetric diamond-like
geometry of the cable support-separator within which another, up to
four pairs of conductors (2996) are situated and separated by the
cross-like separator. Again the central ring portion can optionally
include a hollow region that may be used as an air blown fiber
(ABF) duct which is available for filling with optical fiber which
is comprised of solid, semi-solid, foamed or hollow polymeric
smooth internal and external surfaces.
[0271] FIG. 30a is a cross-section view of another embodiment of
the cable support-separator that includes a more conventional
cross-like separator section (3000) with "rifled" sections (3002
and 3004, for example) extending outward into four quadrants (3010,
3012, 3014, 3016) away from the central region (3000) and is
encased or covered within an outer insulated layer (3020) which is
itself shaped in an identical cross except that the dimensions of
this outer cross is larger than the rifled inner cross and
functions as a "skin". The inner cross-like portion may be
metallized by utilizing electroless or electrolytic plating
techniques over a thermoplastic film.
[0272] FIG. 30b is a cross-section view of another embodiment of
the cable support-separator that includes the same more
conventional cross-like separator section as with FIG. 30a except
that this separator contains a shield (3030) that extends along the
horizontal axis and optionally also along the vertical axis or both
axes within the horizontal hollow portion (3040) of the cross-like
separator. This shield is comprised of aluminum PET film and may be
configured so that it is held within the outer cross-like separator
(3020) and may also be part of an overall shielded cable which is
shielded using aluminum backed PET film or a braided metallic
shield or any combination.
[0273] FIG. 31a is a cross-section view of another embodiment of
the cable support-separator that includes providing variations on a
cross-like arrangement by adding "zig-zag" extensions (3110, 3112,
3114, for example) that extend away from the central region (3100).
Again the cross-like "zig-zag" arrangement may be covered within an
outer insulated layer which is itself shaped in an identical cross
except that the dimensions of this outer cross are larger than the
rifled inner cross and functions as a "skin". This design
optionally includes four separated conductor pairs (3120, 3122,
3124, 3126) in each of the regions defined by the symmetric
diamond-like geometry of the cable support-separator.
[0274] FIG. 31b is a cross-section view of another embodiment of
the cable support-separator that includes providing variations on a
cross-like arrangement by adding "sickle-like" extensions (3130,
3132, 3134, and 3136) that extend away from the central region.
Again the cross-like and sickle-like sections arrangement may be
covered within an outer insulated layer which is itself shaped in
an identical cross except that the dimensions of this outer cross
are larger than the rifled inner cross and functions as a "skin".
This design optionally includes four separated conductor pairs
(3120, 3122, 3124, 3126) in each of the regions defined by the
symmetric diamond-like geometry of the cable support-separator.
[0275] FIG. 32 is a cross-sectional view of another embodiment
(3200) with several hollow regions (3210, 3212, 3214, for example)
for blown fiber or any transmission media for present, future, or
concurrent installations using the support-separator alone or in
combination with a cable.
[0276] FIGS. 33a and 33b are cross-sectional views of another set
of embodiments of the cable support-separator that includes a
circular ring region (3300) which is surrounded by semi-rounded
lobes (3310, 3312, 3314, 3316) in a symmetric star-like geometry
that defines as many as four separate regions for pairs (3320,
3322, 3324, 3326) that are properly separated in the final (often
jacketed) cable design. Again the central ring portion can
optionally include a hollow region (3330) that may be used as an
air blown fiber (ABF) duct which is available for filling with
optical fiber which is comprised of solid, semi-solid, foamed or
hollow polymeric smooth internal and external surfaces. FIGS. 33a
and 33a include view of optionally filled inner hollow regions such
that each can optionally be used for coax or twisted pair as well
as for fiber optic conductors (in advance, during or after
installation). FIG. 33a includes a view of this design including
the optional addition of one or more conductors including
optionally organic or inorganic fibers such as polyamide (for
example Kevlar.RTM.) filling and an optional strength member within
the second inner ring (that may or may not be rifled). FIG. 33b
includes a view of this design that includes the optional addition
of coaxial cable (3302) in the hollow center region. The central
circular region (3301) is of a slightly larger size that that shown
in FIG. 33a in order to allow for coaxial cable in the central
hollow region of the separator.
[0277] It will, of course, be appreciated that the embodiment which
has just been described has been given simply by the way of
illustration, and the invention is not limited to the precise
embodiments described herein, various changes and modifications may
be effected by one skilled in the art without departing from the
scope or spirit of the invention as defined in the appended
claims.
* * * * *