U.S. Patent 8,367,933

(12) United States Patent Mumm et a1.

US008367933B1

US 8,367,933 B1 Feb. 5, 2013

(10) Patent N0.: (45) Date of Patent:

(54)

(75)

(73)

(21)

(22)

(60)

(51)

(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


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


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


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


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


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


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


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


Fig. 7C


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


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


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


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


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


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


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

Documents

U.S. Patent 8,367,933