u.s. patent 8,367,933
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(12) United States Patent Mumm et a1.
US008367933B1
US 8,367,933 B1 Feb. 5, 2013
(10) Patent N0.: (45) Date of Patent:
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(52) (58)
DATA CABLES WITH IMPROVED PAIR PROPERTY BALANCE
Inventors: Jeffrey H. Mumm, Marietta, GA (US); Justin W. Mintz, Hoisington, KS (US); Nathaniel Ostrander, Woodstock, GA (Us)
Assignee: Superior Essex Communications LP, Atlanta, GA (U S)
Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 229 days.
Appl. No.: 12/803,119
Filed: Jun. 18, 2010
Related US. Application Data
Provisional application No. 61/269,075, ?led on Jun. 19, 2009.
Int. Cl. H01B 11/02 (2006.01) US. Cl. ................................................. .. 174/113 R
Field of Classi?cation Search ............ .. 174/113 R,
174/113 C, 110 F See application ?le for complete search history.
(56) References Cited
U.S. PATENT DOCUMENTS
3,945,974 A 3/1976 SchWarcZ et 31. 4,412,094 A 10/1983 Dougherty et a1. 5,162,609 A 11/1992 Adriaenssens et a1. 5,270,486 A 12/1993 Chan et a1. 5,493,071 A 2/ 1996 Newmoyer 5,514,837 A 5/1996 Kenny et a1. 5,576,515 A 11/1996 Bleich et a1. 5,597,981 A 1/1997 Hinoshita et a1. 5,770,820 A 6/1998 Nelson et a1. 5,841,073 A 11/1998 Randa et a1. RE37,010 E 1/2001 Newmoyer 7,030,321 B2 4/2006 Clark 7,084,348 B2 8/2006 Dillon
FOREIGN PATENT DOCUMENTS
JP 2010-123275 * 6/2010
* cited by examiner
Primary Examiner * Chau Nguyen
(57) ABSTRACT A communication cable can comprise twisted pairs of elec trical conductors for transmitting electrical signals, such as for digital communication or data transmission. The pairs can be twisted to different lengths, thereby managing interference among the pairs. The electrical conductors of the pairs can be individually insulated With a polymeric material comprising a base polymer that is foamed With a gas such as nitrogen. The respective foaming levels of the electrical conductors in each pair can be selected to balance electrical properties among the pairs.
25 Claims, 29 Drawing Sheets
US 8,367,933 B1 Sheet 1 0f 29 US. Patent Feb. 5,2013
Feb. 5, 2013 Sheet 2 0f 29 US 8,367,933 B1
100 ‘\ 365
< 1051 / 115
US. Patent
?\ 1052/115 0 1
| 10541115 1
1053/115
Fig. 3
US. Patent Feb. 5, 2013 Sheet 3 0f 29 US 8,367,933 B1
U S. Patent Feb. 5, 2013 Sheet 4 0f 29 US 8,367,933 B1
U S. Patent Feb. 5, 2013 Sheet 5 0f 29 US 8,367,933 B1
US. Patent Feb. 5, 2013 Sheet 6 0f 29 US 8,367,933 B1
Maximum 103.09 at 0.772 MHz
140.0 Mxmmung: 98.10 at 607 69 MI-‘IZ
133.0
126.0
119.0
112.0
Pair I , 20 (2nd OrdzrXOhms) \o 9° o
91.0
84.0
77.0
70.0 1.0 2 3 45 10 20 30 50 100 200 300 500
Frequency(0.772 - 650 MHZ; 801 scan points)
Fig. 6A
US. Patent Feb. 5, 2013 Sheet 7 0f 29 US 8,367,933 B1
Maximmn: 101.67 at 392.22 MHZ Minimum: 100.98 a 0.772 MHz
Pair 2 , Z0 (2nd Order)(0hrn 5 O
91.0
84.0
77.0
70.0 1.0 2 3 4 5 10 20 30 50 100 200 300 500
Frequency(0.77'2 - 650 MHz; 801 scan points)
Fig. 6B
US. Patent Feb. 5, 2013 Sheet 8 0f 29 US 8,367,933 B1
Maximum: 99.17 at 0772 MHz 1400 ' '11 m1: 97.7lat l ‘8'
133.0
126.0
119.0
112.0
10510
9810 Pair 3 , 20 (2nd Ordcr)(0l1ms)
91.0
84.0
7710
1.0 2 3 4 5 10 20 30 50 100 200 300 500
Frequency(0.772 - 650 MHz; 801 scan points)
Fig. 6C
US. Patent Feb. 5, 2013 Sheet 9 0f 29 US 8,367,933 B1
Maximum: 102.81 at 0.772 MHz 1400 Minimum: 98.21 at 628.50 MHz
133.0
Pair 4 , 20 (2nd Order)(0hms)
1.0 2 3 4 5 10 20 3O 50 100 200 300 500
Frequency-‘(0.772. — 650 MHz; 801 scan points)
Fig. 6D
US. Patent Feb. 5, 2013 Sheet 10 0f 29 US 8,367,933 B1
Maximum 561.38 at 0.470 MHZ Minimum: 456.64 at 0 064 IV?-Iz “W
M
\\
/
0. 0. 0. 0. 0. 0. 0 0. 0 O o 0 O 0 0 O 0 0 2 0 8 6 4 a}- 0 8 6 6 6 5 i,- rul- CJ 5 4 4
440.0 100 200 400 I0 20 30 50
Frequency(0.064 - 650 MHz; 1601 scan points)
234 1.0 0.4 0.10 0.2
Fig. 7A
US. Patent Feb. 5, 2013 Sheet 11 0129 US 8,367,933 B1
Maximum: 555.61 at 0.470 MHz 5600 Li Muum: 460.33 at 0.064 MHz
550.0 A\ \ M I 540.0 \\ \\~~ _.____
/1 \\ | 520.0 / \\ 510.0 f \\
Pair 2 , DELAY (nsxmom) 500.0 / 490.0
480.0 I
470.0
460.0 0.10 0.2 0.4 1.0 2 34 10 2030 50 100 200 400
Frequeucy(0.064 ~ 650 MHz; 1601 scan points)
Fig. 7B
US. Patent Feb. 5, 2013 Sheet 12 0f 29 US 8,367,933 B1
Maximmn: 571.09 at 0.470 MHz Minimum: 467.66 '\t 0.064
Pair3,1: .
0.10 0.2 0.4 1.0 2 3 4 1O 2O 30 50 100 200 400
Frequency(0.064 - 650 MHz; 1601 scan points)
Fig. 7C
US. Patent Feb. 5, 2013 Sheet 13 0f 29 US 8,367,933 B1
Maxinmm: 562.05 at 0.470 MHz 660-0 Minimmn: 468.25 at 0.064 MHz
640.0
620.0
600.0
580.0
480.0 /
460.0 .
0.10 0.2 0.4 1.0 2 3 4 10 20 30 50 100 200 400
Frequency(0.064 - 650 MHz; 1601 scan points)
Fig. 70
U.S.
Pair 1 - 2 , SKEW (ns/100m)
Pair 1 - 3 , SKEW (us/100m)
Patent Feb. 5, 2013 Sheet 14 0f 29 US 8,367,933 B1
Maximmn: 5.77 at 0.470 MHz 5.80 Muunnun: 3.91 at 606.94 MHZ
5.60
5.40 5.20
5.00
4.80
4.60
4.40 ,/ 4.20
4.00
3.80
‘x 11 “A, W
1—_...... 0.10 0.2 0.4 1.0 4 10 20 30 50 100
Frequ¢11cy(0.064 - 650 MHz: 1601 scan points)
7 3 200 400
Fig. 8A Maximum]: 11.02 at 0.064 MHZ
12.00
11.50
11.00
10.50!
10.00
9.50
9.00
8.50
8.00
7.50
7.00 I 1 ;I—[_
1.0 2 34 10 2030 50
Frequeucy(0.064 - 650 MHz; 1601 scan points)
100 200 400
Fig. 88
0.4
US. Patent Feb. 5, 2013 Sheet 15 0f 29 US 8,367,933 B1
Maximmn: 11.61 at 0.064 MHz
O. 2
0.8.6.42Q l
w. m m. m
RENE-“m5 BmEm m ‘w- _ hun
10 20 3O 50 100 200 400
Frequency(0.064 - 650 MHz; 1601 scan points)
34 1.0 04 0310 0.2
Fig. ac Maximum: 1548 at 0470 MHz
. . 0. 0” . 0_ . . . . .
_.I 6 .3 4 3 2 I. 0 9 00 7
1 1 1 1 1 1 l 1
“3 4 10 20 30 50 100 200 400
Frequency(0.064 - 650 MHz; 1601 scan pointss)
1.0 0.4 010 0.2
Fig. 8D
US. Patent Feb. 5, 2013 Sheet 16 0f 29 US 8,367,933 B1
Maximum: 7.67 at 0.064 MHZ
10.
10.
‘g 9. O
‘E 9.
8.
Z M 8. U‘)
" 7. ‘1'
r1: 7.
1:? 6.
6.
5. 0.10 0.2 0.4 1.0 2 3 4 1O ‘20 30 50 100 200 400
Frequency(0.064~650 MHz: 1601 scan points) Maxiuuuu: 9.04 at 0.470
'nim m1: Olg?
E 8 \\ Z ‘"“M. a “MM-m.
E w
‘T {'1
‘a 5-.
_ _ —
0.10 0.2 0.4 1.0 2 3 4 10 20 30 50 100 200 400
Frequency(0.064 - 650 MHz; 1601 scan points) Fig. 8 F
US. Patent Feb. 5, 2013 Sheet 17 0129 US 8,367,933 B1
' Measured (in)
Test Average (in) 1 2 3 F00 Outer Jkt 0.3968 0.3049 0.4004 0.3952
FOD Inner Jkt 0.28040 0.2793 0.2808 02811
ID OuterJkt 0.3181 0.3194 0.3170 0.3178
ID Inner Jkt 0.23443 0.2359 0.2362 0.2312
Outer Jkt Thickness 0.0327 0.0333 0.0322 0.0327
Inner JK1 Thickness 0.02200 0.0221 0.0216 0.0216 Shield Overlap 0.12267 0.1194 0.1202 0.1284
Print count/10ft = 5 LHL (lay/10 ft) (inllay)
Bunch Lay 23 5.22
LHL Twin 0.3530
2.116 0.4726 Green 3.108 0.3218 Brown 258 0.4429
Diamete" (in) Insulation Copper
Blue 0.04246 0.02278
White 0.04235 0.02273
Orange 0.04263 0.02292 White 0.04269 0.02295 Green 0.04244 0.02270
White 0.04247 0.02270
Brown 0.04255 0.02291 _
White 0.04274 0.02290 Fig. 9A
US. Patent Feb. 5, 2013 Sheet 18 0f 29 US 8,367,933 B1
Crossweb Dimensions Width Inches
W1 0.0382
W2 0.0348
Thickness Inches
1 Top 00105
1 Bottom 0.0217
2 Top 00103 2 Bottom 0.0207
3 Top 00108 3 Bottom 0.0204
4 Top 00121
4 Bottom 0.0209
613%?131éélél?élfilféiiififféii . ~ Skin Thickness in)
Insulation 1 2 3 4 Avg
Blue 0.00406 0.00283 0.00350 0.00319 0. 00340
White 0.00287 0.00347 0.00291 0.00346 0.00318
Green 0.00406 0.00268 0.00378 0.00318 0.00343 White 0.00346 0.00362 0.00315 0.00327 0.00338
Fig. 98
Density by Density scale:
Sample A (9) (Weight in Air) P (9) (Weight in Water) Density (gicm’) BL Conductor 5.4118 0.6067 8L Insulated Conductor 6.6306 2.0914 BL Insulation 1.2188 1.4847 0.8209 BL/WH Conductor 5.4057 0.6061 BL/WH Insulated Conductor 6.6630 2.0859 BL/WH Insulation 1.2573 1.4798 0.8496 GR Conductor 5.4374 0.6098 GR Insulated Conductor 6.6956 2.1258 GR Insulation '1 .2582 1.5160 0.8299 GRNVH Conductor 5.4492 0.6136 GRNVH Insulated Conductor 6.7114 2.1144 GR/WH Insulation 1.2622 1.5008 0.8410 'Density = A I P * Density of Water [gmm‘]
Fig. 9C
US. Patent Feb. 5, 2013 Sheet 19 0f 29 US 8,367,933 B1
Maximum 100.31 M0772 MHz Minimum: 91.16 M45143 MHz 140.0
133.0
126.0
119.0
112.0
105.0
98.0 Pair 1 . 11.‘!{21151 OrderROhms}
1.0 2 3 4 5 10 20 30 40 100 200 300 500
Frequency({). 172 - 500 MHz; 801 scan points]
Fig. 10A
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