21AWG distance extension POE network cable

Abstract

A network cable is provided with four twisted pairs. Each twisted pair includes a first insulated conductor and a second insulated conductor of 21AWG. Each twisted pair includes a bisecting tape between the twisted first and second insulated conductors. The 21AWG conductor allows for longer distance data transmission and PoE. The thinner wall of the insulating layer of the 21AWG conductor terminates the network cable to industrial standard RJ45 sockets and plugs designed to accommodate insulated conductors of 22-24 AWG, while the bisecting tape between the insulated conductors of each twisted pair allows the network cable to assume an impedance of nominal 100 ohms.

Description

TECHNICAL FIELD

[0001] The present invention relates to a twisted pair cable, such as a Local Area Network (LAN) cable, for transmitting high speed data signals and Power over Ethernet (PoE). More particularly, the present invention relates to a large gauge twisted pair cable for transmitting data and power over an extended distance, wherein the insulated wires of the cable are sized to terminate to a standard RJ45 connector. BACKGROUND

[0002] In accordance with Section 4.3.1 of the standard TIA 568-B.2, published April 23, 2001, which allows twisted pair network cables to have conductors ranging from 22 to 24 AWG, most twisted pair network cables employ 23 AWG (American Wire Gauge) copper conductors. A 23 AWG conductor has a diameter of approximately 0.573 mm (22.6 mils), while a 22 AWG conductor has a diameter of approximately 0.644 mm (25.3 mils). The copper conductors are surrounded by an insulating layer having a radial thickness in the range of 9 to 11 mils, such as approximately 10 to 11 mils for a typical Category 6 cable. The thickness and dielectric constant of the insulating layer provides the twisted pair conductors with a nominal 100 ohm impedance.

[0003] A typical 23 AWG network cable is rated to reliably transmit data and PoE up to 100 meters (328 feet). If a technician attempts to run a 23 AWG cable beyond 100 meters, a significant voltage drop can occur and the devices at the end of the long cable can not boot up and operate properly. The voltage drop is caused by the heat generated by the electrical resistance of the 23 AWG conductors within the cable. In addition, data transmission over the cable can experience packet failures. For a typical network cable designed for low voltage applications, it is not an option to compensate for the voltage drop by increasing the voltage of the network cable.

[0004] It is generally accepted in the cabling industry that a thicker conductor provides lower resistance and can carry more power with less voltage drop, that is, without heating up. To this end, several companies have proposed and / or patented network cable designs employing 22 AWG conductors.

[0005] On June 9, 2010, Quabbin Wire and Cable, Inc. introduced a Tl cable with 22 AWG conductors that is heavier than most Category 5A cables that typically have 24 AWG conductors. The insertion loss of the 22 AWG cable is about 25% lower than the insertion loss measured in a 24 AWG cable. This results in longer distances. Quabbin's "9720, 22 AWG Cable" can meet the required Tl Pulse Mask over a full length of 200 meters, while a 24 AWG cable can only meet it over about 150 meters.

[0006] In 2013, Panduit introduced Category 7 cable with four twisted pairs of 22 AWG stranded copper conductors and insulated with foam polyethylene.

[0007] In September 2014, General Cable introduced a four-pair PoE Category 6 network cable called GenSpeed® EfficienC™ Max. The cable employed 22 AWG conductors. General Electric recognized that industry trends were to send more power over PoE cabling. As stated in its press release, “Large-Gauge Conductors for High-Powered Applications - The 22 AWG conductors provide reduced heat generation, higher maximum current carrying capabilities and improved attenuation performance.”

[0008] On July 19, 2016, Belden issued a specification and technical data sheet for its cable 7922A Category 5e DataTuff® twisted pair cable. The 7922A cable included 22 AWG bare copper conductors surrounded by a 1 1 mil thick polyolefin insulation layer resulting in a total insulation conductor diameter of 48 mils.

[0009] Twisted pair network cables with 22 AWG conductors have also been shown in the patent literature. See, for example, U.S. Patents 6,297,454; 6,787,697; 6,815,611; 10,249,410, 10,453,589; 11,107,605; 11,562,835; and 11,646,133, which are incorporated herein by reference.

[0010] Current RJ45 plugs and RJ45 jacks produced include an organizational sled with rails or channels to hold the network cable in a fixed, predictable position as the cable end is terminated to the conductive blades and lead frame of the plug and jack, respectively. It is important to keep the cable end in a predictable and consistent position within the plug and jack because the plug and jack have an offsetting effect on crosstalk compensation. If the individual wires are not consistently positioned within the plug sled or jack sled, the compensating crosstalk of the jack will not match the induced crosstalk caused by the plug, and vice versa. See the assignee’s previous U.S. Patent 7,972,183 for more details on this consideration, which is incorporated by reference herein.

[0011] A five-page document published by CommScope®, SYSTIMAX® Solutions (Specification 860344274, Issue 10, October 2019, Revision B), which is incorporated by reference herein, shows a method of terminating a CAT cable to a Commscope RJ45 jack. On the fourth page of the specification, a wire pressing operation is demonstrated in which each insulated conductor is pressed into a respective slot leading to an insulation displacement connector (IDC). FIG. 1A shows a side view of a slot section 1 of one side of a Commscope RJ45 jack. FIG. 1A labels the width 5 of one of the slots or openings 3 leading to one of the IDCs of the RJ45 jack. The slots or openings 3 are formed by plastic sidewalls between which the insulated wires pass and reach the IDCs that cut through the insulation layer to make an electrical connection with the conductors within the insulation layer. The width 5 of the openings 3 between the plastic sidewalls leading to the IDCs is 46 mils with a tolerance of +0.003 mils and -0.002 mils. The remaining seven slots or openings of the slot section 1 of the RJ45 jack have the same dimensions with the same tolerance.

[0012] Commscope’s U.S. Patent 7,972,183, which is incorporated by reference herein, demonstrates an RJ45 plug. FIG. IB is based on a portion of FIG. 1 of U.S. Patent 7,972,183. FIG. 1C is based on FIG. 2 of U.S. Patent 7,972,183. The sled 7 of the RJ45 plug includes slots between which the insulated conductors 9, 11, 13, and 15 must pass before being terminated to the conductive blades of the RJ45 plug. To be kept in a consistent position to produce a predictable amount of crosstalk, FIGS. IB and 1C show that two stacked insulated conductors 9 and 11 must pass between a first pair of facing shoulders 17 and 19 and a second pair of facing shoulders 21 and 23. To be kept in a consistent position to produce a predictable amount of crosstalk, FIGS. IB and 1C also show that two stacked insulated conductors 13 and 15 must pass between a third pair of facing shoulders 19 and 23 and a fourth pair of facing shoulders 17 and 21. Figure 7 Figure 9 FIG. 1C. The sled 7 of the RJ45 plug includes slots between which the insulated conductors 9, 11, 13, and 15 must pass before being terminated to the conductive blades of the RJ45 plug. To be kept in a consistent position to produce a predictable amount of crosstalk, FIGS. IB and 1C show that two stacked insulated conductors 9 and 11 must pass between a first pair of facing shoulders 17 and 19 and a second pair of facing shoulders 21 and 23. To be kept in a consistent position to produce a predictable amount of crosstalk, FIGS. IB and 1C also show that two stacked insulated conductors 13 and 15 must pass between a third pair of facing shoulders 19 and 23 and a fourth pair of facing shoulders 17 and 21. ​

[0013] The size of the conductors is made in accordance with the American Wire Gauge (AWG) standard. An example chart of AWG sizes can be obtained on the internet at the following link: https: / / www.engineeringtoolbox.com / awg-wire-gauge-circular-mils-d_819.html, which chart is incorporated herein by reference. Figure 2 reproduces a portion of that chart containing some numbers relevant to the present invention. SUMMARY

[0014] Applicant learned from the chart in Figure 2 that a 21 AWG conductor has a diameter of 28.5 mils. Depending on the dielectric constant of the material used in the insulation layer, a network cable formed with 21 AWG conductors requires an insulation layer of about 9.1 mils to 11.1 mils to achieve the 100 ohm nominal impedance required for a twisted pair. Thus, depending on the dielectric constant of the material used in the insulation layer, each insulated wire in the twisted pair would have a diameter of about 46.7 mils to 50.7 mils. Such a size is too large to fit into the opening 3 between the plastic side walls of the IDC of the slot section 1 of the RJ45 jack of Figure 1A, and too large to fit between the facing shoulders of the RJ45 plug slider 7 of Figures 1B and 1C. Therefore, it is logical that the conductor gauge of the insulated conductors used with the RJ45 jacks and plugs of Figures 1A, 1B and 1C is 22 AWG to 24 AWG, because the standard TIA 568-B.2, 4.3.1, published April 23, 2001, allows network cables to have 22 AWG to 24 AWG conductors.

[0015] However, it is desirable to extend the reach of PoE twisted pair cable beyond what is possible with 22 AWG conductors, such as those sold by Panduit Company, General Cable Company, Belden Company and Paige Electric Company. In addition, there are currently over 1 billion RJ45 jacks as shown in Figure 1A in use. Replacing so many RJ45 jacks (Figure 1A) and RJ45 plugs (Figures 1B and 1C) to accommodate twisted pair network cables with 21 AWG conductors would be wasteful.

[0016] Applicants have recognized a solution to the need for terminating small diameter 21 AWG conductors to standard RJ45 jacks and plugs while still exhibiting a nominal impedance of 100 ohms over the length of the network cable. More specifically, applicants have invented a twisted pair cable having 21 AWG conductors wherein the first and second insulated conductors of each twisted pair have a total diameter of 45.8 mil or less while still exhibiting a nominal impedance of 100 ohms over the length of the network cable. Such insulated conductors can fit into the opening 3 between the plastic side walls of the IDCs of the slot section 1 of the RJ45 jack of FIG. 1A, the lower tolerance limit of the opening, i.e., the narrowest slot dimension, being 0.046 inches to 0.002 inches, or 45.8 mils. Further, applicants have invented a cable having 21 AWG conductors wherein the first and second insulated conductors of each twisted pair have a total diameter of 45.8 mil or less to fit between the facing shoulders 17-19, 21-23, 19-23 and 17-21 of the RJ45 plug slider 7 of FIGS. 1B and 1C.

[0017] These and other objects are achieved by a network cable having four twisted pairs. Each twisted pair includes a first insulated conductor and a second insulated conductor of 21 AWG. Each twisted pair includes a split band between the twisted first and second insulated conductors. The 21 AWG conductors allow for longer distance data transmission and PoE. The thinner wall of the insulation layer on the 21 AWG conductors allows the network cable to be terminated to industry standard RJ45 jacks and plugs designed to accommodate 22 AWG to 24 AWG insulated conductors, and the split band between the insulated conductors of each twisted pair allows the network cable to exhibit a nominal impedance of 100 ohms.

[0018] Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the application, are given by way of illustration only, since various changes and modifications within the spirit and scope of the application will become apparent to those skilled in the art from this detailed description. BRIEF DESCRIPTION OF DRAWINGS

[0019] The present application will be more fully understood from the following detailed description taken in connection with the accompanying drawings, among which:

[0020] FIG. 1A is a side view of a slot section on one side of a Compt RJ45 jack according to the prior art;

[0021] FIG. 1B is a top view of a portion of an RJ45 plug slider according to the prior art;

[0022] FIG. 1C is a cross-sectional view of the RJ45 plug slider of FIG. IB taken along line FIG. 1C-FIG. 1C;

[0023] FIG. 2 is a chart showing dimensions related to the American Wire Gauge (AWG) standard according to the prior art;

[0024] Figure 3 is a perspective view of a twisted pair cable according to a first embodiment of the present application;

[0025] Figure 4 is a cross-sectional view of the twisted pair cable of Figure 3 taken along line IV-IV;

[0026] Figure 5 is a close-up cross-sectional view of the twisted pair of Figure 4

[0027] Figure 5A is a close-up cross-sectional view of the twisted pair similar to Figure 5 but showing that the dielectric tape can include a hollow air pocket;

[0028] Figure 6 is a close-up cross-sectional view of a twisted pair cable having a twisted pair with an alternative shape of dielectric tape according to a second embodiment of the present application;

[0029] Figure 7 is a cross-sectional view of a twisted pair cable employing a twisted pair according to Figure 6

[0030] Figure 8 is a close-up cross-sectional view of a twisted pair cable having a twisted pair with an alternative shape of dielectric tape according to a third embodiment of the present application;

[0031] Figure 8A is a close-up cross-sectional view of a twisted pair cable having a twisted pair with an alternative shape of dielectric tape according to a fourth embodiment of the present application;

[0032] Figure 8B is a cross-sectional view of a twisted pair cable employing a twisted pair according to Figure 8A

[0033] Figure 9 is a perspective view of a twisted pair cable according to a fifth embodiment of the present application;

[0034] Figure 10 is a cross-sectional view of the twisted pair cable of Figure 9 taken along line X-X;

[0035] Figure 11 is a close-up cross-sectional view of the twisted pair of Figure 10

[0036] Figure 12 ​​​​is a magnified cross-sectional view of a twisted pair cable including dielectric strips having alternative shapes according to a sixth embodiment of the present invention. DETAILED DESCRIPTION

[0037] The present invention will now be described more fully with reference to the accompanying drawings, in which embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art.

[0038] Like reference numerals refer to like elements throughout. In the drawings, the thickness of certain lines, layers, components, elements, or features can be exaggerated for clarity. The dashed lines indicate optional features or operations.

[0039] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an overly idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions can not be described in detail for brevity and / or clarity.

[0040] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as "between approximately X and Y" and "between about X and Y" should be interpreted to include X and Y. As used herein, phrases such as "between about X and Y" mean "between about X and about Y." As used herein, phrases such as "from about X to Y" mean "from about X to about Y."

[0041] It will be understood that when an element is referred to as being "on" another element, "attached" to another element, "connected" to another element, "coupled" to another element, "in contact" with another element, etc., it can be directly on, attached to, connected to, coupled to, in contact with, or some other relationship, or there can be one or more intervening elements. Conversely, when an element is referred to as being "directly on", "directly attached" to, "directly connected" to, "directly coupled" to, or "directly in contact" with another element, there are no intervening elements. It will also be understood that references to structures or features that are "adjacent" to one another can have portions that are overlapping or underlapping one another.

[0042] For purposes of the description hereinafter, spatially relative terms, such as "below", "lower", "down", "above", "upper", "lateral", "left", "right", and the like, can be used herein for describing the relative positioning of one element or feature to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the description of relative spatial relationships herein interpreted accordingly.

[0043] Generally, the twisted pair network cable according to the present application is formed from conductors having a 21 AWG size, surrounded by a thin insulating layer. Several embodiments showing different configurations will now be described in detail. Figure 3 is a perspective view of a twisted pair cable 31 according to a first embodiment of the present application. Figure 4 is a cross-sectional view of the cable 31 taken along line IV-IV in Figure 3 The cable 31 includes a jacket 32 formed around and surrounding first, second, third, and fourth twisted pairs 33, 34, 35, and 36, respectively. The jacket 32 can be formed from polyvinyl chloride (PVC), low smoke zero halogen PVC, polyethylene (PE), fluorinated ethylene propylene (FEP), polyvinylidene fluoride (PVDF), ethylene chlorotrifluoroethylene (ECTFE), or other foamed or solid materials common in the wiring arts.

[0044] A divider 37 within the jacket 32 resides between and separates the first and fourth twisted pairs 33 and 36 from the second and third twisted pairs 34 and 35. In Figure 3 and Figure 4In this design, the separator 37 is formed from a thin strip of dielectric material with a thickness of about 15 mils or less, more preferably 13 mils or less, for example, about 7 to 12 mils. However, other sizes and shapes of the separator 37 can be used in conjunction with the invention, such as plus-shaped or star-shaped separators, which are sometimes referred to as grooves, spacers, or transverse webs. The separator 37 can be made of any solid or foamed material commonly found in the wiring industry, such as polyolefins or fluoropolymers, such as fluorinated ethylene propylene (FEP) or polyvinyl chloride (PVC).

[0045] like Figure 4 As best shown in the cross-sectional view, the first twisted pair 33 includes a first insulated conductor 38, a first dielectric strip 39, and a second insulated conductor 40. The first insulated conductor 38 and the second insulated conductor 40 are twisted in a helical manner, wherein the first dielectric strip 39 resides between the first insulated conductor 38 and the second insulated conductor 40.

[0046] The second twisted pair 34 includes a third insulating conductor 41, a second dielectric strip 42, and a fourth insulating conductor 43. The third insulating conductor 41 and the fourth insulating conductor 43 are twisted together in a spiral manner, wherein the second dielectric strip 42 resides between the third insulating conductor 41 and the fourth insulating conductor 43.

[0047] The third twisted pair 35 includes a fifth insulated conductor 44, a third dielectric strip 45, and a sixth insulated conductor 46. The fifth insulated conductor 44 and the sixth insulated conductor 46 are twisted together in a spiral manner, wherein the third dielectric strip 45 resides between the fifth insulated conductor 44 and the sixth insulated conductor 46.

[0048] The fourth twisted pair 36 includes a seventh insulated conductor 47, a fourth dielectric tape 48, and an eighth insulated conductor 49. The seventh insulated conductor 47 and the eighth insulated conductor 49 are twisted together in a spiral manner, wherein the fourth dielectric tape 48 resides between the seventh insulated conductor 47 and the eighth insulated conductor 49.

[0049] Figure 5is a magnified view of the first twisted pair 33, which is constructed similarly to the second, third, and fourth twisted pairs 34, 35, and 36, although the construction is not identical (as will be explained in detail later in the specification). Each of the first through eighth insulated conductors 38, 40, 41, 43, 44, 46, 47, 49 is formed of a conductor K surrounded by a layer of dielectric insulating material R, such as a polymer or foamed polymer commonly found in the wiring arts, such as fluorinated ethylene propylene (FEP), polyethylene (PE), or polypropylene (PP). In addition, the insulating material R can be formed of an enamel coating, or another non-conductive coating from a different field, such as motor armature windings. The conductor K can be solid or stranded, and can be formed of a conductive metal or alloy, such as copper. In a preferred embodiment, the conductor K is a solid copper wire of about 21 gauge size (i.e., about 28.5 mils in diameter).

[0050] In one embodiment, the radial thickness of the insulating material R can be less than about 8.65 mils, more preferably about 7 mils or less, more preferably about 6 mils or less, such as between about 5.2 mils and 5.8 mils. The radial thickness of this insulating layer R is at least 20% less, more preferably at least 25% to 30% less, than the standard insulating layer thickness of the conductors in the typical equivalent twisted pair in an insulated conductor of a network cable. Typically, such a thin insulating layer R is not possible because the conductors K of the first and second insulated conductors 38 and 40 become too close in spacing during the twisting operation, resulting in an incorrect nominal impedance being achieved. Typically, such a thin insulating layer is not practiced in the background art because a method to solve this mechanical and performance problem is not recognized. With the present invention, the interposed first dielectric strip 39 relieves the mechanical stresses during twisting so that the thinner insulating layer R is not damaged, and also spaces the conductors K apart so that a proper nominal impedance, such as 100 ohms, can be achieved.

[0051] As Figure 5As best shown, the first dielectric tape 39 has a first width extending from a first edge 51 of the first dielectric tape 39 to an opposite second edge 53 of the first dielectric tape 39 substantially perpendicular to an extent of the first dielectric tape 39. The first width is less than the diameter of the first insulated conductor 38 plus the diameter of the second insulated conductor 40 plus the thickness of the first dielectric tape 39, where the thickness is measured from the spacing created between the first and second insulated conductors 38 and 40. A typical spacing can be between 4 mils and 12 mils, such as about 8 mils or about 10 mils. With this arrangement, the twist of the first twisted pair 33 occupies the space within the dashed line 55 defined by the helical twist of the first and second insulated conductors 38 and 40. In this arrangement, the first through eighth insulated conductors 38, 40, 41, 43, 44, 46, 47, and 49, if adjacent, can be in contact with each other and can also contact the inner wall of the jacket 32.

[0052] In Figure 5 , the dielectric tape 39 is formed as a single structure (e.g., the dielectric tape does not include multiple elements attached together or layered). Figure 5A The solid dielectric tape 39 shown in Figure 5 may be replaced by a dielectric tape 39A having a hollow core filled with a gas (e.g., air) (dielectric constant of 1.0) or a foamed insulating material (dielectric constant close to 1.0). By filling the hollow core with a gas or a material having a lower dielectric constant than the material used to form the first dielectric tape 39 or 39A, the overall dielectric constant of the first dielectric tape 39A can be reduced. The hollow core can extend the entire length of the dielectric tape 39A, forming a "straw-like" structure. Alternatively, support structures can be formed at intervals along the length of the dielectric tape 39A to form closed-cell air pockets, each having a short length, such as ½ inch, 1 inch, 2 inches, etc. Alternatively, one or more support structures can be formed within the hollow core that extend along the length of the dielectric tape 39A and are connected between the lateral walls of the hollow core to prevent the hollow core from being crushed during the twisting of the first twisted pair 33A. While other embodiments of the dielectric tape of the present application are illustrated with solid cores, as described in connection with Figure 5A , hollow cores can be used in any or all of the other dielectric tapes. Figure 5A The first twisted pair 33A shown in Figure 4 may replace the first twisted pair 33 shown in

[0053] The first through fourth twisted pairs 33, 34, 35, and 36 can be twisted in the direction 57 (see Figure 3The strands are twisted together to form a core (see arrow 57 in FIG. 1). In one embodiment, the core twist direction 57 is opposite the twist direction of the twisted pairs 33, 34, 35, and 36. However, this is not a required feature, as in a preferred embodiment the twist direction 57 is the same as the twist direction of the twisted pairs. In a preferred embodiment, both the twist direction of the twisted pairs and the core twist are left-handed.

[0054] In a preferred embodiment, the core twist length is about six inches or less, and more preferably about five inches or less. In a more preferred embodiment, the core twist length is purposefully varied or modulated from an average twist length along the length of the cable 31. Core twist modulation can help reduce external crosstalk. For example, the core twist length can be modulated between 3 inches and 6 inches along the length of the cable 31, with an average of about 4.4 inches.

[0055] The first twist length w (see FIG. 1) of the first twisted pair 33 is preferably set to a short length, such as between about 0.22 inches and about 0.47 inches. The second twist length x of the second twisted pair 34 is different from the first twist length w and is between about 0.22 inches and about 0.47 inches. For example, the first twist length w can be set to about 0.405 inches, and the second twist length x can be set to about 0.438 inches. Figure 3 In one embodiment, the first twist length w is purposefully modulated from a first average (e.g., 0.405 inches). For example, the first twist length can be purposefully varied by a percentage range, such as + / - 30%, along the length of the cable. Likewise, the second twist length can be purposefully modulated from a second average (e.g., 0.438 inches). For example, the second twist length can be purposefully varied by the same or a different percentage range along the length of the cable.

[0056] The third twisted pair 35 can have a third twist length y, such as 0.607 inches, and the fourth twisted pair 36 can have a fourth twist length z, such as 0.683 inches. In one embodiment, the third twist length y is different from the first, second, and fourth twist lengths w, x, and z, and the fourth twist length z is different from the first, second, and third twist lengths w, x, and y. Of course, the third and fourth twisted pairs 35 and 36 can employ similar twist length modulation as described in connection with the first and second twisted pairs 33 and 34.

[0057]

[0058] Figure 6 ​is a magnified cross-sectional view of a twisted pair 60 according to a second embodiment of the present invention, the twisted pair including a dielectric tape 61 having an alternative shape. The dielectric tape 61 has a width extending from a first edge 62 of the dielectric tape 61 to an opposite second edge 63 of the dielectric tape 61 substantially perpendicular to an extension length of the twisted pair 60. In Figure 6 embodiments, the width is equal to or less than a diameter of the first insulated conductor 38. In Figure 6 embodiments, less material is used to form the dielectric tape 61. An advantage of doing so is to reduce the amount of consumable material in the event of a fire and to reduce the amount of smoke emitted from the cable 31 in the event of a fire. Such a construction can also reduce the weight and outer diameter of the cable and improve the flexibility of the cable. As Figure 6 shown, the dielectric tape 61 has a cross-sectional shape along a direction perpendicular to the extension length of the twisted pair 60 having a first recessed portion 64 for seating the first insulated conductor 38 and a second recessed portion 65 for seating the second insulated conductor 40.

[0059] Figure 5 and Figure 6 the cross-sectional shape of the dielectric tapes 39 and 61 in Figure 6 the first and second recessed portions 64 and 65 of the dielectric tape 61 in Figure 5 are semicircular. However, the first and second recessed portions 64 and 65 need not necessarily be semicircular. In fact, the recesses for receiving the first and second insulated conductors 38 and 40 in the dielectric tape 39 of

[0060] are not semicircular. In addition, the first and second recessed portions 64 and 65 can include serrations to form air pockets at the seating portions adjacent the first and second insulated conductors 38 and 40. Figure 7 Figure 6 Figure 6 is a cross-sectional view of a twisted pair cable 66 employing the first twisted pair 60 of The first, second, third, and fourth twisted pairs 60, 67, 68, and 69 are twisted to occupy respective spaces within the dashed line 55 (see

[0061] ). Figure 8is a magnified cross-sectional view of a twisted pair 70 according to a third embodiment of the present application, the twisted pair including a dielectric tape 71 having an alternative shape. The dielectric tape 71 has a width extending from a first edge 72 of the dielectric tape 71 to an opposite second edge 73 of the dielectric tape 71 substantially perpendicular to an extent of the twisted pair 70. In Figure 8 embodiments, the width is equal to or less than a diameter of the first insulated conductor 38.

[0062] Figure 8 embodiments show that the dielectric tape 71 need not have recessed portions 64 and 65 (as shown in Figure 5 and 6 ) to seat the insulated conductors 38 and 40. Rather, the dielectric tape 71 can be formed as a substantially flat member. Upon formation of the twisted pair 70, the dielectric tape 71 will be held between the first insulated conductor 38 and the second insulated conductor 40 due to frictional forces generated during the twisting operation.

[0063] Figure 8A is a magnified cross-sectional view of a twisted pair 70A according to a fourth embodiment of the present application, the twisted pair including a dielectric tape 71A having an alternative shape. The dielectric tape 71A has a width extending from a first edge 72A of the dielectric tape 71A to an opposite second edge 73A of the dielectric tape 71A substantially perpendicular to an extent of the twisted pair 70A. In Figure 8A embodiments, the width is equal to or slightly less than (e.g., 2 to 4 mils less than) a diameter of the first insulated conductor 38 plus a diameter of the second insulated conductor 40 plus a thickness of the dielectric tape 71A.

[0064] Figure 8A embodiments show that the dielectric tape 71A can be a substantially flat member having a width approximately equal to a diameter of the first insulated conductor 38 plus a diameter of the second insulated conductor 40 plus a thickness of the dielectric tape 71A, e.g., about 88 mils plus or minus about 5 mils.

[0065] Figure 8B is a cross-sectional view of a twisted pair cable 76 employing Figure 8A a first twisted pair 70A according to a preferred embodiment of the present application. The twisted pair cable 76 also includes second, third, and fourth twisted pairs 77, 78, and 79 of similar configuration. The twist of the first, second, third, and fourth twisted pairs 70A, 77, 78, and 79 occupies respective spaces within a dashed line 55 (see Figure 8A ). In this arrangement, the first through eighth insulated conductors 38, 40, 41, 43, 44, 46, 47, and 49 can contact a plus sign shaped divider 37A (sometimes referred to as a spacer, a groove, or a cross web) and can also contact inner ends of protrusions or fins 32A on an inner wall of the jacket 32. Figure 8BTwelve protrusions 32A are shown, however, more or less protrusions can be included with the goal of holding the cores of the twisted pairs 70A, 77, 78, and 79 in the center of the cable 76 while forming air pockets around the periphery of the cores of the twisted pairs.

[0066] Figure 9 is a perspective view of a twisted pair cable 81 according to a fifth embodiment of the present application. Figure 10 is a cross-sectional view of the cable 81 taken along the line X--X in Figure 9 The cable 81 includes a jacket 82 formed around and encasing first, second, third, and fourth twisted pairs 83, 84, 85, and 86, respectively.

[0067] As shown in Figure 9 and Figure 10 the fifth embodiment of the present application does not include the divider 37. However, a pair of dividers (sometimes referred to as bands, spacers, grooves, or cross webs) can optionally be included if desired.

[0068] As best shown in the cross-sectional view of Figure 10 the first twisted pair 83 includes a first insulated conductor 88, a first dielectric band 89, and a second insulated conductor 90. The first insulated conductor 88 is twisted in a helical manner with the second insulated conductor 90, with the first dielectric band 89 residing between the first insulated conductor 88 and the second insulated conductor 90.

[0069] The second twisted pair 84 includes a third insulated conductor 91, a second dielectric band 92, and a fourth insulated conductor 93. The third insulated conductor 91 is twisted in a helical manner with the fourth insulated conductor 93, with the second dielectric band 92 residing between the third insulated conductor 91 and the fourth insulated conductor 93.

[0070] The third twisted pair 85 includes a fifth insulated conductor 94, a third dielectric band 95, and a sixth insulated conductor 96. The fifth insulated conductor 94 is twisted in a helical manner with the sixth insulated conductor 96, with the third dielectric band 95 residing between the fifth insulated conductor 94 and the sixth insulated conductor 96.

[0071] The fourth twisted pair 86 includes a seventh insulated conductor 97, a fourth dielectric band 98, and an eighth insulated conductor 99. The seventh insulated conductor 97 is twisted in a helical manner with the eighth insulated conductor 99, with the fourth dielectric band 98 residing between the seventh insulated conductor 97 and the eighth insulated conductor 99.

[0072] Figure 11 is an enlarged view of the first twisted pair 83, which is constructed similarly to the second, third, and fourth twisted pairs 84, 85, and 86. As shown in Figures 3-8Embodiments similar to the first embodiment, each of the first through eighth insulated conductors 88, 90, 91, 93, 94, 96, 97, and 99 is formed from a conductor K (configured as a solid conductor or a stranded conductor having a 21 AWG size) surrounded by a layer of dielectric insulating material R. Further, the radial thickness of the insulating material R can be about 8.65 mils or less, such as 7 mils or less, and more preferably about 5 mils or less.

[0073] As Figure 11 As best shown, the first dielectric tape 89 has a first width extending from a first edge 101 of the first dielectric tape 89 to a second edge 103 of the first dielectric tape 89 substantially perpendicular to the length of extension of the first twisted pair 83. The first width is greater than the diameter of the first insulated conductor 88 plus the diameter of the second insulated conductor 90 plus the thickness of the first dielectric tape 89, where the thickness is measured from the spacing created between the first insulated conductor 88 and the second insulated conductor 90. A typical spacing can be between 4 mils and 12 mils, such as about 8 mils or about 10 mils. With this arrangement, the twist of the first twisted pair 83 occupies the space within the dashed line 105 defined by the helical twist of the first edge 101 and the second edge 103 of the first dielectric tape 89. In this arrangement, the first through eighth insulated conductors 88, 90, 91, 93, 94, 96, 97, and 99 do not contact each other or the inner wall of the jacket 82. Instead, a small air pocket 107 is maintained around the outer periphery of the dielectric insulating material R. Thus, the first insulated conductor 88 will be spaced apart from the inner wall of the jacket 82 by a first minimum distance, where the first minimum distance can be fixed in the range of 1 mil to 20 mils, such as 2 mils or 4 mils. Further, the first insulated conductor 88 will be spaced apart from any other insulated conductors of another twisted pair 84, 85, or 86 of the cable 81 by a second minimum distance. The second minimum distance can be equal to twice the first minimum distance because the small air pocket 107 of the first twisted pair 83 will be added to the small air pocket 107 of the other twisted pair 84, 85, or 86.

[0074] As Figures 3-5 With the first embodiment of the first through fourth twisted pairs 83, 84, 85, and 86 can be twisted together in a direction 109 (see arrow in Figure 9 ) to form a core. In one embodiment, the core twist direction 109 is opposite the twisted pair twist directions of the first through fourth twisted pairs 83, 84, 85, and 86. However, this is not a necessary feature. The core twist length and the twisted pair twist lengths w, x, y, and z can be tight, as described in connection with Figures 3-5 , and can be selectively modulated.

[0075] As Figure 11of the cross-sectional view, the first dielectric tape 89 includes a first recess 111 and a second recess 113 to accommodate the first insulated conductor 88 and the second insulated conductor 90. The first recess 111 and the second recess 113 can help to properly position the three portions 88, 89, and 90 of the first twisted pair 83 during the manufacturing process, and can also help to keep the three portions 88, 89, and 90 of the first twisted pair 83 in place during use of the cable 81 (e.g., pulling the cable through a conduit or pipe system). However, as shown in Figure 12 the many advantages of the present invention can still be realized even without the recesses 111 and 113.

[0076] Figure 12 is an enlarged cross-sectional view of a twisted pair 120 according to a sixth embodiment of the present invention, the twisted pair including a dielectric tape 121 having an alternative shape. The dielectric tape 121 has a width extending from a first edge 122 of the dielectric tape 121 to a second edge 123 of the dielectric tape 121 substantially perpendicular to the length of extension of the twisted pair 120. Like the embodiments of Figures 9-11 the width of the dielectric tape 121 is greater than the diameter of the first insulated conductor 88 plus the diameter of the second insulated conductor 90 plus the thickness of the first dielectric tape 121. The dielectric tape 121 can be formed as a substantially flat member. When the twisted pair 120 is formed, the dielectric tape 121 will be held between the first insulated conductor 88 and the second insulated conductor 90 due to the frictional forces generated during the twisting operation.

[0077] In the background art cable, each of the four twisted pairs employs a different twist length. The different twist lengths are advantageous in reducing crosstalk between adjacent twisted pairs within the cable. However, employing different twist lengths also presents some disadvantages, such as delay skew (e.g., a signal takes longer to travel to the far end of the cable on a relatively tighter twisted pair compared to a relatively longer twisted pair in the same cable). The different twist lengths also result in relative differences in performance characteristics of the twisted pairs, such as attenuation and impedance.

[0078] In the background art, the thickness and / or material composition of the insulation layer R is varied to compensate for the differences. For example, the insulation layer R of the insulated conductors 91 and 93 in the tighter twisted pair 84 Figure 9 may be formed of a material having a different dielectric constant than the insulation layer R of the insulated conductors 94 and 96 in the longer twisted pair 85 Figure 9 In addition, air can be introduced into the insulation layer R to foam the insulation layer R. The degree of foaming of one or more of the twisted pairs can be set to different degrees depending on the twist length of the twisted pair.

[0079] These measures of the background art help to counteract the performance characteristic differences caused by the different twist lengths of the twisted pairs. However, the insulated conductors used in different twisted pairs of the same cable have to be manufactured differently, which increases the costs. This requires an inventory of different types of insulated conductors and increases the complexity of the manufacturing process.

[0080] According to one embodiment of the present application, the insulated conductors 38, 40, 41, 43, 44, 46, 47, and 49 of each of the twisted pairs 33, 34, 35, and 36 in the cable 31 can be manufactured to be structurally identical (note that certain non-structural features, such as color, stripe pattern, or printed markings, can be employed to merely identify the insulated conductors from one another). In this embodiment of the present application, the dielectric tape structures can be used to mitigate the performance differences that arise when different twist lengths are employed in the twisted pairs. Furthermore, the insulated conductors 38, 40, 41, 43, 44, 46, 47, and 49 can be manufactured to be structurally identical and also identical in appearance. In this embodiment, the color or markings of the first through fourth dielectric tapes 39, 42, 45, and 48 can be used to distinguish the first through fourth twisted pairs 33, 34, 35, and 36 of the cable 31 when the cable 31 is terminated and the connectors are attached thereto.

[0081] For example, the dielectric tape of one twisted pair of a given cable can differ in shape, size, or material composition from the dielectric tape of another twisted pair in the same cable. In Figure 4 In the first twisted pair 33, the first dielectric tape 39 has a first thickness that sets the separation distance between the first insulated conductor 38 and the second insulated conductor 40. In the third twisted pair 35, the third dielectric tape 45 has a second thickness that sets the separation distance between the fifth insulated conductor 44 and the sixth insulated conductor 46. The second thickness is different from the first thickness, which also means that the shape of the first dielectric tape 39 is different from the shape of the third dielectric tape 45.

[0082] In one embodiment, the difference between the second thickness and the first thickness is at least 1 mil. For example, the first dielectric tape 39 can have a thickness of about 10 mils, and the third dielectric tape 45 can have a thickness of about 8 mils. This change in thickness and shape will affect the respective performance characteristics of the first twisted pair 33 and the third twisted pair 35, such as their respective attenuation, impedance, delay skew, etc.

[0083] Furthermore, in Figure 4 In the first twisted pair 33, the first dielectric tape 39 has a first width that extends from a first edge 51 of the first dielectric tape to a second edge 53 of the first dielectric tape (see FIG. 3) substantially perpendicular to the length of extension of the cable 31. In the third twisted pair 35, the third dielectric tape 45 has a second width that extends from a first edge 55 of the third dielectric tape to a second edge 57 of the third dielectric tape substantially perpendicular to the length of extension of the cable 31. The second width is different from the first width, which also means that the shape of the first dielectric tape 39 is different from the shape of the third dielectric tape 45. Figure 5). In the fourth twisted pair 36, the fourth dielectric strip 48 has a second width extending from a corresponding first edge 51 to a corresponding second edge 53 of the fourth dielectric strip substantially perpendicular to the length of extension of the cable 31. The second width is different than the first width. For example, the second width can be shorter than the first width by a number of mils, such as by about 2 mils to 12 mils, for example, by about 5 mils. Again, the respective differences in width will result in differences in performance characteristics that can be adjusted and used to offset the performance differences caused by the different twist lengths.

[0084] Again in Figure 4 the first dielectric strip 39 of the first twisted pair 33 is formed of a first material having a first dielectric constant. In the second twisted pair 34, the second dielectric strip 42 is formed of a second material having a second dielectric constant (as shown by the different thicknesses in the cross-sections). The second dielectric constant is different than the first dielectric constant. For example, the second dielectric constant can differ from the first dielectric constant by about 0.1 to about 0.8, for example, the first dielectric constant can be 1.2 and the second dielectric constant is 1.4, illustrating a difference in dielectric constant between the two materials of 0.2. Again, the respective differences in materials will result in differences in performance characteristics that can be adjusted and used to offset the performance differences caused by the different twist lengths. Of course, the differences between the dielectric strips can also be combined with the differences in the insulation layers on the insulated conductors as a supplement to provide additional ability to compensate for the performance differences between the twisted pairs.

[0085] The cables 31, 66, 76, and 81 of the present application can be manufactured using standard twisting equipment, such as a double-twist balun machine known in the art of twisted pair cable manufacturing. Additional spools can be added to feed the dielectric strips into the twisting machine and between the insulated conductors of the twisted pairs. More manufacturing details regarding similar cables that take 23 AWG conductors that are not able to transmit data and Power over Ethernet (PoE) over the same distances as the cables of the present application have been shown in Applicant’s issued U.S. Patents 11,424,052; 10,573,430; 9,978,480; 9,418,775; and 7,999,184, which are incorporated herein by reference.

[0086] While the cable shown in the drawings includes four twisted pairs, it should be understood that the present application is not limited to cables having only four twisted pairs. Cables having other numbers of twisted pairs (e.g., one twisted pair, two twisted pairs, or even twenty-five twisted pairs) can benefit from the structures disclosed in the present application. Further, while the drawings show that each of the twisted pairs within the cable has a dielectric tape, not all of the twisted pairs have a dielectric tape. For example, the first through third twisted pairs can include a dielectric tape, while the fourth twisted pair can be formed without a dielectric tape. Further, while the drawings show unshielded cables, the cables can include a shield layer and / or a core wrap between the cores of the twisted pairs and the inner wall of the outermost jacket are within the scope of the appended claims. Further, while some of the drawings have shown jackets with smooth inner walls, the inner walls of the jackets in all embodiments can include fins or protrusions (as shown in Figure 8B the scope of the present application. Further, all embodiments of the present application can include a separator (e.g., a tape, a spacer, a groove, a cross web). Further, all embodiments of the present application can include a dielectric tape formed as a single structure, such as 71, 121 (e.g., the dielectric tape does not include multiple elements attached together or layered).

[0087] Cables with 21 AWG conductors made in accordance with several embodiments of the present application have been constructed and tested with good performance results. Test data for the cables are contained in Applicant’s priority provisional application serial number 63 / 555,203, filed February 19, 2024, which is incorporated herein by reference. In the embodiments tested, each twisted pair included first and second insulated conductors of 21 AWG size. Each twisted pair had a split tape between the twisted first and second insulated conductors. The 21 AWG conductors allowed longer distance data transmission and Power over Ethernet (PoE), such as extended reach distances. The thinner wall of the insulation layer on the 21 AWG conductors allowed the network cable to terminate to industry standard RJ45 jacks and plugs that are designed to accommodate 22-24 AWG insulated conductors, while the dielectric tape between the insulated conductors of the twisted pairs maintained the 100 ohm nominal impedance required for each insulated conductor twisted pair.

[0088] The network cable of the present invention can be made into plenum, riser, outdoor, and LSZH (low smoke zero halogen) products. The network cable construction can include cross webbing separators or flat band separators. Alternatively, no cross webbing separators or flat band separators can be used in the cable core. The network cable can be shielded or unshielded. In a preferred embodiment, both twist modulation and strand modulation are used. For the first through fourth twisted pairs, the preferred average twist length is about 0.683", 0.405", 0.607" and 0.438", while the average core strand lay is about 4.4". In a preferred embodiment, the twist direction and strand lay direction of all twisted pairs is left-handed.

Claims

1. A Power over Ethernet (PoE) network cable, comprising: Four insulated conductor twisted pairs; as well as A sheath surrounding the four insulated conductor twisted pairs, wherein each insulated conductor twisted pair comprises: A first insulating conductor, the first insulating conductor having a first conductor of 21AWG or greater surrounded by a first layer of a first dielectric insulating material; First dielectric band; and The second insulating conductor has a second conductor of 21AWG or larger surrounded by a second layer of second dielectric insulating material, wherein the first insulating conductor and the second insulating conductor are twisted together such that the first dielectric strip resides between the first insulating conductor and the second insulating conductor to form a twisted pair.

2. The cable according to claim 1, wherein, The first layer of the first dielectric insulating material has a radial thickness of 8.65 mils or less, and the second layer of the second dielectric insulating material has a radial thickness of 8.65 mils or less, thereby each of the first insulating conductor and the second insulating conductor has a total outer diameter of 45.8 mils or less.

3. The cable according to claim 1, wherein, The first layer of the first dielectric insulating material has a radial thickness of 7 mils or less, and the second layer of the second dielectric insulating material has a radial thickness of 7 mils or less, thereby each of the first insulating conductor and the second insulating conductor has a diameter of 42.5 mils or less.

4. The cable according to claim 1, wherein, The first layer of the first dielectric insulating material has a radial thickness of 6 mils or less, and the second layer of the second dielectric insulating material has a radial thickness of 6 mils or less, thereby each of the first insulating conductor and the second insulating conductor has a diameter of 40.5 mils or less.

5. The cable according to claim 1, wherein, The first layer of the first dielectric insulating material has a radial thickness of about 5.2 mils, and the second layer of the second dielectric insulating material has a radial thickness of about 5.2 mils, so that each of the first insulating conductor and the second insulating conductor has a diameter of about 38.9 mils.

6. The cable according to claim 1, wherein, The radial thickness of the first layer of the first dielectric insulating material is between 4 mils and 7 mils, and the radial thickness of the second layer of the second dielectric insulating material is between 4 mils and 7 mils.

7. The cable according to claim 1, wherein, The twist lengths of the four insulated conductor twisted pairs are set to different median values ​​and are intentionally modulated from their median values.

8. The cable according to claim 1, wherein, The four insulated conductors are twisted together to form a strand core, the strand length of which is approximately 4 to 5 inches.

9. The cable according to claim 8, wherein, The strand length of the strand core is modulated along the length of the cable.

10. The cable according to claim 1, further comprising: The flat strip separator within the sheath is positioned to separate the first and second twisted pairs of the four insulated conductor twisted pairs from the third and fourth twisted pairs of the four insulated conductor twisted pairs.

11. The cable according to claim 1, further comprising: The cross-shaped web separator within the sheath is positioned to separate each of the four insulated conductor twisted pairs from the other four insulated conductor twisted pairs.

12. A Power over Ethernet (PoE) network cable, comprising: Four insulated conductor twisted pairs, each with a nominal impedance of 100 ohms; as well as A sheath surrounding the four insulated conductor twisted pairs, wherein each insulated conductor twisted pair comprises: A first insulating conductor, the first insulating conductor having a first conductor body of 21 AWG or greater surrounded by a first layer of a first dielectric insulating material with a radial thickness of 8.65 mils or less; and The second insulating conductor has a second conductor of 21 AWG or greater surrounded by a second layer of a second dielectric insulating material with a radial thickness of 8.65 mils or less, whereby each of the first and second insulating conductors has a total outer diameter of 45.8 mils or less.

13. The cable according to claim 12, wherein, The first layer of the first dielectric insulating material has a radial thickness of 7 mils or less, and the second layer of the second dielectric insulating material has a radial thickness of 7 mils or less, thereby each of the first insulating conductor and the second insulating conductor has a diameter of 42.5 mils or less.

14. The cable according to claim 12, wherein, The first layer of the first dielectric insulating material has a radial thickness of 6 mils or less, and the second layer of the second dielectric insulating material has a radial thickness of 6 mils or less, thereby each of the first insulating conductor and the second insulating conductor has a diameter of 40.5 mils or less.

15. The cable according to claim 12, wherein, The first layer of the first dielectric insulating material has a radial thickness of about 5.2 mils, and the second layer of the second dielectric insulating material has a radial thickness of about 5.2 mils, so that each of the first insulating conductor and the second insulating conductor has a diameter of about 38.9 mils.

16. The cable according to claim 12, wherein, The twist lengths of the four insulated conductor twisted pairs are set to different median values ​​and are intentionally modulated from their median values.

17. The cable according to claim 12, wherein, The four insulated conductors are twisted together to form a strand core, wherein the strand length of the strand core is approximately 4 to 5 inches.

18. The cable according to claim 17, wherein, The strand length of the strand core is modulated along the length of the cable.

19. The cable according to claim 12, further comprising: The flat strip separator within the sheath is positioned to separate the first and second twisted pairs of the four insulated conductor twisted pairs from the third and fourth twisted pairs of the four insulated conductor twisted pairs.

20. The cable according to claim 12, further comprising: The cross-shaped web separator within the sheath is positioned to separate each of the four insulated conductor twisted pairs from the other four insulated conductor twisted pairs.

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