Systems and methods for forming wires and cables

Abstract

A system and method for manufacturing wires and cable products having polymeric cable assemblies is provided. The systems and methods include increasing the stiffness of the polymeric cable assembly in order to reduce compression and deformation of the cable assembly during manufacture. In some cases, the hardness is temporarily increased before or during the process of forming twisted pairs or during the cabling process. In particular applications, the Young's modulus of the insulated wire is increased during the twisting process by controlling convective heat transfer.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 408,724, filed on September 21, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates to forming communication cables and, more particularly, to modulating the stiffness of a polymer cable component to form a high performance communication cable having a reduced crush ratio. Background Art

[0004] When transmitting power or signals, various approaches may be utilized. The invention disclosed herein generally focuses on wire and cable products that utilize insulated coated conductors to transmit electrical current. Summary of the invention

[0005] Technical issues

[0006] When designing wire and cable products, many factors must be considered. Applications such as Ethernet, CATV, and systems based on factory floors can specify certain design features such as size, electrical characteristics, and physical properties. In the case of size, the coordination of cables in standard connections, pipes, raceways, and pipelines may be important. For electrical characteristics, capacitance, inductance, DC resistance, current, and voltage carrying capacity may be design considerations. For some specialized high-bandwidth cables, additional electrical parameters such as attenuation, propagation velocity, delay skew, impedance, insertion loss, and noise mitigation may be important. For physical properties, flame and smoke resistance, chemical resistance, ozone resistance, moisture resistance, and / or pull strength are common properties that need to be considered. Fortunately, when considering the best options for building wire and cable products, there are many tools and equations that can be used to help design engineers.

[0007] The process of manufacturing wires and cables is essentially continuous. Continuous production lines usually include pay-outs, where material is paid out or distributed to start the line process. There may be an accumulator that helps to retain a portion of the material being paid out to promote a consistent line speed. Usually there is a collection at the end of the line process, which may also have an accumulator so that the manufactured product can be manufactured at a consistent line speed and the finished product can be collected on a drum or other form of packaging. These types of operations may include: insulation, twisting, cabling, braiding, jacketing, and building wire and cable products into set lengths, etc. For most wire and cable products, the first step is the insulation process. This situation is to coat or cover the conductor with a polymer material to electrically insulate the conductor.

[0008] During and after the insulation process, it is likely that forces will be encountered that can affect the ability of the final product to meet the intended specifications. For example, in the case of a coaxial type cable, it is desirable to add a foil and / or metal braid to protect the inner insulation layer and the electrical signals contained therein. It is well known that metal braiding devices can create indentations along the surface of the insulation it wraps around. In other words, the bare strands of the braided shield will deform the underlying insulation surface because the insulation surface is generally softer than the metal wires applied to it. These deformations in the insulation can affect the ability of the final cable to transmit signals as capacitance and insertion loss increase. To account for these indentations, design engineers can add additional insulation material to account for the depth of the indentations.

[0009] In the case of multi-conductor cables, the various insulated conductors are brought together by a twisting mechanism commonly referred to as a twinner, a buncher, or a cabler. The forces encountered in each of these mechanisms can compress and deform the polymer components of the cable. Again, the cable designer is likely to increase insulation to compensate for any compression, thereby increasing the size and cost of the final product. Similar compressive forces may be experienced during jacketing and construction operations. In order to compensate for any deformation caused by the compressive forces, a thicker and / or harder jacket layer may be used, which increases the size and cost of the final product.

[0010] Sometimes the adverse forces or compressive forces acting on the cable assembly can be cyclic in nature. For example, if the wheel is not aligned correctly, it may oscillate back and forth as it moves laterally in a circular rotation. This can produce a sinusoidal deformation of the material. If this sinusoidal pattern matches the expected frequency of the application (or any harmonics thereof), signal integrity may be compromised. Whether consistent or sinusoidal in nature, existing methods to help reduce the effects of such forces include reducing production line speeds. Speeds can be reduced to mitigate and reduce the compressive forces caused by manufacturing equipment when manufacturing products. To do this, the equipment is typically operated at a fraction of its potential speed. However, this is undesirable because the equipment cannot be utilized to its full potential.

[0011] Another way that compression forces can potentially create problems is with capacitance targets. Capacitance is a function of the distance between metal surfaces and the properties of the materials between those metal surfaces. In the case of wires and cables, the conductive surfaces can include two conductors in close proximity or a shield and conductor in close proximity, among other things. The distance between these conductive surfaces is a key design consideration in the manufacture of wire and cable products. So care should be taken to ensure that the proper conductor-to-conductor distance is achieved.

[0012] In some embodiments, two insulated conductors are formed together to produce a twisted pair. Similarly, many insulated conductors can be formed together to produce a multi-conductor cable unit. In the case of twisting two insulated conductors together, a spiral pattern is achieved along the length of the twisted pair unit. The twisted pair unit is usually composed of a metal conductor, an insulating material, and air contained in the gap between two substantially circular insulated conductors. As is well known, air is a very ideal dielectric material. For example, air has a dielectric constant of 1.0, wherein materials such as polyolefins have a typical dielectric constant range between 2.3 and 2.6. Therefore, the more air is preserved in the gap of the twisted pair unit, the more ideal the electrical effect. However, when the compressive force encountered during the cabling process brings these insulated conductors closer together, the insulating material may be displaced into these gaps, thereby reducing the total air content. The result can lead to higher, usually less desirable capacitance, and in some cases, lead to a reduced signal speed that can reduce the signal propagation capability.

[0013] Insulated conductors, such as twisted pair communications cables, are used for high frequency signal transmission, typically in plenum areas of buildings. In twisted pair data cable implementations, individual conductors are insulated using a polymer, and then two such insulated conductors are twisted around each other to form a single twisted pair. Twisted pair cables are typically comprised of multiple twisted pairs contained within a single outer sheath to form the cable. The individual twisted pairs within the cable may be twisted with different lays (conventionally measured in mm / turn) to reduce electrical coupling (i.e., crosstalk) between adjacent twisted pairs.

[0014] The process of twisting the individual insulated conductors together generally compresses the polymer insulation. The magnitude of the force that compresses the insulation varies with the twisting equipment and the tightness of the twist (i.e., the number of turns per inch). The compressive forces caused by twisting the insulated conductors result in deformation of the insulation separating the two conductors and a reduction in the thickness of the insulation. This results in an increase in the capacitance measured between the two conductors, thereby reducing the overall impedance of the twisted pair unit. In some cases, the compression results in a loss of air content in the gaps of the twisted pair or a loss of air content from the foam insulation.

[0015] In order to compensate for this undesirable loss of insulation thickness, polymer insulated wire manufacturers usually increase the thickness of the polymer insulation material. The shorter the lay, the tighter the twist, and the greater the crush or compression of the polymer insulation material (whether foamed or solid). Some twisted pairs are designed to have 100 ohm impedance. The center-to-center spacing of the conductors in the twisted pair is a key factor affecting impedance. Therefore, because the increased compression brings the conductors closer together, additional insulation thickness is required to maintain the desired conductor-to-conductor spacing and impedance as the twist length becomes shorter. Increasing the amount of polymer insulation used leads to an increase in total cable weight, cable size and cost.

[0016] What is needed is a new method and apparatus for controlling the deformation of the insulation layer during cable manufacturing to produce a polymer insulated cable that maintains the desired spacing of the conductors by controlling the amount that the insulated conductors are compressed together. Controlling the deformation can help maintain the desired impedance and other electrical and mechanical properties before and after twisting. Controlling the deformation of the insulation layer caused by braiding, mechanical devices such as sheaves (wheels) and take-ups, and non-metallic substrates such as cross-mesh fillers also help maintain the desired electrical and mechanical properties of the cable.

[0017] There is also a need for a method of modulating the deformation of insulation during cable manufacturing to obtain desired impedance, electrical and mechanical properties. Increased control of such properties can be obtained by controlling the hardness and / or stress / strain response of the insulation. The response of the compressive properties of insulation is usually described in terms of Young's modulus.

[0018] It should also be mentioned that in the case of torsion (a type of force encountered when insulated conductors are twisted together), the deformation may not be uniform. This is because the insulating material may be displaced disproportionately depending on the direction of the torsion. This is particularly undesirable in balanced pair applications. For example, in some applications involving a twisted pair unit with two insulated conductors, it is desired that the signal in each conductor of the two insulated conductors is a mirror image of the signal in the other conductor. In this way, the electrical noise coupled to each insulated conductor of the twisted pair unit is coupled in the same manner, thereby allowing the electronic filtering mechanism to offset the noise element. When the shape of one insulated conductor in a pair is not proportional, it becomes challenging to subtract any noise element from the desired signal. Typically, the specifications of wire and cable products have both near-end crosstalk specifications and far-end crosstalk specifications to ensure that the amount of noise between the transmission pairs is low enough not to hinder signal transmission. If the balance of the insulated conductors is not good, the ability to meet these specifications becomes more difficult.

[0019] When cable designers consider how much additional insulation material is needed to compensate for any insulation displacement or deformation caused by the forces encountered during the manufacturing process, the softness of the insulation material must be understood. Since these displacements and deformations are usually permanent in nature, the hardness of the composite is best understood. Hardness (usually expressed in Pascals) measures the surface deformation resistance of the material. In other words, hardness is the localized surface deformation resistance. Indentation hardness can be measured in various ways, including Britnell, Meyer, Vickers, Rockwell, and / or Shore durometers. For polymer materials (such as fluorinated ethylene propylene (fluorinated Ethylene Propylene (FEP)), polyethylene (PE), polypropylene (PP), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyvinyl chloride (PVC), etc.), Shore D hardness scale is usually used. For other materials (such as rubber), other Shore scales, such as Shore A, can be used. In the case of Shore D, the test protocol is defined in ASTM D2240 and / or ISO 868 and will be used herein as the baseline hardness reference.

[0020] It will be appreciated that changes in ambient temperature conditions can affect the softness of the material. For example, in warm weather climates, temperature control of the production floor may be necessary during months when the ambient temperature is seasonally high, thereby reducing the hardness of any polymeric materials in the production floor. Additionally, heat is generated within the cable assembly when subjecting the cable assembly to compression, torsion, or other deformation forces. In some applications, the forces involved increase the temperature of the assembly above the ambient temperature as the assembly deforms, thereby reducing the hardness of the assembly and increasing the assembly's sensitivity to deformation under this and any subsequent deformation events.

[0021] Conversely, if the composite is cooled below ambient temperature, the hardness of the composite can increase. Such hardening can make the material more resistant to compressive forces that can deform the material or cause indentations in the material.

[0022] The temperature adjustment need not last beyond the compression event. Since the deformations discussed herein are permanent in nature (i.e., not elastic), the disclosed methods need only be applied before or during the compression event. Once the compression event is over, the material can be allowed to return to ambient temperature. Other methods previously described are more permanent in nature (such as slowing the machine, adding a skin, or adding a harder material to the insulation). By utilizing a temporary adjustment of the material's hardness, many of the adverse effects of these solutions can be avoided.

[0023] It would be desirable in the industry to have a method of hardening a composite or reducing the applied compressive forces that is less costly than adding insulating material to counteract the effects of deformation of a polymer cable assembly. It would also be desirable that any method incorporated to reduce the effects of compressive forces on the insulating material could be adapted within the current mechanical footprint with little modification to the positioning of the equipment itself. One such method is to control the temperature of the composite to produce a hardness shift in the composite. It will be appreciated that a harder composite is less affected by compressive forces than a softer composite. When the Shore D scale is used, a higher number indicates a harder state of the composite. This assumes the same material type, where the only change is the temperature of the material itself.

[0024] As explained previously, reducing deformation caused by forces encountered during the manufacturing process can improve performance and reduce costs. Both can be achieved by shifting the material hardness through a temporary temperature change.

[0025] By increasing the stiffness of a polymer cable component, deformation of polymer insulation, cross-web filler, polymer tube, or other polymer cable components can be reduced. Such deformation is typically caused by compressive or torsional forces during manufacturing operations such as twisting, braiding, operation of mechanical devices such as sheaves (wheels) and take-ups.

[0026] What is needed is an economical way to increase the stiffness of a material. What is needed is a method of cooling an insulating material at or near the point where a compressive force is applied. In this way, the stiffness of the material can be increased relative to its stiffness at ambient temperature and any deformation caused by the compressive force can be reduced.

[0027] Technical Solution

[0028] The present disclosure generally relates to the manufacture of wire and cable products that incorporate methods for temporarily changing the material hardness and / or stress / strain response, which is typically defined by Young's modulus. The response of the insulation to stress and strain forces can be shifted by controlling the temperature of the insulation layer surrounding the wire. Maintaining low temperatures will result in a shift in the Young's modulus response, as will an increase in temperature. This is particularly true for polymer insulation materials, as most such materials soften at higher temperatures. Some disclosed embodiments relate to methods and devices for increasing the hardness and / or stress / strain response of polymer insulation materials, which can be used online as part of a continuous or semi-continuous manufacturing process. Some disclosed embodiments relate to a method for reducing the effects of compressive forces on a polymer cable assembly, the method comprising the following steps: providing a polymer cable assembly having a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; subjecting the polymer cable assembly to a compressive force; and restoring the polymer cable assembly to the first hardness.

[0029] Some disclosed embodiments relate to a method of forming a twisted pair, the method comprising the steps of providing a first polymer insulated conductor, the first polymer insulated conductor comprising a first conductor electrically insulated by a first polymer insulation layer, and providing a second polymer insulated conductor, the second polymer insulated conductor comprising a second conductor electrically insulated by a second polymer insulation layer; exposing the first insulated conductor to a cryogenic fluid; and twisting the first polymer insulated conductor and the second polymer insulated conductor around each other to form a twisted pair.

[0030] It has also been found that by controlling the convective heat transfer, the temperature of the insulated wire can be effectively controlled during the twisting process. Heat transfer between the wire and the atmosphere (or other fluid) is efficient, and if the convective heat transfer can be controlled, the temperature of the wire can be controlled. This can be achieved using little energy by partially or completely shielding the insulated wire from the air or other fluid while it is being processed on a rotating yoke in the twisting unit.

[0031] Some disclosed embodiments relate to a method for controlling the effects of compressive forces on a polymer cable assembly, the method comprising the steps of: providing a polymer cable assembly having a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; subjecting the polymer cable assembly to a compressive force in a twisting machine having a bow, wherein the polymer cable assembly is at least partially shielded from convective heat transfer while it is in the bow; and allowing the polymer cable assembly to return to the first hardness.

[0032] Some disclosed embodiments relate to a method for manufacturing a communication cable, the method comprising the steps of: providing a polymer cable assembly having a first cross-sectional radius and a second cross-sectional radius, wherein the first cross-sectional radius is a maximum distance along the cross-section from a center of the polymer cable assembly to an edge of the polymer cable assembly, and the second cross-sectional radius is a minimum distance along the cross-section from the center of the polymer cable assembly to an edge of the polymer cable assembly, and wherein the first cross-sectional radius is approximately equal to the second cross-sectional radius + / - 3%, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; and subjecting the polymer cable assembly to a compressive force in a twisting unit having a bow, wherein the polymer cable assembly is at least partially shielded from convective heat transfer when it is in the bow, and wherein, after the compressive force, the first cross-sectional radius is approximately equal to the second cross-sectional radius ±10%.

[0033] Some disclosed embodiments relate to a method for manufacturing a communication cable, the method comprising the steps of: providing a polymer cable assembly having a first cross-sectional radius and a second cross-sectional radius, wherein the first cross-sectional radius is a maximum distance along the cross-section from a center of the polymer cable assembly to an edge of the polymer cable assembly, and the second cross-sectional radius is a minimum distance along the cross-section from the center of the polymer cable assembly to an edge of the polymer cable assembly, and wherein the first cross-sectional radius is approximately equal to ±3% of the second cross-sectional radius, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; and subjecting the polymer cable assembly to a compressive force in a twisting unit having a bow frame, wherein the polymer cable assembly is at least partially shielded from convective heat transfer when in the bow frame, and wherein, after the compressive force, the first cross-sectional radius is approximately equal to ±10% of the second cross-sectional radius.

[0034] Some disclosed embodiments relate to a method for manufacturing a communication cable, the method comprising the following steps: providing a polymer cable assembly having a first diameter and a second diameter, wherein the first diameter and the second diameter are perpendicular to each other, and wherein the first diameter is approximately equal to ±3% of the second diameter, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; and subjecting the polymer cable assembly to a compressive force in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow, wherein, after the compressive force, the first diameter is approximately equal to ±10% of the second diameter; and allowing the polymer cable assembly to recover to the first hardness.

[0035] Some disclosed embodiments relate to a method for manufacturing a communication cable, the method comprising the following steps: providing a first pair of polymer insulated conductors, a second pair of polymer insulated conductors, a third pair of polymer insulated conductors, and a fourth pair of polymer insulated conductors, wherein each pair of polymer insulated conductors includes two polymer insulated conductors, and wherein each polymer insulated conductor has a first hardness, wherein the first hardness is the hardness of the polymer insulated conductor under environmental conditions; temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, and the third pair of polymer insulated conductors to a second hardness, wherein the second hardness is different from the first hardness; twisting the polymer insulated conductors in the first pair of polymer insulated conductors together to form a first twisted pair, the first twisted pair having a first propagation delay over 100 meters; twisting the polymer insulated conductors in the second pair of polymer insulated conductors together to form a second .... The two twisted pairs have a second propagation delay over 100 meters; the polymer insulated conductors in the third pair of polymer insulated conductors are twisted together to form a third twisted pair, the third twisted pair has a third propagation delay over 100 meters; and the polymer insulated conductors in the fourth pair of polymer insulated conductors are twisted together to form a fourth twisted pair, the fourth twisted pair has a fourth propagation delay over 100 meters, wherein for the first propagation delay, the second propagation delay, the third propagation delay, and the fourth propagation delay over 100 meters, the propagation delay difference over 100 meters is within 50 nanoseconds of each other; wherein the step of twisting the polymer insulated conductors of at least one pair of the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors and the fourth pair of polymer insulated conductors includes: feeding the polymer insulated conductors into a bow frame of a twisting unit, wherein the polymer insulated conductors are at least partially shielded in the bow frame from the influence of convective heat transfer.

[0036] Some disclosed embodiments relate to a method for manufacturing a communication cable, the method comprising the following steps: providing a first pair of polymer insulated conductors and a second pair of polymer insulated conductors, wherein each pair of polymer insulated conductors includes two polymer insulated conductors, and wherein each polymer insulated conductor has a first hardness, wherein the first hardness is the hardness of the polymer insulated conductor under environmental conditions; temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors to a second hardness, wherein the second hardness is different from the first hardness; twisting the polymer insulated conductors in the first pair of polymer insulated conductors together in a bow frame of a twisting unit, wherein the polymer insulated conductors are at least partially shielded from convective heat transfer in the bow frame to form a first twisted pair, the first twisted pair having a first propagation delay over 100 meters; and twisting the polymer insulated conductors in the second pair of polymer insulated conductors together to form a second twisted pair, the second twisted pair having a second propagation delay over 100 meters, wherein the first propagation delay over 100 meters and the second propagation delay over 100 meters are within 25 nanoseconds of each other.

[0037] Some disclosed embodiments relate to a system for manufacturing wire and cable products, the system for manufacturing wire and cable products comprising: a payout device, the payout device being configured to pay out a polymer cable assembly; a cooling container, the cooling container being configured to receive the polymer cable assembly, wherein the cooling container contains a cryogenic fluid; a take-up device, the take-up device being configured to tighten the polymer cable assembly; and a twisting machine, the twisting machine being configured to receive a first polymer insulated conductor and a second polymer insulated conductor and form a twisted pair, the twisting machine comprising a bow frame in the fluid, the bow frame comprising a device for shielding the insulated conductor from the effects of convective heat transfer with the fluid when the bow frame rotates.

[0038] Some disclosed embodiments relate to a system for manufacturing wire and cable products, the system for manufacturing wire and cable products comprising: a payout device, the payout device being configured to pay out a polymer cable assembly; and a take-up device, the take-up device being configured to tighten the polymer cable assembly; and a twisting machine, the twisting machine being configured to receive the first polymer insulated conductor and the second polymer insulated conductor and form a twisted pair, the twisting machine comprising a bow in a fluid, the bow comprising a device for shielding the insulated conductor from the effects of convective heat transfer with the fluid when the bow rotates.

[0039] Some disclosed embodiments relate to a method of manufacturing a low combustible loading wire and cable product, the method comprising the steps of: establishing desired electrical characteristics of the wire and cable product, wherein the wire and cable product comprises a polymer cable assembly, wherein the polymer cable assembly has a first combustible loading and a first hardness, and wherein the polymer cable assembly has a flame travel distance equal to or less than about five feet, a smoke peak optical density equal to or less than about 0.5, and an average optical density equal to or less than about 0.15 when measured according to the Steiner Tunnel Test Method of ASTM E84, and wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; and compressing the polymer cable assembly by subjecting the polymer cable assembly to a compressive force while the polymer cable assembly is at the second hardness in a twisting unit having a bow. The assembly causes a first deformation, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow frame; the wire and cable products are formed using the polymer cable assembly, wherein when the polymer cable assembly is deformed to the first deformation amount, the wire and cable products meet the established desired electrical characteristics, but if the polymer cable assembly is deformed to a second deformation amount, the wire and cable products will not meet the desired electrical characteristics, wherein the second deformation amount is the amount by which the polymer cable assembly will deform when subjected to the compressive force when the polymer cable assembly is at the first hardness.

[0040] Some disclosed embodiments relate to a rotating gantry for use in a twisting unit for making twisted pairs of insulated conductors, wherein the gantry is used in a fluid, the gantry including means for shielding the insulated conductors from convective heat transfer with the fluid as the gantry rotates.

[0041] Some disclosed embodiments relate to a method of manufacturing a twisted pair of insulated conductors having improved resistance to crushing, the method comprising the steps of: cooling a first insulated conductor to increase the hardness of the first insulated conductor; cooling a second insulated conductor to increase the hardness of the second insulated conductor; feeding the first insulated conductor and the second insulated conductor into a bow of a twisting unit in the presence of a fluid; and at least partially shielding the insulated conductors from convective heat transfer from the fluid when the bow rotates.

[0042] Some disclosed embodiments relate to a method of manufacturing a twisted pair of insulated conductors having improved resistance to crushing, the method comprising the steps of cooling the atmosphere within a twisting unit to below ambient temperature; feeding a first insulated conductor and a second insulated conductor into a bow of the twisting unit; and at least partially shielding the insulated conductors from convective heat transfer from the cooled atmosphere within the twisting unit as the bow rotates.

[0043] Some embodiments relate to a method for manufacturing a twisted pair of insulated conductors having a predetermined impedance, the method comprising the steps of: feeding a first insulated conductor and a second insulated conductor into a rotating bow frame as part of a twisting machine in the presence of a fluid, wherein the first insulated conductor includes a first conductor surrounded by a first insulator, and wherein the second insulated conductor includes a second conductor surrounded by a second insulator; controlling convective heat transfer between the first insulated conductor and the second insulator and the fluid to control the temperature of the first insulator and the second insulator, thereby imparting hardness to the first insulator and the second insulator; and twisting the first insulated conductor with the second insulated conductor to form a twisted pair, wherein the first insulated conductor and the second insulated conductor undergo an amount of deformation during twisting that is a function of the hardness, and wherein the impedance of the twisted pair is a function of the degree of deformation.

[0044] Some embodiments relate to a method for manufacturing a twisted pair of insulated conductors within a predetermined impedance tolerance range, the method comprising the steps of: feeding a first insulated conductor and a second insulated conductor into a rotating bow frame as part of a twisting machine in the presence of a fluid, wherein the first insulated conductor includes a first conductor surrounded by a first insulator, and wherein the second insulated conductor includes a second conductor surrounded by a second insulator; controlling convective heat transfer from the fluid to the first insulated conductor and the second insulated conductor; and twisting the first insulated conductor with the second insulated conductor to form a twisted pair, wherein the first insulated conductor and the second insulated conductor experience an amount of deformation during twisting; measuring the impedance of the twisted pair; and if the impedance of the twisted pair is outside the predetermined tolerance range, adjusting the convective heat transfer from the fluid to the first insulated conductor and the second insulated conductor.

[0045] Some embodiments are directed to a twisted pair of insulated conductors having increased resistance to deformation as a product of any of the above methods.

[0046] Some embodiments are directed to a twisted pair of insulated conductors having a predetermined impedance as a product of any of the above methods.

[0047] Some embodiments are directed to a twisted pair of insulated conductors having an impedance within a predetermined tolerance range as a product of any of the above methods.

[0048] Some embodiments relate to a cable comprising any of the above-described twisted pairs.

[0049] Convection requires the presence of some fluid in contact with the insulated wire. In many embodiments, the fluid in contact with the insulated wire can be air. In some embodiments, the fluid in the twister can include various substitutes, such as cryogenic fluids, inert gases (e.g., helium, N2, argon, krypton, radon, neon, xenon, and combinations thereof). In some embodiments, the fluid in the twister or in the cooling chamber can include cooling air produced by an air conditioner or refrigeration unit, fluorocarbon solutions, saline solutions, gases obtained by evaporating solids or liquids with an evaporation temperature of 0°C or less (e.g., dry ice or liquid nitrogen), liquids with a freezing point of 0°C or less, frozen acetone, and combinations thereof.

[0050] In some embodiments, polymer insulated conductors used in multiple twisted pairs are protected from convective heat transfer or exposed to cryogenic fluids for varying periods of time to produce a cable with reduced delay differential.

[0051] Certain disclosed embodiments relate to methods of manufacturing communications cables to reduce deformation of polymeric cable components and maintain roundness of insulated conductors and other cable components.

[0052] Some disclosed embodiments relate to apparatus for systems for manufacturing wire and cable products with improved electrical properties. Some of these embodiments relate to cooling vessels and / or secondary structures for holding a cooling medium (eg, such as a cryogenic fluid or a cryogenic solid surface).

[0053] Some disclosed embodiments relate to methods of manufacturing communication cables with reduced fuel loads. Some of these embodiments relate to methods of forming wire and cable products having less total polymer insulation relative to conventional cables, such that the cables having less total polymer insulation have lower total fuel loads and improved flammability and / or smoke generation characteristics.

[0054] Some disclosed embodiments relate to methods of manufacturing communication cables at faster speeds. Some of these embodiments relate to operating the twisting equipment at faster speeds, which generally increases the compressive forces on the polymer insulation. Some of these embodiments relate to hardening the polymer insulation material prior to twisting so that the twisting machine can be operated at faster speeds and produce cables with tolerable deformation and desired electrical properties.

[0055] The disclosed invention can be applied to any form of polymer cable assembly or cable construction, including, for example: solid, foam, profile extrusion, insulation layer, hollow tube, cross mesh, rod filler, film, tape, coaxial construction involving a braiding process, and / or multiple layers of insulation materials.

[0056] In addition to reducing deformation of the insulation layer when twisting insulated wires into twisted pairs, the disclosed invention can also be used to reduce deformation of any polymer material exposed to compressive forces (for example, such as braid indentation or mechanical systems (such as take-ups, sheaves, or wheels)).

[0057] A simplified summary is presented above in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an exhaustive overview. It is not intended to identify key / important elements or to describe the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to a more detailed description that will be presented later. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the disclosure and together with the description, serve to explain the principles of the disclosure.

[0059] Figure 1 Schematic cross-sectional views of embodiments of insulated conductors according to the present disclosure are illustrated.

[0060] Figure 2A and Figure 2B A schematic cross-sectional view of an embodiment of a twisted pair is illustrated.

[0061] Figure 3 Schematic cross-sectional views of embodiments of insulated conductors according to the present disclosure are illustrated.

[0062] FIG. 4A to FIG. 4C A schematic diagram illustrating an embodiment of a cooling container according to the present disclosure is illustrated.

[0063] Figure 5A and Figure 5B Schematic diagram illustrating an embodiment of a cooling vessel having a secondary structure according to the present disclosure.

[0064] Figure 6 A graph of the crush ratio data is shown.

[0065] Figure 7 Plots of surface temperature data and crush ratio data versus exposure time are shown.

[0066] Figure 8 A cross-sectional image of a foam insulated conductor is shown.

[0067] Fig. 9 Surface temperature data for foam and solid polymer insulation is shown versus exposure time.

[0068] Fig.10 The temperature variation over time of foam and solid polymer insulated copper conductors is shown.

[0069] Fig.11 The temperature variation over time of foam and solid polymer insulated copper conductors is shown.

[0070] Fig.12 A schematic diagram illustrating an embodiment of a twisted pair cable according to the present disclosure is illustrated.

[0071] Fig.13 Views illustrating embodiments of a cable according to the present disclosure.

[0072] Fig.14 Schematic cross-sectional views of embodiments of cables according to the present disclosure are illustrated.

[0073] Fig.15 Schematic cross-sectional views of embodiments of cables according to the present disclosure are illustrated.

[0074] Fig.16 Schematic cross-sectional views of embodiments of insulated conductors according to the present disclosure are illustrated.

[0075] Fig.17 Schematic cross-sectional views of embodiments of cables according to the present disclosure are illustrated.

[0076] Fig.18 Schematic diagram illustrating an embodiment of a cable according to the present disclosure.

[0077] FIG. 19A to FIG. 19C A schematic diagram illustrating an embodiment of a cooling container according to the present disclosure is illustrated.

[0078] FIG. 20A to FIG. 20C A schematic diagram illustrating an embodiment of a cooling container according to the present disclosure is illustrated.

[0079] Fig.21 Shown is a graph of Shore D hardness of solid FEP versus time of exposure to liquid nitrogen.

[0080] Fig. 22 Shown is a graph of Shore D hardness of solid FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0081] FIG. 23A to FIG. 23C Shown is a graph of the Shore D hardness of solid FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0082] Fig.24 Shown is a graph of Shore D hardness of foamed FEP versus time of exposure to liquid nitrogen.

[0083] Fig.25 Shown is a graph of the Shore D hardness of foamed FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0084] Fig.26 Shown is a graph of the Shore D hardness of foamed FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0085] Fig. 27 Shown is a comparison of the Shore D hardness of solid and foamed FEP versus time of exposure to liquid nitrogen.

[0086] Fig.28 Shown is a comparison of the Shore D hardness of solid and foamed FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0087] Fig.29 Shown is a comparison of the temperature of solid and foamed FEP after exposure to liquid nitrogen versus time of exposure to ambient atmosphere.

[0088] Fig.30 An embodiment of a bracket including a tube to shield the polymer cable assembly from convective heat transfer is shown.

[0089] Fig.31 Shows Fig.30 Side view of the bow stand shown.

[0090] Fig.32 An embodiment of a bracket including channels to shield the polymer cable assembly from convective heat transfer is shown.

[0091] Fig.33 Shows Fig.30 Details of the embodiment shown.

[0092] Fig.34 Shows Fig.32 Details of the embodiment shown.

[0093] Fig.35 Details of an embodiment of a partially covered and partially open channel are shown.

[0094] Fig.36 Shows Fig.35 Side view of the embodiment shown.

[0095] Fig.37 Shows Fig.35Details of the embodiment shown.

[0096] Fig.38 An embodiment of a bow having several wind shields to shield the polymer cables from convective heat transfer is shown.

[0097] Fig.39 Shows Fig.38 A side view of an embodiment of the present invention.

[0098] Fig.40 Details of an embodiment of a wind deflector are shown.

[0099] Fig.41 An embodiment of a tube for shielding a polymer cable comprising a vent is shown, the vent being in an open configuration.

[0100] Fig.42 An embodiment of a partially open channel in a bow for shielding a polymer cable comprising a vent in an open configuration is shown.

[0101] Fig.43 Shows Fig.41 In an embodiment, the vent is in a closed configuration.

[0102] Fig.44 Shows Fig.42 In an embodiment, the vent is in a closed configuration.

[0103] FIG. 45A to FIG. 45E An embodiment of a bracket including channels to shield the polymer cable assembly from convective heat transfer is shown. Fig.45A An embodiment is shown where 0% of the channel is covered. Fig.45B An embodiment is shown in which 25% of the channel is covered. Fig.45C An embodiment is shown in which 50% of the channel is covered. Fig.45D An embodiment is shown in which 75% of the channel is covered. Fig.45E An embodiment is shown in which 100% of the channel is covered.

[0104] Fig.46 Test results regarding the change of shielding level to the impedance of twisted pair cables are shown.

[0105] Fig.47 Test results regarding the variation of shielding level versus delay of twisted pair cables are shown. DETAILED DESCRIPTION

[0106] The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the present disclosure, and illustrate the best mode for practicing the present disclosure. When reading the following description in view of the accompanying drawings, those skilled in the art will understand the concepts of the present disclosure, and will recognize the application of these concepts that are not particularly focused on herein. It should be understood that these concepts and applications fall within the scope of the present disclosure and the appended claims.

[0107] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art of the present disclosure. It should also be understood that, unless so explicitly defined herein, terms such as those defined in public dictionaries should be interpreted as having a meaning consistent with their meaning in the context of this specification and should not be interpreted in an idealized or overly formal sense. For the sake of brevity or clarity, well-known functions or configurations may not be described in detail.

[0108] The terms "about" and "approximately" generally refer to an acceptable degree of error or variation in a measured quantity given the nature or precision of the measurements. Typically, exemplary degrees of error or variation are within 20%, preferably within 10%, and more preferably within 5% of a given value or range of values. Unless otherwise stated, the numerical quantities given in this specification are approximate, meaning that the term "about" or "approximately" can be inferred when not explicitly stated. Unless otherwise stated, the numerical quantities in the claims are exact.

[0109] The term "adapted to" means designed or configured to achieve a specified purpose, rather than merely capable of achieving a specified purpose.

[0110] The term "capable of" means capable of achieving a specified goal.

[0111] It should be understood that when a feature or element is referred to as being "on another feature or element", it can be directly on another feature or element, or there can be intermediate features and / or elements. In contrast, when a feature or element is referred to as being "directly on another feature or element", there are no intermediate features or elements. It should also be understood that when a feature or element is referred to as being "connected to", "attached to" or "coupled to" another feature or element, the feature or element can be directly connected to, attached to or coupled to another feature or element, or there can be intermediate features or elements. In contrast, when a feature or element is referred to as being "directly connected to", "directly attached to" or "directly coupled to" another feature or element, there are no intermediate features or elements. Although described or illustrated with respect to one embodiment, the features and elements described or illustrated in this manner can be applied to other embodiments.

[0112] The terms used herein are only used to describe particular embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an", "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0113] The terms "first", "second", etc. are used herein to describe various features or elements, but these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Therefore, without departing from the teachings of the present disclosure, the first feature or element discussed below can be referred to as the second feature or element, and similarly, the second feature or element discussed below can be referred to as the first feature or element.

[0114] Terms such as “at least one of A and B” should be understood to mean “only A, only B, or both A and B.” The same construction should apply to longer lists (eg, “at least one of A, B, and C”).

[0115] With reference to the use of the words "includes," "comprising," and "including" in the foregoing description and / or the appended claims, these words are used on the basis and with the clear understanding that they are to be interpreted inclusively rather than exclusively, unless the context requires otherwise, and each of these words should be so interpreted in interpreting the foregoing description and / or the appended claims.

[0116] The term "comprising" should be interpreted to mean "including, but not limited to... " unless the context clearly indicates otherwise.

[0117] The term "consisting essentially of" means that in addition to the listed elements, the claimed content may include other elements (steps, structures, ingredients, components, etc.) that do not adversely affect the operability of the claimed content for its intended purpose as stated in this disclosure. The term excludes such other elements that adversely affect the operability of the claimed content for its intended purpose as stated in this disclosure, even if such other elements may enhance the operability of the claimed content for some other purpose.

[0118] In some places, references are made to standard methods, such as but not limited to measurement methods. It is understood that such standards are revised from time to time, and unless expressly stated otherwise, references to such standards in this disclosure must be interpreted as referring to the most recent published standard at the time of filing.

[0119] The present disclosure describes embodiments of methods and systems for manufacturing wire and cable products having improved electrical properties and / or improved manufacturing characteristics. Although the disclosed invention is generally discussed in the context of twisting polymer insulated wires to form twisted pairs, it should be appreciated that the disclosed invention is applicable to many applications other than twisted insulated conductors, including, for example, polymer insulation layers, foam insulation layers, foam skins, cross-mesh, polymer tapes, hollow tubes, rod-shaped fillers, sheaths, and other polymer cable assemblies. The following disclosure often refers to insulated conductors, which include polymer assemblies used as insulators around conductive assemblies, which are typically conductive metal wires, such as copper or copper alloys. However, the subject matter described herein may also be used for polymer assemblies in other contexts.

[0120] According to an example embodiment of the present disclosure, a method for controlling the effects of compressive forces on a polymer cable assembly is provided. The polymer cable assembly may have a first hardness, which may be the hardness of the polymer cable assembly under ambient conditions. The method may include temporarily changing the hardness of the polymer cable assembly to a second hardness different from the first hardness. In some examples, the polymer cable assembly may be processed by a twisting unit having a bow, wherein the polymer cable assembly may be subjected to compressive forces. During the twisting unit processing, the polymer cable assembly may be at least partially shielded from convective heat transfer while it is in the bow. The method may include allowing the polymer cable assembly to return to the first hardness.

[0121] According to another example embodiment of the present disclosure, a method for manufacturing a communication cable is provided. The method may include providing a polymer cable assembly. The polymer cable assembly may have a first cross-sectional radius and a second cross-sectional radius. The first cross-section may be the maximum distance from the center of the polymer cable assembly to the edge of the polymer cable assembly along the cross-section. The second cross-section may be the minimum distance from the center of the polymer cable assembly to the edge of the polymer cable assembly along the cross-section. Under ambient conditions, the first cross-sectional radius may be approximately equal to ±3% of the second cross-sectional radius. Under ambient conditions, the polymer cable assembly may have a first hardness. The method may include temporarily changing the hardness of the polymer cable assembly to a second hardness. In some examples, the second hardness may be greater than the first hardness. The polymer cable assembly may be subjected to a treatment in a twisting unit having a bow. The treatment may involve subjecting the polymer cable assembly to a compressive force within the twisting unit. During the treatment, the polymer cable assembly may be at least partially shielded from convective heat transfer in the bow of the twisting unit. After the compressive force, the first cross-sectional radius is approximately equal to ±10% of the second cross-sectional radius.

[0122] In another example embodiment of the present disclosure, a method for manufacturing a communication cable is provided. The method may include providing a polymer cable assembly having a first diameter and a second diameter. The first diameter may be perpendicular to the second diameter by ±3%. The polymer cable assembly may have a first hardness, which is the hardness of the polymer cable assembly under ambient conditions. The method may include temporarily changing the hardness of the polymer cable assembly to a second hardness, which may be greater than the first hardness. The method may include processing the polymer cable assembly in a twisting unit having a bow frame. The processing may include subjecting the polymer cable assembly to a compressive force. During the processing, the polymer cable assembly may be at least partially shielded from convective heat transfer in the bow frame. After the compressive force, the first diameter may be approximately equal to the second diameter by ±10%. The method may include allowing the polymer cable assembly to return to the first hardness.

[0123] In another example embodiment of the present disclosure, a method for manufacturing a communication cable is provided. The method may include providing a first pair of polymer insulated conductors, a second pair of polymer insulated conductors, a third pair of polymer insulated conductors, and a fourth pair of polymer insulated conductors. The pair of polymer insulated conductors may include two polymer insulated conductors. Each polymer insulated conductor may have a first hardness, which may be the hardness of the polymer insulated conductor under environmental conditions. The method may include temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and / or the fourth pair of polymer insulated conductors to a second hardness, which may be a hardness different from the first hardness. The method may include twisting the polymer insulated conductors in the first pair of polymer insulated conductors together to form a first twisted pair. The first twisted pair may have a first propagation delay after 100 meters. The method may include twisting the polymer insulated conductors in the second pair of polymer insulated conductors together to form a second twisted pair. The second twisted pair may have a second propagation delay after 100 meters. The method may include twisting the polymer insulated conductors in the third pair of polymer insulated conductors together to form a third twisted pair. The third twisted pair may have a third propagation delay after 100 meters. The method may include twisting together the polymer insulated conductors in a fourth pair of polymer insulated conductors to form a fourth twisted pair. The fourth twisted pair may have a fourth propagation delay over 100 meters. For the first propagation delay, the second propagation delay, the third propagation delay, and the fourth propagation delay over 100 meters, the propagation delay differences over 100 meters are within 50 nanoseconds of each other. In some examples, the step of twisting at least the first pair, the second pair, the third pair, and the fourth pair of polymer insulated conductors may include feeding the polymer insulated conductors into a bow of a twisting unit. The polymer insulated conductors may be at least partially shielded in the bow from convective heat transfer.

[0124] In another example embodiment of the present disclosure, a method for manufacturing a communication cable is provided. The method may include providing a first pair of polymer insulated conductors and a second pair of polymer insulated conductors. Each pair of polymer insulated conductors may include two polymer insulated conductors. Each polymer insulated conductor may have a first hardness, the first hardness being the hardness of the polymer insulated conductor under ambient conditions. The method may include temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors to a second hardness. The second hardness may be different from the first hardness. The method may include twisting the polymer insulated conductors in the first pair of polymer insulated conductors together in a bow frame of a twisting unit to form a first twisted pair. The polymer insulated conductors may be at least partially shielded from convective heat transfer in the bow frame. The first twisted pair may have a first propagation delay after 100 meters. The method may include twisting the polymer insulated conductors in the second pair of polymer insulated conductors together to form a second twisted pair. The second twisted pair may have a second propagation delay after 100 meters. The first propagation delay after 100 meters and the second propagation delay after 100 meters may be within 25 nanoseconds of each other.

[0125] In another example embodiment of the present disclosure, a system for manufacturing wire and cable products is provided. The system may include a payout device configured to pay out a polymer cable assembly. The system may include a cooling container, which may be configured to receive the polymer cable assembly. The cooling container may contain a refrigerated fluid. The system may include a take-up device configured to tighten the polymer cable assembly. The system may include a twisting machine, which is configured to receive a first polymer insulated conductor and a second polymer insulated conductor to form a twisted pair. The twisting machine may include a bow in the fluid, and the bow may include a device for shielding the insulated conductor from the effects of convective heat transfer with the fluid when the bow rotates.

[0126] In another example embodiment of the present disclosure, a system for manufacturing wire and cable products is provided. The system may include a payout device configured to pay out a polymer cable assembly. The system may include a take-up device configured to tighten the polymer cable assembly. The system may include a twister configured to receive a first polymer insulated conductor and a second polymer insulated conductor and form a twisted pair. The twister may include a bow in a fluid. The bow may include a device for shielding the insulated conductor from convective heat transfer with the fluid when the bow rotates.

[0127] In another example embodiment of the present disclosure, a method for manufacturing a low combustible load wire and cable product is provided. The method may include establishing desired electrical characteristics of the wire and cable product. The wire and cable product may include a polymer cable assembly. The polymer cable assembly may have a first combustible load and a first hardness. In some examples, the polymer cable assembly may have a flame travel distance equal to or less than about five feet. In some examples, when measured according to the Steiner tunnel test method of ASTM E84, the polymer cable assembly may have an average optical density equal to or less than about 0.15. In some examples, the first hardness of the polymer cable assembly may be the hardness of the polymer cable assembly under ambient conditions. The method may include temporarily changing the hardness of the polymer cable assembly to a second hardness, which may be different from the first hardness. The method may include causing a first deformation amount to the polymer cable assembly by subjecting the polymer cable assembly to a compressive force in a twisting unit having a bow frame. In some examples, the polymer cable assembly may be in a second hardness while being subjected to the compressive force. In some examples, the polymer cable assembly can be at least partially shielded from convective heat transfer in the bow while being subjected to a compressive force in or after the bow of the twisting unit. The method can include forming a wire and cable product using the polymer cable assembly. When the polymer cable assembly is deformed by a first deformation amount, the wire and cable product can meet the established desired electrical characteristics, but if the polymer cable assembly is deformed by a second deformation amount, the wire and cable product will not meet the desired electrical characteristics. The second deformation amount can be the amount that the polymer cable assembly will deform when subjected to the compressive force when the polymer cable assembly is at a first stiffness.

[0128] In at least some examples, the change in hardness between the first hardness and the second hardness of the polymer cable assembly and / or the polymer insulated conductor can be between about 5% and about 95%. In some examples, the change in hardness between the first hardness and the second hardness of the polymer cable assembly and / or the polymer insulated conductor can preferably be between about 25% and about 75%. In some examples, the change in hardness between the first hardness and the second hardness of the polymer cable assembly and / or the polymer insulated conductor can more preferably be between about 35% and about 65%.

[0129] In at least some examples, the polymer cable assembly and / or polymer insulated conductor can be shielded from about 5% to about 95% of convective heat transfer with the environment of the bow. In this context, the shielding percentage refers to the fraction of the length of the bow covered by the device for shielding the insulated conductors to reduce or prevent the flow of air or other fluids in the twister over the insulated conductor cable assembly. For example, if the device is a covered channel and 75% of the length of the channel is covered, the shielding percentage is 75%. In another example, if the device is an adjustable vent along the length of the bow, and the vent is adjusted to reduce the airflow in the bow by 25%, the shielding is 25%. In some examples, the polymer cable assembly and / or polymer insulated conductor can be at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100% shielded from convective heat transfer. In other embodiments, the polymer cable assembly or insulated conductors can be up to 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% shielded from convective heat transfer. In another example, the polymer cable assembly and / or polymer insulated conductors can be shielded from about 50% to about 80% convective heat transfer with the environment of the bow.

[0130] In some examples, a device for shielding polymer cable assemblies and / or polymer insulated conductors from the effects of convective heat transfer can be implemented by including one or more optional vents in the bow of the twisting machine. In some examples, a device for shielding polymer cable assemblies and / or polymer insulated conductors from the effects of convective heat transfer can be implemented by including one or more partially or completely open channels in the bow of the twisting machine. In other examples, a device for shielding polymer cable assemblies and / or polymer insulated conductors can be implemented by placing one or more wind shields throughout the bow. In some examples, the wind shield can be adjustable so that the optimal level of heat transfer shielding can be achieved. The adjustable wind shield can be of any suitable type, including but not limited to a wind shield with an adjustable hole leading to the environment of the twisting unit and / or an adjustable wind deflector that can be adjusted when the bow rotates.

[0131] Some embodiments of the apparatus for shielding a polymer component or an insulated wire as an insulated conductor from convective heat transfer are adjustable to vary the degree of shielding. For example, the channel or tube may include an adjustable vent. The vent may be of any suitable form. For example, the vent may include a plurality of rotating slats, such as Figure 41 to Figure 44Some embodiments of adjustable vents may be connected to a control unit that transmits a signal to open and close the vents. Such a control unit may be used, for example, to modulate the amount of convective heat transfer to the polymer assembly in response to a measurement of the impedance of the twisted pair. Such a control unit may be used to modulate the amount of convective heat transfer as the bow rotates.

[0132] In at least some examples, the present disclosure refers to environmental conditions. Environmental conditions refer to temperature, humidity, and atmospheric pressure conditions that typically occur in indoor spaces.

[0133] In at least some examples, a system for manufacturing wire and cable products is disclosed. The system may include, but is not limited to, components such as a payout device and a take-up device.

[0134] As used herein, a payout device may refer to a machine that allows an operator to unload or unwind flexible materials (e.g., such as polymer insulated conductors and / or polymer cable assemblies) in a controlled manner. Payout machines may provide high-quality rewinding and winding, may protect the material from damage, and may assist the operator during the rewinding and winding process. Payout machines may have different designs based on many parameters, such as the size and type of material used, the size of the reel, the weight of the entire product for winding and winding, whether the machine is mobile, floor mounted, etc.

[0135] As used herein, a take-up device may refer to a machine configured to receive a flexible material (such as, for example, a polymer insulated conductor and / or a polymer cable assembly) and wind the flexible material onto a wheel or spool for rewinding and / or spooling.

[0136] In some examples, certain characteristics of the polymer cable assembly and / or the polymer insulated conductor may be desired. For example, it may be desired that the polymer insulated conductor and / or the polymer cable assembly have a desired peak optical density of smoke, an average optical density, and a flame travel distance. In some examples, the desired peak optical density of smoke of the polymer insulated conductor and / or the polymer cable assembly may be equal to or less than about 0.5. In some examples, when measured according to the Steiner tunnel test method of ASTM E84, the desired average optical density of the polymer insulated conductor and / or the polymer cable assembly may be equal to or less than about 0.15. In some examples, the desired flame travel distance of the polymer insulated conductor and / or the polymer cable assembly may be equal to or less than about 0.5. In some examples, the flame travel distance, the peak optical density of smoke, and / or the average optical density may be measured after the polymer insulated conductor and / or the polymer cable assembly is subjected to a compressive force in the bow of the twisting unit.

[0137] When a polymer insulated conductor is subjected to compressive forces, such as when the wires are twisted to form a twisted pair, the polymer insulation assembly may be compressed or otherwise deformed. For polymer insulation layers, such deformation may destroy the conductor-to-conductor spacing of the wire and affect the electrical performance of the wire or the resulting cable.

[0138] Figure 1 A cross section of an insulated wire having a polymer insulation layer 110 surrounding a conductor 120 is schematically illustrated. When the insulated wire is subjected to a compressive force, the insulation layer 110 may deform. The degree to which the insulation layer 110 deforms can be described by a crush ratio. The crush ratio is defined as deformed length / original OD*100 and expressed as a percentage.

[0139] Figure 2A A cross section of two insulated wires is schematically illustrated, each having a polymer insulation layer 210 surrounding a conductor 220 . Figure 2A Two insulated wires are shown in contact with each other and without deformation of the circular polymer insulation. Figure 2A The shaded area of ​​the polymer insulation layer 210 in illustrative figures illustrates the area that is deformed due to compressive forces when the two wires are twisted together.

[0140] Figure 2B A cross section of two insulated wires is schematically illustrated, each having a polymer insulation layer 210 surrounding a conductor 220 . Figure 2B Two wires are illustrated in contact with each other after the compressive force has caused deformation in the polymer insulation layer.

[0141] Will Figure 2B The conductor-to-conductor distance of the extruded wire is Figure 2A , shows that the distance between the two conductors is reduced due to the deformation of the two insulation layers. This type of compression can occur when the wires are twisted together or during other compression events. This reduction in conductor-to-conductor distance has a negative impact on the electrical performance of the twisted pair and any resulting cable.

[0142] The forces applied to polymer cable assemblies depend on the type and manufacturer of equipment utilized by any particular wire and cable company. For example, there are many different types of cabling machines. Each of these machines will exhibit unique forces to the various components being cabled. When wire and cable manufacturers determine how much additional insulation to introduce into the design to compensate for deformation, it is largely empirical, combined with knowledge of the material's hardness (harness), which will ultimately determine how much additional insulation is needed.

[0143] In the industry, the term "wall thickness" is used to capture how much insulation and / or jacket material is needed to produce the desired product. Most application designs will have an absolute minimum wall thickness, an average minimum wall thickness, a nominal wall thickness, and an absolute maximum wall thickness. The nominal wall thickness is usually considered when compensating for deformation and depressions in the insulation layer.

[0144] The softer the insulating material, the greater the amount of additional wall thickness required to compensate for the wall thickness lost due to compression under a given set of conditions. As an example, FEP is a softer insulating material than HDPE or PP, and requires a larger amount of additional insulating material. Understanding the hardness of the insulating material is useful for determining the required amount of compensation. If the deformation is better controlled, the amount of required additional insulating material can be reduced. This will contribute to both the size and cost of the final product. In some embodiments, relative to the cable produced under the same conditions but without the cooling technology described herein, the amount of additional insulating material added for producing the desired cable is reduced by at least about 0.0005 inches, or at least about 0.001 inches, at least about 0.003 inches, at least about 0.005 inches, at least about 0.01 inches.

[0145] Softer insulating polymers, such as fluorinated ethylene propylene (FEP), are more likely to have increased deformation when force is applied to the insulating layer relative to insulating layers made with harder polymers. Foam insulating layers may also deform more easily than solid polymers.

[0146] The deformation resistance of the insulating layer can generally be measured or described based on the hardness of the insulating material. As discussed, hardness is a measure of the resistance to localized plastic deformation caused by mechanical indentation or wear. Typically, the hardness of different materials is different. In some embodiments, Young's modulus can affect the degree of deformation due to compressive force. Young's modulus is a mechanical property that measures the stiffness of a solid material. It defines the relationship between stress (force per unit area) and strain (proportional deformation) in a material. The higher the Young's modulus, the smaller the elastic deformation of the material under the same force can be.

[0147] One way to control the hardness and stress / strain response of the polymer insulation layer is to adjust the amount of convective heat transfer during the twisting process. Another way is to cool the polymer material. This cooling can be achieved by any reasonable method, for example, by exposing the insulation layer directly or indirectly to a freezing or cooling fluid (such as a freezing liquid or gas). In some embodiments, the polymer cable assembly can be exposed to freezing water or an aqueous solution. In some embodiments, the polymer cable assembly can be exposed to a cryogenic fluid, such as liquid nitrogen. In some embodiments, the polymer cable assembly can be exposed to a freezing gas or vapor. In some embodiments, the polymer cable assembly can be exposed to one or more freezing wheels, rollers, tubes, or other solid surfaces. In some embodiments, the polymer cable assembly can be indirectly cooled. For example, the polymer cable assembly can pass through the inside of the tube while the outside of the tube is being cooled. The atmosphere in the tube will be frozen, thereby cooling the polymer cable assembly. The invention described herein is generally described in the context of a cryogenic fluid, but it should be appreciated that any of these methods may also or alternatively be used.

[0148] In some cases, the time required to cool the entire thickness of the polymer insulation layer may make this method impractical. In one embodiment, the disclosed invention cools the outer surface of the insulation layer without cooling the inner body of the insulation layer to the same extent. In some embodiments, cooling only the outer portion of the insulation layer helps to reduce the overall deformation of the insulation layer because the outer surface is typically the portion of the insulation layer that is most subject to compressive forces during manufacturing.

[0149] Figure 3 A cross section of an insulated wire having a polymer insulation layer surrounding a conductor 340 is schematically illustrated. Figure 3 The insulating layer of the depicted embodiment is a single uniform polymer layer, however, for clarity, Figure 3 A uniform insulating layer divided into discrete concentric sections is shown. The outer surface 310 of the polymer insulating layer is generally exposed to the external environment and is first subjected to any external compressive forces. The outer portion 320 of the insulating layer is directly below the outer surface. The inner body 330 of the insulating layer surrounds the conductor 340 and is least subjected to external compressive forces because the outer surface 310 and the outer portion 320 of the insulating layer must deform before impacting the inner body 330.

[0150] When the polymer insulated wire is exposed to a freezing liquid or cryogenic fluid (e.g., such as liquid nitrogen), the outer surface 310 cools rapidly as it comes into direct contact with the cryogenic fluid. Next, the outer portion 320 of the insulation layer will be cooled as heat is removed from the insulation layer and enters the cryogenic fluid. The rate at which the outer portion of the insulation layer cools will vary based on the thermal conductivity of the polymer material forming the insulation layer. The inner body 330 of the insulation layer will cool after the outer surface and outer portion cool. It should be appreciated that a temperature gradient will be formed rather than a sharp line, separating the outer portion 320 from the inner body 330.

[0151] As the outer surface and outer portions of the insulation layer cool, the stress / strain response of these portions of the insulation layer can increase. In some embodiments, this creates a hardened "skin" on the outer portions of the insulation layer that surrounds a relatively less cooled or relatively higher temperature inner body of the insulation layer.

[0152] If the insulation layer is kept in contact with the cryogenic fluid for a long enough time, then the entire body of the insulation layer can be cooled and the hardness of the entire insulation layer can be increased. However, wire and cable manufacturing facilities typically produce cables at relatively high speeds. In order to cool the entire thickness of the insulation layer while the cable is moving at a relatively high speed, the length of the cooling equipment will need to be longer than desired for certain applications. By using an embodiment of the disclosed invention and cooling the outer portion of the insulation layer while keeping the inner body of the insulation layer at a relatively high temperature, the length of the necessary cooling equipment can be reduced and deformation of the insulation layer can be minimized. By creating a hardened skin within a uniform polymer insulation layer, the crush ratio can be reduced when the insulated wires are twisted together and when the polymer insulated wires are exposed to other external compressive forces.

[0153] It should be appreciated that when the polymer insulated conductor is removed from the cryogenic fluid or other cooling medium and exposed to the ambient atmosphere, the polymer insulation material will begin to recover to the ambient temperature. As the temperature increases, the hardness and stress / strain response of the polymer insulation material decrease, and the polymer insulation material will become more susceptible to deformation due to compressive forces. In some embodiments of the disclosed invention, one or more polymer insulation layers are cooled shortly before being subjected to a compression event (for example, such as twisting to form a twisted pair). In some applications, the speed at which the insulated conductor is moving and the distance between the cooling container and the twister take-up device will determine the time when the polymer insulated conductor is exposed to the ambient atmosphere after being cooled but before being subjected to compressive forces. In some embodiments, the end of the cooling container is less than 10 feet from the point where the polymer insulated conductor is subjected to subsequent compressive forces. In some embodiments, the end of the cooling container is less than 8 feet, 6 feet, 4 feet, or 2 feet from the point where the polymer insulated conductor is subjected to subsequent compressive forces.

[0154] It will be appreciated that the hardness of a given material depends on the temperature of the material. Thus, as the temperature of a given material increases and decreases, the hardness decreases and increases accordingly. In some embodiments, the material will be cooled shortly before the compressive force, thereby increasing the hardness, and then allowed to return to ambient temperature. Even if the hardness is only temporarily increased, increasing the hardness when a compressive force is present can help the material resist deformation caused by the compressive force.

[0155] It should be appreciated that the disclosed invention does not require a change in the composition of the polymeric insulating material. As the polymeric insulating material is cooled, the composition of the polymeric insulating layer remains constant, thereby changing the stress / strain response. As the insulating layer is subjected to any compressive or deforming forces and as the polymeric insulating layer is allowed to return to ambient temperature, the composition of the polymeric insulating layer remains constant, thereby reducing its hardness.

[0156] In some embodiments, the conductor can be insulated by more than one insulating layer. In some embodiments, the conductor can be insulated by, for example, a polymer foam layer and also by a solid polymer layer. In some embodiments, the multiple layers of polymer insulation can be made of different polymers. In some embodiments, the multiple layers of polymer insulation can be made of the same polymer. Each insulating layer can have a different thickness than any other insulating layer, or can have approximately the same thickness.

[0157] It should be appreciated that a thicker polymer insulation layer may require more time to reach a higher hardness relative to a thinner polymer insulation layer because the temperature gradient will need to propagate into the body of the thicker polymer insulation layer. In some embodiments, the exposure time for which the insulated conductor is exposed to the cryogenic fluid can be adjusted based on the thickness of the polymer insulation layer.

[0158] In some embodiments, some of the conductors of the multiple twisted pairs contained in a single cable can be exposed to the cryogenic fluid for different amounts of time. By controlling the amount of time the conductors are exposed to the cryogenic fluid, the degree of compression of the twisted pairs and the resulting electrical properties can be modulated.

[0159] In some embodiments, by increasing the stiffness of the polymer insulated conductor, the conductor will maintain a generally circular cross-section and will not deform due to compressive forces. This can reduce the amount of surface-to-surface contact between the two polymer insulated conductors and reduce friction or torsional forces between the insulated conductors.

[0160] In some embodiments, the polymer insulated conductor or other polymer cable component is cooled to increase stiffness before being subjected to a compressive force. In some embodiments, the reduced temperature of the polymer cable component compensates for any heat generated within the polymer cable component by the compressive force. In some embodiments, the temperature of the polymer cable component during or just after the compression event is equal to or lower than the ambient temperature.

[0161] In some embodiments, the disclosed invention can be used to twist polymer insulated wires to form twisted pairs. Twisted pair wiring is usually made by twisting two polymer insulated wires with each other using a machine called a twisting machine. The process of twisting the wires to form a twisted pair creates a compressive force between the two wires at the point where they contact each other. The compressive force increases with the increase of the pitch or twist rate of the twisted pair.

[0162] The purpose of twisting the wires to form a twisted pair is to improve the electromagnetic compatibility of the wires. Twisted pair wiring reduces electromagnetic radiation from the twisted pair, and reduces crosstalk and electromagnetic interference between adjacent twisted pairs relative to non-twisted pairs. A twisted pair can be used to form a single-pair Ethernet cable, or multiple twisted pairs can be combined to form various other forms of cabling, including Ethernet cabling. It is desirable that each insulated conductor of the twisted pair is the same mirror image of another insulated conductor in the twisted pair. When the two insulated conductors in the twisted pair are mirror images of each other, this achieves improved noise cancellation between the insulated conductors and produces a balanced pair system. Typically, the insulation layers around the conductors contained in the twisted pair are subject to different effects of compression forces. This may result in differences between the two insulated conductors, and result in imbalance, thereby resulting in reduced noise cancellation, which is an undesirable result for the final product.

[0163] In one embodiment, the insulated wire is passed through a cooling container before the polymer insulated wire is fed into the twisting machine. In some embodiments, the cooling container exposes the insulated wire to a cryogenic fluid, thereby increasing the hardness of at least the outer surface of the polymer insulation layer. In some embodiments, the cooling container contains a pool of a cryogenic fluid (for example, such as liquid nitrogen). In some embodiments, the cooling container contains a cryogenic fluid spray. It should be appreciated that the cooling container can be used to expose any polymer cable assembly to any form of cooling medium. For clarity, the disclosed invention will be described in the context of a cryogenic fluid, however, frozen air or any other gas or vapor, as well as frozen water or any other frozen liquid or frozen solid surface can be used.

[0164] Figure 4A Schematic diagram of a cooling container 410 according to one embodiment is shown. Figure 4AAs shown, the insulated wire 420 can enter the cooling container 410 through a hole 440 in the cooling container below the surface of the cryogenic fluid 430, so that the insulated wire is immersed in a pool of cryogenic fluid 430. The cooled insulated wire 420 can exit the cooling container 410 through a similar hole 440 in the side of the cooling container. In some embodiments, a flexible gasket, membrane, or valve can be used to limit the flow of cryogenic fluid out of the cooling container.

[0165] Figure 4B Another schematic diagram of a cooling container 411 according to one embodiment is shown. In some embodiments, wheels, rollers, or wire guides 441 are used to guide the insulated wire 421 downward into a pool of cryogenic fluid 431. This allows the cooling container to maintain a pool of liquid without leaking. In some embodiments, the cooling container includes a top or lid (not shown) with holes that allow the wire to enter the cooling container and reduce the overall loss of cryogenic fluid due to evaporation or dissipation.

[0166] Figure 4C Another schematic diagram of a cooling vessel 412 according to one embodiment is shown. In some embodiments, the cooling vessel 412 is equipped with one or more nozzles 432 that spray a cryogenic fluid or another refrigerated liquid or gas onto the insulated wire 422. In some nozzle embodiments, the insulated wire 422 is not in physical contact with the cooling vessel or associated equipment, thereby avoiding any compressive forces prior to cooling. In some embodiments, the insulated wire enters and exits the cooling chamber through a small hole 442 to be sprayed with the cryogenic fluid. Since there is no standing pool of cryogenic liquid in some nozzle embodiments, the loss of cryogenic fluid is less of a concern.

[0167] It will be appreciated that some embodiments include combinations of the above cooling vessels. In some embodiments, multiple cooling vessels may be used in series to achieve a particular desired effect. In some embodiments, a single cooling chamber may have one, or two, or more insulated conductors that pass through the cooling chamber simultaneously. In some embodiments, a single cooling chamber may be used to cool two wires to be formed into a single twisted pair. In some embodiments, a single cooling chamber may be used to cool multiple insulated wires that may be used to form multiple twisted pairs.

[0168] In some embodiments, the cooling container can be at least about 2 feet long, or about 4 feet long, or about 6 feet long, or about 10 feet long, or about 15 feet long. In some embodiments, the cooling container is at most about 20 feet long, or about 15 feet long, or about 10 feet long, or about 8 feet long, or about 6 feet long. In some embodiments, one or more groove wheels, wheels, capstans, and / or rollers can be used in the cooling container to change the path of the polymer cable assembly in the cooling container. This arrangement allows the polymer cable assembly to remain in the cooling container for a longer period of time without increasing the length of the cooling container or reducing the linear speed of the assembly. In some embodiments, the polymer cable assembly enters the cooling container in the upper vapor region of the container (where the low-temperature vapor evaporated has risen above the cryogenic liquid), and is subsequently redirected to pass through the liquid region of the container (where liquid cryogenic fluid is maintained). This arrangement allows the polymer cable assembly to initially transfer heat to the cryogenic vapor before contacting the cryogenic liquid, thereby reducing the total heat load being transferred to the cryogenic liquid and increasing the total residence time of the polymer cable assembly in the cooling container.

[0169] The length of time that the insulated wire is exposed to the cryogenic fluid will depend on the length of the cooling vessel and the speed at which the insulated wire is traveling. In some embodiments, the wire is exposed to the cryogenic fluid for at least about 1 second, or at least about 2 seconds, or at least about 4 seconds, or at least about 6 seconds, or at least about 8 seconds, or at least about 10 seconds. In some embodiments, the wire is exposed to the cryogenic fluid for up to about 30 seconds, or up to about 20 seconds, or up to about 10 seconds, or up to about 8 seconds, or up to about 6 seconds, or up to about 4 seconds.

[0170] In some embodiments, after leaving the cooling container, the insulated wire enters a twisting machine, in which the insulated wire can be twisted around a second cooled insulated wire to form a twisted pair with less deformation of the two insulation layers. In some embodiments, the insulated wire enters the twisting machine within about 1 second of leaving the cooling container, or within about 2 seconds of leaving the cooling container, or within about 4 seconds of leaving the cooling container. In some embodiments, the cooling container is positioned relative to the twisting machine or other device that applies compressive force on the insulated wire so that the polymer insulated wire experiences subsequent compressive force before the increased stress / strain response of the polymer insulated wire is reduced by more than about 10%, or by more than about 20%, or by more than about 30%. In other words, in some embodiments, the cooling container is positioned so that the polymer insulated wire leaving the cooling container experiences any subsequent compressive force before the polymer insulated wire significantly heats up and reduces its hardness.

[0171] In some embodiments, one or more secondary structures can be positioned to maintain an atmosphere that is cooler than the ambient temperature surrounding the polymeric insulated conductor after the polymeric insulated conductor exits the cooling chamber. Figure 5A An example of a cooling container 510 having a secondary structure 550 positioned around a polymer insulated conductor 520 when the polymer insulated conductor 520 leaves the cooling container is illustrated. In some embodiments, the secondary structure 550 is a hollow tube that is configured to maintain a refrigerated atmosphere around the polymer insulated conductor before subjecting the conductor to compressive forces as part of the twisting process. The secondary structure 550 can be made of any thermally conductive material, including metals and / or polymers, for example. In some embodiments, the secondary structure 550 can be a larger tube that is configured to surround multiple conductors when they leave the cooling chamber so as to maintain increased hardness before subjecting the conductors to any compressive or deforming forces. In some embodiments, the secondary structure 550 can be a tube with an adjustable length that can be extended and / or retracted to adjust the residence time of the polymer cable assembly in the tube. In some embodiments, the secondary structure includes a removable or openable portion, such as a top or cover. In such an embodiment, the secondary structure may be opened to allow initial treading or tightening of the wires or cable lines and then closed to exclude the ambient atmosphere and maintain a cooler than ambient atmosphere within the secondary structure.

[0172] In some embodiments, the secondary structure is arranged to receive a cryogenic fluid from a cooling vessel. In one example, the secondary structure can be arranged to receive cold nitrogen vapor from a liquid nitrogen evaporation pool contained in the cooling vessel. By maintaining an atmosphere colder than ambient temperature around the wire leaving the cooling vessel, when the wire travels to a twisting machine or other subsequent steps involving compressive force from the cooling vessel, the secondary structure can contribute to maintaining increased hardness and Young's modulus. In some embodiments, any cryogenic fluid leaking out of the cooling vessel is received by the secondary structure. In the case of a cryogenic liquid, the cryogenic liquid received by the secondary structure can evaporate in the secondary structure, thereby producing a freezing atmosphere in the secondary structure, and preventing any cryogenic liquid from leaking into the production workshop.

[0173] In some embodiments, the secondary container can be connected to the cooling container, the twisting machine, or both. In some embodiments, the secondary structure can guide the expanded or evaporated low temperature vapor from the cooling container through the secondary structure and into the twisting machine. In such embodiments, the atmosphere in the twisting machine can be maintained at a lower temperature than the ambient atmosphere around the twisting machine.

[0174] While the present disclosure is generally described in the context of exposing a polymer cable assembly to a cryogenic fluid, it will be appreciated that other methods of cooling a polymer cable assembly to increase its stiffness and stress / strain response may also be used.

[0175] In some embodiments, the polymer cable assembly can be passed through the inside of the freezing tube. The outside of the tube can be exposed to a cooling medium such as a freezing or cryogenic fluid, thereby reducing the temperature of the tube itself. In such an embodiment, when heat is drawn into the freezing or cryogenic fluid from the tube, the atmosphere in the freezing tube will be indirectly cooled by the freezing or cryogenic fluid. The polymer cable assembly can be cooled by being exposed to the freezing atmosphere in the tube, thereby increasing the hardness and stress / strain response of the polymer cable assembly. In some embodiments, the tube can be only slightly larger than the polymer cable assembly passing through the tube. By reducing the distance between the inner surface of the tube and the polymer cable assembly, the degree of cooling of the polymer cable assembly can be controlled. In some embodiments, the tube can have a removable cover or a cover attached in a hinged manner, which allows the tube to be opened so that the polymer cable assembly passes through the initial tightening of the tube. Once the tube is closed, the outside of the tube can be exposed to the freezing or cryogenic fluid, so as to establish a cooled internal atmosphere in the tube. In some embodiments, the tube can be retractable or use modular components to increase or decrease the length of the tube during continuous operation. In some embodiments, this allows an operator to adjust the total residence time of the polymer cable assembly within the cooled atmosphere of the tube without having to stop production to change the tube, tube length, and / or tube assembly.

[0176] Figure 5B A freezing tube embodiment as described above is schematically illustrated. In the illustrated embodiment, the tube 610 passes through the cooled material 620, thereby generating a freezing atmosphere within the tube 610. The polymer cable assembly 605 passes through the freezing tube 610 and is exposed to the freezing atmosphere within the tube 610. In the illustrated embodiment, a heat exchanger 630 can be used to control the temperature of the cooled material 620. In some embodiments, the temperature of the cooled material 620 can be adjusted in response to the temperature of the atmosphere within the tube 610. In some embodiments, the freezing material 620 can be a freezing liquid that circulates around the tube 610. If the atmosphere within the tube 610 increases beyond a desired range, the freezing liquid can be circulated faster, or the temperature of the freezing liquid can be reduced until the temperature of the atmosphere within the tube 610 is reduced to a desired range.

[0177] In some embodiments, the freezing pipe comprises an inlet hole or slit, which is configured to allow a certain amount of freezing material to travel to the inside of the pipe. The size, shape, and quantity of these holes or slits can be arranged differently according to the expected conditions. In some embodiments, the freezing material is a cryogenic liquid that is allowed to enter the pipe through the hole or slit. This will reduce the temperature in the pipe, and also allow some direct contacts between the polymer cable assembly and the cryogenic liquid. In some embodiments, the amount of the cryogenic liquid that is allowed to enter the pipe can be regulated so that under operating conditions, all cryogenic liquids that enter the pipe evaporate in the pipe. This will prevent the cryogenic liquid from leaking out of the cooling device, and allow faster and / or greater cooling of the polymer cable assembly.

[0178] In some embodiments, frozen wheels, rollers or groove wheels can be used to increase the hardness and stress / strain response of polymer cable assembly. The manufacture of wire and cable is usually a continuous process, which involves multiple wheels, rollers and / or groove wheels for a variety of different purposes (such as guiding process, controlling tension and / or gathering cable assembly). When polymer cable assembly contacts these wheels, at least some compressive forces are applied to cable assembly. In some embodiments, freezing or cryogenic fluid can pass through the inside of the wheel, thereby cooling the wheel. When the solid surface of the wheel rotates, it can cool the polymer cable assembly in contact with the rotating surface without producing significant additional deformation force. When the polymer cable assembly contacts the wheel, the polymer cable assembly will be at least slightly cooled and therefore become harder. In some embodiments, a series of frozen wheels, rollers or groove wheels can be used to increase the exposure time between cable assembly and the freezing surface, thereby allowing the cable assembly to reach the hardness of the desired degree before being subjected to subsequent compression force.

[0179] In some embodiments, instead of using a liquid or solid cooling medium, refrigerated air or another refrigerated gas or vapor can be used to reduce the temperature and increase the hardness and stress / strain response of the polymer cable assembly. The medium or fluid in the twisting machine may include various substitutes, such as cryogenic fluids, inert gases (e.g., helium, N2, argon, krypton, radon, neon, xenon, and combinations thereof). In some embodiments, the fluid in the twisting machine or cooling chamber may include cooling air produced by an air conditioner or refrigeration device, fluorocarbon solutions, saline solutions, gases obtained by evaporating solids or liquids (e.g., dry ice or liquid nitrogen) with an evaporation temperature of 0°C or less, liquids with a freezing point of 0°C or less, frozen acetone, and combinations thereof. Seasonal variations in wire and cable manufacturing are known phenomena. In hotter months, manufacturing facilities may have higher ambient temperatures. This can result in an increase in the temperature of the polymer cable assembly being used in a particular facility and a corresponding decrease in hardness. In order to address this seasonal variation, some manufacturing facilities utilize standard air conditioning to maintain a relatively constant temperature within the facility. However, the increased electrical performance of the manufactured cable does not require a moderate temperature to be maintained throughout the manufacturing facility.

[0180] In some embodiments, air conditioning equipment can be used to direct cold air directly into the twisting machine or into a cooling room surrounding the polymer cable assembly. By reducing the temperature of the atmosphere surrounding the polymer cable assembly, the hardness and Young's modulus of the polymer can be increased shortly before or during the compression event. In some embodiments, air conditioning equipment can be used to produce air at a temperature lower than the temperature that the entire manufacturing facility can withstand. In some embodiments, the air conditioning system can be configured to direct air less than about 60℉ to the polymer cable assembly. In some embodiments, the air conditioning or refrigeration system can be configured to direct air less than about 50℉, or less than about 40℉, or less than about 30℉, or less than about 20℉, or less than about 10℉, or less than about 0℉ to the polymer cable assembly. In some embodiments, the air conditioning or refrigeration system can be configured to direct air less than about 10℃, or less than about 5℃, or less than about 0℃, or less than about -5℃, or less than about -10℃, or less than about -15℃ to the polymer cable assembly.

[0181] In some embodiments, structures can be used to contain an ambient atmosphere that is cooler than the ambient atmosphere surrounding the polymer cable assembly before or during a compression event. In some embodiments, a chamber surrounding a twister take-up device can be used to contain a gas that is cooler than the surrounding atmosphere. It should be appreciated that for certain applications, specialized refrigeration equipment may be required to produce large quantities of very cold air. It should also be appreciated that cold air can be applied to the polymer cable assembly at any step in the manufacturing process where increased stiffness will help reduce deformation caused by compressive forces.

[0182] In an illustrative example, multiple twisted pairs of fluorinated ethylene propylene (FEP) insulated wire were formed at a line speed of 19 meters per minute or about 63 feet per minute. The twisting machine parameters were set to 3000 twists per minute and the lay length was set to 6.2 mm. Before the insulated wire was fed into the twisting machine, the wire was passed through a cooling container and immersed in liquid nitrogen for different lengths of time. Computed tomography (CT) scanning was used to check the crush ratio of the resulting twisted pair.

[0183] Table 1 below shows a table of data collected in three tests. Each test includes four samples passing through a cooling container of varying length. The length of the cooling container varies from 0 feet (control) to 2 feet, 4 feet, and 6 feet. The twisting parameters including line speed described above remain constant in all tests.

[0184] Table 1 - Crushing ratio

[0185]

[0186] As can be seen from Table 1, the average crush ratio decreases as the length of the cooling vessel increases. A line speed of 19 meters per minute is approximately 1 foot per second, so the length of the cooling vessel in feet is approximately equal to the time measured in seconds that the insulated wire is exposed to the liquid nitrogen.

[0187] Figure 6 A graph of the data presented in Table 1 is shown. Figure 6 As can be seen from the graph of FIG. 1 and Table 1, the average crush ratio is reduced from 6.74% when the FEP insulated wire is not exposed to liquid nitrogen to 1.09% when the FEP insulated wire is exposed to liquid nitrogen for about 6 seconds. This represents a reduction of the crush ratio by about 83% in about 6 seconds.

[0188] Table 2 (below) shows the surface temperature of FEP insulated wire samples exposed to liquid nitrogen for different lengths. The surface temperature was measured using a temperature probe while the FEP insulated wire was twisted after passing through the cooling chamber. The twisting parameters including line speed were consistent with the above parameters.

[0189] Table 2 - Surface temperature of FEP insulated wire

[0190]

[0191] Figure 7 The data presented in Table 1 and Table 2 are presented on a single graph. Figure 7It can be seen that the surface temperature of the FEP coated wire drops significantly after being exposed to liquid nitrogen for about 2 seconds and then continues to drop at a slower rate. The crush ratio of the FEP insulated wire drops after being exposed to liquid nitrogen for about two seconds and continues to drop as the length of the cooling container and the time the wire is exposed to liquid nitrogen increase.

[0192] The reduction in surface temperature of the insulated conductor and the corresponding reduction in crush ratio indicate that it is not always necessary to expose the insulated conductor to a cryogenic fluid for an extended period of time to reduce the crush ratio. In some embodiments, it is not necessary to reduce the temperature of the entire thickness of the insulation layer in order to significantly reduce the crush ratio. The outer skin of the insulation layer can be cooled to increase the stiffness of the outer portion of the insulation layer and reduce the amount of compression caused by twisting the insulated conductor.

[0193] Without being bound by theory, it is believed that the reduced crush ratio is due to the increased stress / strain response and hardness of the outer portion of the FEP insulated wire. When the insulated wire is exposed to liquid nitrogen for a longer period of time, the thickness of the outer portion of the insulation layer with increased stress / strain response increases. The degree of increased hardness and increased stress / strain response at the outer surface of the polymer insulation layer may also increase when the wire is exposed to liquid nitrogen for a longer period of time.

[0194] By exposing a polymer insulated conductor to liquid nitrogen or another cryogenic fluid for a brief period of time, a "harder" polymer skin can be formed within a uniform polymer layer. The hardened polymer layer having an increased stress / strain response reduces the deformation of the polymer insulation layer when the conductor is exposed to external forces. By reducing the deformation of the polymer insulating material, the conductor-to-conductor distance can be more consistently maintained. In some embodiments, by using the disclosed method, the total amount of polymer insulating material used can be reduced while maintaining the same conductor-to-conductor distance. In some cases, reducing the deformation of the polymer insulation layer increases the electrical properties of the conductor and the resulting cable. Reducing the amount of deformation also helps to maintain the shape of each insulated conductor, which improves the electrical consistency between the two insulated conductors of the twisted pair and maintains the balance of the twisted pair.

[0195] In some embodiments, the outer surface of the polymer insulation layer drops below 0° C. while the interior of the polymer insulation layer remains above about 5° C. In some embodiments, less than half the thickness of the polymer insulation layer will have a temperature below about 5° C.

[0196] In some embodiments, the polymer insulation layer or a portion of the polymer insulation layer can be a foamed polymer. In such embodiments, the foamed polymer insulation material includes many small air pockets created during the manufacturing process. Air is known to be an excellent electrical insulator, and therefore, incorporating air pockets throughout the polymer insulation layer reduces the dielectric constant of the insulation layer. This is because the dielectric constant of air is 1.0, which is superior to the dielectric constants of other materials, such as FEP (2.0), polyethylene (2.3), and polyvinyl chloride (3.5).

[0197] Although air has excellent dielectric values, it does not provide mechanical hardness. Therefore, foam materials or other polymer components incorporating air will have a lower hardness than similar components that do not incorporate air. Because air can be incorporated into polymer cable components in any number of ways (small cells, large cells, cavities, etc.), the final strength will be reduced according to the percentage of air that replaces the solid polymer and the size of the air cavity utilized. In some embodiments, the method described herein for increasing hardness is conducive to increasing the hardness of the remaining polymer material that is not replaced by air. Since foamed polymers are more easily deformed than solid polymers, the amount of additional material added to offset deformation can be increased. In some embodiments, before or during a compression event, the Shore D hardness of the foamed polymer material increases by at least about 10% relative to similar materials at 20°C.

[0198] Figure 8 A cross-sectional image of a foam insulated conductor is shown having a plurality of air pockets distributed throughout the insulation layer. It will be appreciated that these air pockets are closed and do not allow air or any other fluid to pass through the insulation layer.

[0199] In some examples, a single wire insulated with foamed FEP (rather than solid FEP) was twisted on a Setic twisting machine and analyzed for crush ratio and electrical impedance. Samples of foamed FEP insulated wire were exposed to cryogenic fluids for varying lengths of time. The samples exposed to the cryogenic fluids were compared to samples of the same foam insulated wire that were not exposed to the cryogenic fluids.

[0200] In one example, one twisted pair was used as a control and was not exposed to any cryogenic fluid, while a similar pair of foamed polymer insulated wires was exposed to a liquid nitrogen bath for 5.6 seconds before being twisted. The twisted pair made using both sets of wires had a lay length of 8.5 mm. For this analysis, a 6-inch sample of each of the two twisted pairs was imaged at three separate locations along its length using X-ray / CT.

[0201] As can be seen in Table 3 below, the average crush ratio of the foam insulated twisted pairs was reduced from an average of 17.75% when the wires were not exposed to liquid nitrogen to an average of 12.92% when the pairs were exposed to liquid nitrogen for 5.6 seconds. This represents an improvement of 27.21%. The crush ratio analysis was performed using X-ray / CT. Table 3 shows the crush ratio data for each of the three analysis points in both the control wire and the treated wire. The electrical impedance of the cryogenically cooled twisted pairs also increased from 136 ohms to 146 ohms, an increase of 10 ohms or 7.4% relative to the control twisted pairs.

[0202] Table 3-5.6 seconds crushing ratio of foam insulated twisted pair

[0203]

[0204] In another example, a second FEP bubble insulated twisted pair was used as a control and was not exposed to any cryogenic fluid, while a similar pair of wires was exposed to a liquid nitrogen bath for 9.1 seconds before being twisted. The twisted pairs made using these wires had a lay length of 8.5 mm. Also for this analysis, a 6-inch sample of each of the twisted pairs was imaged at three separate locations along their length using X-ray / CT.

[0205] As can be seen in Table 4 below, the average crush ratio of the twisted pair was reduced from an average of 18.84% when the wire was not exposed to liquid nitrogen to an average of 9.74% when the wire was exposed to liquid nitrogen for 9.1 seconds. This represents an improvement of 48.3%. The crush ratio analysis was performed using X-ray / CT. Table 4 shows the crush ratio data for each of the three analysis points in both the control wire and the treated wire. The electrical impedance of the cryogenically cooled twisted pair also increased from 142 ohms to 154 ohms, an increase of 12 ohms or 8.5% relative to the control twisted pair.

[0206] Table 4-9. Crushing ratio of foam-insulated twisted pair at 1 second

[0207]

[0208] One of the benefits of the disclosed invention is the ability to produce twisted pair and / or other cable designs with improved electrical properties by increasing hardness and reducing the amount of deformation produced during the twisting, cabling, and / or manufacturing process. One source of deformation of the insulation layer in a twisted pair is the twisting process, in which the two insulated conductors are twisted around each other. The degree of deformation that occurs during the twisting process is affected by multiple factors, including, for example, the lay length, the line tension, the insulating material, the hardness of the insulating material, and / or the heat generated in the polymer insulating material during the twisting process. When the insulated conductors are subjected to the greatest deforming forces, in order to reduce the deformation as much as possible, it is desirable to increase the hardness of the insulating material during the twisting process. As discussed, one way to temporarily increase the hardness of the insulating layer is to reduce the temperature. In some embodiments, it is desirable to reduce the temperature of the insulating layer when the wire is twisted.

[0209] In some examples, the relationship between the exposure time, surface temperature, and crush ratio of solid polymer insulated conductors and foamed polymer insulated conductors to cryogenic fluids was further investigated. In the following example, a pair of FEP insulated conductors was twisted together at a speed of 19 m / min after exposure to the cryogenic fluid. The surface temperature of the insulation layer was measured by direct contact with a temperature probe placed at the first contact point of the two insulated conductors.

[0210] Both the foamed FEP insulated conductor and the solid FEP insulated conductor were exposed to a cryogenic fluid (liquid nitrogen) for different lengths of time, and the surface temperature was measured. Table 5 shows the results of this example. Fig. 9 A graph of these results is shown.

[0211] Table 5 - Surface Temperature

[0212]

[0213] Table 5 and Fig. 9 It is shown that there is a significant difference in the surface temperature of the foamed polymer insulated conductor and the solid polymer insulated conductor even when exposed to the cryogenic fluid for the same amount of time. After six seconds of exposure to liquid nitrogen, the foamed insulated conductor maintained a much lower surface temperature than the solid polymer insulated conductor.

[0214] The surface temperature of the insulated conductor was measured approximately 1 second after the conductor was removed from the liquid nitrogen. Without being bound by theory, it is believed that the surface of the solid polymer insulation material heats up faster than the surface of the foam insulation layer. The foam insulation layer contains a plurality of closed air pockets. When the foam insulated conductor is immersed in liquid nitrogen, the air trapped in these air pockets is likely to cool, and the cooled air then slows the temperature rise of the surrounding insulation layer. In other words, the frozen air pockets within the foam insulation layer can help maintain a lower surface temperature of the foam insulation layer compared to the solid polymer insulation layer. Over time, both the solid polymer insulation layer and the foam insulation layer will warm up to the ambient temperature, but the foam insulation layer can maintain a significantly cooler temperature for a longer period of time.

[0215] In some embodiments, the cable is manufactured without significantly deforming the polymer cable assembly incorporated into the cable. Many polymer cable assemblies have a plurality of substantially circular cross-sections of approximately equal diameter. Similarly, before the cable is compressed or deformed, the substantially circular cross-sections of many polymer cable assemblies will have a plurality of radii that are approximately equal to each other. To be clear, before the polymer cable assembly is compressed or deformed, the radius with the maximum length is approximately equal to the radius with the minimum length. Although there are some natural deviations in the wall thickness of the polymer cable assembly, the maximum radius and the minimum radius are generally within 3% of each other. In some polymer cable assemblies, the initial maximum radius and the minimum radius may be within 5% of each other before being compressed or deformed.

[0216] In some embodiments, the generally circular cross-section of the polymer cable assembly is maintained after the polymer cable assembly is subjected to a compressive force or a deforming force. By increasing the hardness of the polymer cable assembly (as described herein), the polymer assembly can be less deformed, thereby maintaining its generally circular cross-section. In some embodiments, after subjecting the polymer cable assembly to a compressive force, the maximum length radius and the minimum length radius are within about 10% of each other. In some embodiments, the maximum length radius and the minimum length radius are within about 8% or about 5% of each other. In some embodiments, the maximum length radius and the minimum length radius are within about 15% or about 12% of each other. It should be appreciated that the closer the maximum length radius and the minimum length radius are to being equal to each other, the closer the cross-section is to being circular, and the smaller the deformation of the polymer cable assembly is generally.

[0217] In some embodiments, the hardness of the polymer cable assembly is increased by cooling the cable assembly for about 10 seconds or less, and the polymer assembly can be less deformed after being subjected to a compressive force or a deforming force. In some embodiments, after subjecting the polymer cable assembly to a compressive force, the maximum length diameter and the minimum length diameter are within about 10% of each other. In some embodiments, the maximum length diameter and the minimum length diameter are within about 8% or about 5% of each other. In some embodiments, the maximum length diameter and the minimum length diameter are within about 15% or about 12% of each other. It should be appreciated that the closer the maximum length diameter and the minimum length diameter are to being equal to each other, the closer the cross-section is to being circular, and the less deformation of the polymer cable assembly is generally.

[0218] Twisting the insulated conductor while it is still in a cooled state and thus has a higher stiffness is a way to reduce the amount of deformation during the twisting process. In some embodiments, this results in a lower crush ratio and improved electrical properties of the resulting twisted pair. In some embodiments, the amount of time the insulated conductor is exposed to a cryogenic fluid before being twisted and / or the amount of time the cooled insulated conductor is exposed to ambient temperature before being twisted can be adjusted to adjust the electrical properties of the resulting twisted pair.

[0219] In some embodiments, the crush ratio and / or associated electrical properties of a single conductor or twisted pair can be adjusted to produce multiple twisted pairs having approximately the same propagation delay. In some embodiments, twisted pairs having shorter lay lengths can be twisted when the individual insulated conductors are at a lower temperature and therefore have a higher stiffness to produce twisted pairs having reduced propagation delays relative to twisted pairs having longer lay lengths. In some embodiments, twisted pairs having longer lay lengths can be twisted when the individual insulated conductors are at a higher temperature relative to twisted pairs having shorter lay lengths to produce twisted pairs having higher propagation delays relative to twisted pairs having shorter lay lengths. In some embodiments, the surface temperature of the insulated conductors constituting the first twisted pair can be adjusted relative to the surface temperature of the insulated conductors constituting the second twisted pair, so as to form a first twisted pair and a second twisted pair with the following propagation delays: 100 meters of propagation delays are approximately equal, or 100 meters of propagation delays are within 10 nanoseconds of each other, or 100 meters of propagation delays are within 15 nanoseconds of each other, or 100 meters of propagation delays are within 25 nanoseconds of each other, or 100 meters of propagation delays are within 50 nanoseconds of each other. It should be appreciated that the surface temperature of the insulated conductors can be modulated by adjusting the time interval at which the insulated conductors are exposed to the cryogenic fluid, or by adjusting the time interval after the insulated conductors are removed from the cryogenic fluid but before the conductors are twisted or subjected to other compressive forces. It should also be appreciated that in addition to exposure to cryogenic fluids, other cooling methods as described herein can also be used. In all forms of cooling, the total degree of cooling can be modulated by controlling the temperature of the cooling material and / or the time when the polymer cable assembly is exposed to the cooling material. Similarly, regardless of the cooling method used, when a polymer cable assembly is subjected to a compressive or deforming force, the temperature of the polymer cable assembly can be controlled by adjusting the amount of time the polymer cable assembly is exposed to the ambient atmosphere after being cooled and before being subjected to the force.

[0220] In some embodiments, temporarily cool the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors and / or the fourth pair of polymer insulated conductors (wherein each pair includes two polymer insulated conductors) to increase the hardness of each pair to a certain extent. In some embodiments, the degree of hardness increase of each pair can be different. Once a pair of polymer insulated conductors has the desired hardness, the pair is twisted together to form the first twisted pair, the second twisted pair, the third twisted pair, and / or the fourth twisted pair. Each twisted pair has a propagation delay of 100 meters. In some embodiments, for the first propagation delay of 100 meters, the second propagation delay, the third propagation delay, and the fourth propagation delay, the propagation delay difference of 100 meters is within 50 nanoseconds of each other. In some embodiments, the propagation delay is within 25 nanoseconds of each other. In some embodiments, the first propagation delay of 100 meters, the second propagation delay, the third propagation delay, and the fourth propagation delay have a delay difference of less than 25 nanoseconds.

[0221] In some embodiments, the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and / or the fourth pair of polymer insulated conductors are cooled for different time periods to achieve the desired hardness of each pair individually. In some embodiments, the cooling time periods are all less than about 20 seconds, or are all less than about 15 seconds, or are all less than about 10 seconds. In some embodiments, the first time period is between about 8 seconds and 10 seconds, the second time period is between about 6 seconds and 8 seconds, and the third time period is between about 4 seconds and 6 seconds. In some embodiments, the fourth time period is less than about 4 seconds and can be zero seconds, which indicates that one of the four pairs may not be significantly cooled at all.

[0222] In some embodiments, the cooling period and / or the degree of increase in hardness of the polymer insulated conductor are related to the expected lay length of the twisted pair made of the polymer insulated conductor. Generally, the shorter the lay length, the longer the cooling period before twisting and / or the greater the increase in hardness relative to other conductor pairs.

[0223] In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and / or the fourth twisted pair have a first lay length, a second lay length, a third lay length, and / or a fourth lay length, respectively. The first lay length is shorter than the second lay length, and the second lay length is shorter than the third lay length. In some embodiments, the first cooling period is longer than the second cooling period, and the second cooling period is longer than the third cooling period.

[0224] In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and / or the fourth twisted pair have a first crushing ratio, a second crushing ratio, a third crushing ratio, and / or a fourth crushing ratio, respectively. In some embodiments, the first crushing ratio is less than the second crushing ratio, and the second crushing ratio is less than the third crushing ratio.

[0225] In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and the fourth twisted pair have a first signal speed, a second signal speed, a third signal speed, and a fourth signal speed, respectively. In some embodiments, the first signal speed is greater than the second signal speed, and the second signal speed is greater than the third signal speed.

[0226] In some embodiments, the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and / or the fourth pair of polymer insulated conductors each have a different increased stiffness. In some embodiments, the increased stiffness of the first pair of polymer insulated conductors is greater than the increased stiffness of the second pair of polymer insulated conductors, and the increased stiffness of the second pair of polymer insulated conductors is greater than the increased stiffness of the third pair of polymer insulated conductors.

[0227] It should be appreciated that when two insulated conductors are twisted together, the generally circular cross-section of each insulated conductor is at least slightly deformed. The closer the cross-section of each insulated conductor is to a circle, the greater the amount of air retained in the gap between the two insulated conductors. When more air is retained in the gap, the overall dielectric constant of the twisted pair of conductors is reduced, and the propagation speed is increased. By cooling the polymer insulated conductor and increasing the hardness, while the conductor is twisted to form a twisted pair, the polymer insulating material is deformed less and maintains a more round cross-section. It should be appreciated that the dielectric constant of the insulating material itself does not increase or decrease. However, since the insulating layer maintains its generally circular cross-section and incorporates a larger amount of air into the gap of the twisted pair, the dielectric constant of the twisted pair finally obtained can be reduced. In some embodiments, the purpose of cooling the polymer insulated conductor is to retain a larger amount of air in the gap of the twisted pair finally obtained.

[0228] In some examples, the temperature of the conductors within the twisted pair is analyzed during and after exposure to a cryogenic fluid (liquid nitrogen). The analysis is performed based on the resistance of the conductors using the equation shown below. Equation 1:

[0229] R=R ref [1+α(TT ref )]

[0230] in:

[0231] R = conductor resistance at temperature T;

[0232] R ref= At reference temperature T ref The conductor resistance under

[0233] α = Conductor material at T ref The resistivity under

[0234] T ref = reference temperature (°C) for a given α for the conductor material;

[0235] T = conductor temperature (°C).

[0236] In one example, the α of copper at 20°C is known to be 0.00393K -1 . R ref Determined to be 1.25 ohms based on the following calculation. To analyze the temperature of the conductor, the twisted pair was connected to a handheld cable analyzer that records the resistance of the conductor in real time. The insulated conductor was immersed in a liquid nitrogen bath and the change in resistance over time was recorded. Equation 1 (above) was then solved for T.

[0237] In this example, a 24'9" length of FEP insulated copper wire is used. The resistance of the 24'9" length of wire is known to be 1.51 ohms. The resistance of the 6" length of wire is known to be 0.26 ohms. To calculate R ref , subtract the resistance of the 6" length of copper wire from the resistance of the 24' 9" length of copper wire to approximate the resistance of any other components in the circuit that are not insulated conductors. Once R ref Once R is determined to be 1.25 ohms, the measured value of R can be used to solve Equation 1 for T.

[0238] exist Fig.10 and Fig.11 The calculated temperature of the copper conductor over time is shown in . Fig.10 The first 20 seconds after immersion of the conductor in liquid nitrogen are shown in more detail. Fig.11 The temperature of the conductor when immersed in liquid nitrogen and after being removed from the liquid nitrogen is shown. The conductor is placed in the liquid nitrogen bath at time = 0. The conductor temperature drops rapidly during the first five to ten seconds before reaching equilibrium at about -176°C. The cable is kept in the liquid nitrogen bath for 120 seconds. When the conductor is removed from the liquid nitrogen bath at 120 seconds, the conductor temperature begins to warm up, as shown in FIG. Fig.11 Both the solid insulated conductor and the foam insulated conductor reached about 0°C about 40 seconds after being removed from the liquid nitrogen. Fig.10 and Fig.11 It is seen that the solid insulated conductors and the foam insulated conductors maintain substantially similar temperatures relative to each other as they are cooled in the liquid nitrogen and as they are warmed after being removed from the liquid nitrogen.

[0239] Although the disclosed invention has been generally described in the context of twisted pair cables, it may be applied to a wide variety of other applications.

[0240] In some embodiments, when two insulated conductors are put together to form a twisted pair, additional tapes, fillers, or hollow tubes may be added or incorporated into the twisted pair. In the case of tapes, they may be added between the insulated conductors, outside the twisted pair unit, and / or around the twisted pair unit.

[0241] Fig.12 Schematic diagram of a twisted pair of wires incorporated into a ribbon according to an embodiment is shown. Fig.12 As shown, a tape 930 can be placed between two insulated conductors 920 of a twisted pair 910. The tape 930 generates forces during the twisting of the twisted pair. As a result of these forces, the tape 930 can be compressed or otherwise deformed during the twisting process. The deformation of the tape 930 can result in increased capacitance, increased insertion loss, reduced electrical impedance, and / or other undesirable effects on the electrical properties of the resulting twisted pair. By increasing the stress / strain response of the tape shortly before exposing the tape 930 to the forces of the twisting process, the deformation of the tape can be reduced, and the electrical properties of the resulting twisted pair can be maintained or enhanced. As described elsewhere herein, the stress / strain response (and hardness) of the tape can be increased by exposing the tape to a cryogenic fluid.

[0242] Fig.13Schematically illustrated is an embodiment in which a tape is wrapped around a twisted pair. In some embodiments, one or more than one twisted pair 1010 may be surrounded by a tape 1020. Each twisted pair 1010 may include two conductors 1030 surrounded by an insulating layer 1040. In some cables, multiple twisted pairs 1010 are surrounded by a jacket 1050. The tape 1020 may be formed tightly around the twisted pair 1010, thereby causing deformation and increasing capacitance, reducing impedance, and / or increasing insertion loss. In some embodiments, the tape 1020 may include a combination of metal and polymer insulating materials. As described above, polymer materials may be susceptible to compression or other forms of deformation. In some embodiments, the tape is passed through a cooling chamber before being wrapped around the twisted pair, in which the tape is immersed, sprayed, or otherwise exposed to a cryogenic fluid or other cooling medium. By exposing the tape to a cryogenic fluid and increasing the stress / strain response and hardness of the polymer, the tape may become more rigid and resist deformation. It is believed that the amount of air between the twisted pair and the tape layer surrounding the twisted pair can be increased by the higher stiffness (i.e., increased stiffness) of the tape. This is because the harder tape will not mold itself tightly around the insulated conductor relative to a polymer tape with a lower hardness, and will maintain a larger amount of air space inside the wound tape. Increasing the amount of air trapped between the tape and the twisted pair will improve the electrical properties of the conductor or the resulting cable. Air is a strong dielectric material. Increasing the volume of air in the cable or in the insulating layer generally has a positive effect on the electrical properties of the resulting conductor and / or cable.

[0243] Fig.14 A cross section of an embodiment incorporating a hollow tube into a twisted pair cable is schematically illustrated. Fig.14 A cable comprising two conductors 1110 is shown, each conductor being surrounded by an insulating layer 1120. The insulated conductors are located within a sheath 1130. In some embodiments, the twisted pair may be combined with a hollow tube 1140 and / or a filler positioned in the gap between the two insulated conductors to form an additional air space 1150 within the sheath 1130. These hollow tubes 1140 are typically made of a polymer material and may be compressed or otherwise deformed when they are compressed against the insulated conductors of the twisted pair during the twisting process. When the hollow tube or filler is deformed, the amount of air contained in the hollow tube and / or contained in the sheath may be reduced. In addition, if the hollow tube or filler is deformed, the twisted pair to twisted pair spacing may be reduced or become inconsistent, thereby increasing the amount of crosstalk between different twisted pairs. In some cases, the reduced twisted pair to twisted pair spacing may also increase capacitance, increase insertion loss, reduce impedance, and / or otherwise degrade the electrical performance of the resulting cable.

[0244] By exposing the hollow tube 1140 or filler to a cryogenic fluid to increase their stress / strain response and thus hardness, they are more resistant to deformation and collapse into the gaps of the twisted pairs, thereby maintaining air spaces 1150 and improving electrical performance. The air pockets formed between the hollow tube 1140 and the gaps of the pair contribute to electrical performance. This is because the dielectric constant of air is 1.0, which is superior to the dielectric constants of other materials, such as FEP (2.0), polyethylene (2.3), and polyvinyl chloride (3.5). In some embodiments, maximizing the air content contributes to the electrical performance of the wires and cables.

[0245] Fig.15 Schematically illustrated are cross sections of embodiments in which protrusions are used to increase air space, reduce material costs, and / or reduce weight. In some embodiments, the jacket 1210, twisted pair 1220, and / or hollow tube 1230 include protrusions 1240 or stripes on the inner and / or outer surfaces to form additional air space 1250. In some embodiments, the protrusions 1240 and / or stripes are susceptible to deformation. In such embodiments, increasing the stress / strain response and hardness of the hollow tube 1230 including stripes and / or protrusions 1240 to prevent deformation or collapse of the protrusions 1240 can help maintain and / or maximize the air space 1250 in the cable.

[0246] In some embodiments, the protrusions from the hollow tube, insulation layer, or jacket layer are formed during profile extrusion of the cable assembly. In some embodiments, the protrusions can be easily compressed or deformed. Surface hardening (i.e., increasing the stress / strain response) by exposing the material to a cryogenic fluid can help reduce the impact of forces on the protrusions, thereby maintaining the air volume that would exist if the protrusions were not compressed or deformed.

[0247] It should be appreciated that not only the polymer insulated wires can be exposed to cryogenic temperatures or cooling fluids, but also the hollow tubes, filler tubes, tapes, jackets, and / or other polymer cabling components can be exposed to cryogenic temperatures or cooling fluids or another cooling medium to increase stress / strain response and stiffness. By reducing deformation of the cable components, the air volume within the cable can be maintained or increased and the electrical performance of the cable improved relative to similar cables that are allowed to compress or deform.

[0248] Fig.16Schematically illustrates a cross section of an embodiment in which a conductor is insulated by multiple insulating layers. In some embodiments, multiple layers of different insulating materials can be used to surround the conductor. In some embodiments, an outer material layer with a higher inherent hardness can be used to help reduce the compression of a softer inner material layer. In some embodiments, a layer of foam insulation 1320 can be used to insulate the conductor 1310. The Young's modulus and hardness of the foam insulation layer can be significantly lower than a solid insulation layer of the same polymer material because the foam insulation layer contains many discrete air pockets. Therefore, the foam insulation layer is more susceptible to compression during manufacturing. A surface layer 1330 of a harder material with a higher Young's modulus than the foam insulation material 1320 below can be used to reduce the compression of the foam insulation material 1320. By exposing the insulated conductor (including the foam insulation material and the foam skin) to a cryogenic fluid, the stress / strain response and hardness of the outer portion of the insulation material can be temporarily increased so as to reduce the compression or deformation of the insulation layer during the manufacturing or cabling process. It should be appreciated that the entire thickness of the inner foam insulation layer may not need to be cooled so that the outer portion of the foam insulation layer has a temporarily increased stress / strain response and hardness and resists compression during the cabling process. It should also be appreciated that the skin 1330 itself may or may not be foam. In some embodiments, the skin will be a solid polymer designed to protect the foam insulation material below. In some embodiments, the skin will include a different polymer than the foam insulation layer.

[0249] In some cable embodiments, separator tapes, cross-webs, and / or star fillers are used between twisted pair units to separate the twisted pair units from each other. Due to the forces experienced during the cabling process, these separators may deform, thereby reducing the air volume within the cable and negatively affecting the electrical performance of the cable.

[0250] Fig.17 Schematically illustrates a cross section of an embodiment in which a plurality of twisted pairs are separated by a crossbar. Fig.17 In the illustrated embodiment, the twisted pairs 1410 are separated from each other by a polymer cross-web 1420. This reduces the amount of electromagnetic interference between the twisted pairs 1420. The cross-web 1420 and the twisted pairs are housed in a jacket 1430.

[0251] In some embodiments, the separator, cross net and / or star-shaped filler are in the shape of extruded polymers without the benefit of metal backing or rigid internal components. The polymer separator can be made of high dielectric material (3.0 or greater). In some embodiments, the separator can be made of foam material, thereby improving their dielectric properties and also increasing their sensitivity to deformation. During the cabling process, the cable assembly is subjected to multiple compressive forces or deformation forces usually. By exposing the separator, cross net or star-shaped filler to cryogenic fluid and temporarily increasing stress / strain response and hardness before or during the cabling process, the compression or deformation of the separator or other components can be reduced, thereby increasing the air volume in the cable and improving the electrical properties of the cable finally obtained.

[0252] In some embodiments, the polymer cable assembly can be hardened before being compressed to reduce the degree of deformation of the polymer cable assembly. In some embodiments, the polymer cable assembly can be hardened before being compressed so that the polymer cable assembly can withstand greater compressive forces while compressing to about the same degree as if the cable had not been hardened before being compressed.

[0253] In some embodiments, a first twisted pair is manufactured by operating a twisting device or twisting machine at a first line speed. The resulting first twisted pair has a certain first crush ratio. Another twisted pair can be manufactured by cooling a polymer insulated conductor to increase the hardness of the polymer insulation layer, and then twisting the polymer insulated conductor by operating a cable twisting device at a second, faster speed to produce a second twisted pair with a second crush ratio. In some embodiments, the second twisted pair is made at a faster second speed and has approximately the same crush ratio as the first twisted pair. In some embodiments, the second crush ratio is within about 10% of the first crush ratio. In some embodiments, the second crush ratio is less than the first crush ratio. In some embodiments, the second speed is at least about 15% faster than the first speed. In some embodiments, the second speed is at least about 25% faster than the first speed.

[0254] In some embodiments, the twisting machine or twisting equipment used will have a rated speed for a particular type of wire and cable product. In some embodiments, the above-mentioned first speed is the rated speed of a given twisting machine and cable product, and the second speed is at least about 10% faster than the rated speed of the same product. In some embodiments, the first line speed is about 60 feet per minute, and the second line speed is about 70 feet per minute. In some embodiments, the first line speed is about 160 feet per minute, and the second line speed is about 180 feet per minute. In some embodiments, the first line speed is about 220 feet per minute, and the second line speed is about 275 feet per minute.

[0255] Fig.18Schematically illustrated is a cross section of an embodiment in which the conductor includes a metal braid. In some embodiments, the conductor 1510 is insulated by a polymer insulating layer 1520, and a metal wire braid 1530 is constructed above the insulating layer 1520. The metal wire braid 1530 can be made of a metal such as copper, or plated with silver or tin. The metal wire braid 1530 can include a plurality of metal strands that are woven together. When the braid is applied to the polymer insulating layer 1520, the individual metal strands that constitute the braid can produce an indentation and / or compress the polymer insulating layer 1520 in the surface, thereby negatively affecting the electrical properties of the cable. In some embodiments, a plurality of polymer cable assemblies (such as insulated conductors and hollow tubes) are cabled together using a metal braid. In such an embodiment, each polymer cable assembly that contacts the metal strands can be deformed due to the compression force of the metal strands, thereby adversely affecting the electrical properties of the resulting cable.

[0256] In some cases, braid indentation on the polymer insulation layer repeats at regular intervals. This can negatively impact a cyclic electrical signal that repeats at approximately the same regular intervals or frequency or any harmonics thereof. By increasing the stress / strain response and hardness of the polymer insulation layer prior to applying the braid or metal strands, braid indentation, compression, and other deformations of the polymer insulation layer can be reduced.

[0257] In some embodiments, the cooling chamber, or other structure containing a cooling medium, located immediately in front of the braiding machine has a length of less than about 5 feet, or a length of less than about 3 feet, or a length of less than about 1 foot. Since the line speed of most braiding machines is relatively slow, the footprint of the cooling chamber can be reduced without reducing the residence time of the polymer cable assembly in the cooling chamber.

[0258] In one non-limiting embodiment, uninsulated copper wire is used to simulate the indentation made in the polymer cable assembly during the metal braiding process. The metal braid is usually applied to the polymer cable assembly by braiding or weaving a plurality of individual metal strands together on the polymer assembly. When these individual strands are braided together, they compress the polymer assembly below and deform the polymer assembly. In order to simulate the deformation process, a conductor insulated with foam FEP is twisted with an uninsulated copper wire using a twisting machine. When the uninsulated copper wire is twisted around the foam FEP insulation material, the indentation left in the foam FEP insulation layer can be checked. The bare copper wire is a 24AWG conductor, and the outer diameter of the FEP foam insulated conductor is about 82.68 mils (mil) or about 2.1mm.

[0259] The samples were formed using a 6.2 mm lay length and a twister running at 1400 twists per minute and 30 feet per minute. The samples were collected after the FEP foam insulation was exposed to liquid nitrogen for 10 seconds and without using a cooling chamber as a control. The depth of the indentation left by the copper wire on the foam insulation was analyzed using a laser microscope.

[0260] Upon initial visual inspection, the polymer insulation layer that was not exposed to liquid nitrogen deformed into a generally spiral shape when twisted with the bare copper wire. The polymer insulation material that was exposed to liquid nitrogen for 10 seconds to increase its hardness appeared to be generally straight, with the copper wire wrapped in a spiral fashion around the straight foam insulation layer. The foam FEP insulation layer appeared unchanged through the twisting process with the bare copper wire.

[0261] The depth of the indentation made by the bare copper wire into the FEP foam insulation was measured three times at each of three locations, before the twister take-up, inside the twister bow, and at the twister take-up reel. The data is presented in Table 6 below.

[0262] Table 6 - Indentation Depth

[0263]

[0264] As the twisted pair moves from before the take-up to inside the bow, to the take-up reel, the amount of force and total number of compression events increases, and the lay length decreases. The distance and time the polymer insulation has to travel away from the cooling chamber also increases, allowing the stiffness of the polymer insulation to decrease as the polymer returns to ambient temperature.

[0265] As can be seen in Table 6, at each location, the samples exposed to liquid nitrogen for 10 seconds showed a significant reduction in indentations formed by the copper wire. Therefore, it can be expected that the metal braid shielding layer applied on top of the polymer insulation layer will cause less deformation of the polymer insulation layer if the polymer insulation layer is hardened by cooling the polymer before the braid is applied. Wire and cable products with less deformed polymer insulation layers generally have improved electrical properties relative to wire and cable products with compressed or otherwise deformed polymer insulation layers.

[0266] In some embodiments, during the cabling process, compression and / or deformation may occur when individual insulated conductors and / or other cable components are bundled together. This deformation can lead to compression of the insulation layer, forcing the insulated conductors into the cross-mesh or other separators, and / or collapse of the jacket layer. During the cabling process, the twisting of the existing twisted pair can lead to an increase in the twist rate of the twisted pair, thereby generating additional compressive forces within the existing twisted pair. Hardening the cable assembly by temporarily increasing the stress / strain response and hardness during the cabling process can help reduce or avoid deformation of the individual cable components individually and relative to each other. By exposing the cabling assembly to a cryogenic fluid before and / or during the cabling process, the desired arrangement of the cable can be maintained. Avoiding deformation maximizes the amount of air space in the cable and improves electrical performance. Allowing the physical arrangement of the cable to deform has a negative impact on the electrical performance of the cable.

[0267] As described herein, air is a favorable dielectric material, but air does not provide physical support to prevent conductors from contacting each other. Therefore, an insulator is used to prevent contact and reduce interference between conductors. In order to improve the electrical properties of the insulating layer, air can be introduced into the insulating material via air channels (profile extrusion) or foam formation (generating bubbles in the insulating material). Because air itself does not have physical strength, the overall stress / strain response and hardness of the insulator are reduced by introducing air into the insulating layer. Due to the same external force, lower Young's modulus and hardness lead to larger compression or deformation. By exposing the insulating component to a cryogenic fluid and temporarily increasing the stress / strain response and hardness of the insulating layer, the deformation generated during the manufacturing process can be alleviated. In some embodiments, air is introduced into the insulating layer to allow cryogenic fluid to cool the closed air pockets. Relative to a solid insulating layer without any air pockets, this can help maintain the insulating layer at a reduced temperature for a longer period of time. This can also allow the cryogenic fluid to penetrate deeper into the insulating layer and / or provide a larger surface area for the cryogenic fluid to act on during the same exposure time.

[0268] During the process of forming a twisted pair from separate insulated conductors, compressive forces generally increase as the lay length of the twisted pair increases.In some embodiments, the foam insulation layer is exposed to a cryogenic fluid prior to being twisted to produce the twisted pair.

[0269] In some embodiments, a lighter, smaller, and / or more useful cable can be manufactured by increasing the stress / strain response and hardness of a polymer cable assembly before or during manufacturing. If the cable assembly is not compressed or otherwise deformed, less total insulation material may be required to achieve the same electrical performance. If the insulation layer is less compressed during manufacturing due to increased stress / strain response and hardness, the overall thickness of the insulation layer can be reduced.

[0270] In some embodiments, untwisted pairs can benefit from temporarily increasing the stress / strain response and hardness of the polymer insulation layer. For example, the polymer insulation layer of a single polymer insulated conductor can deform during the manufacturing process as the conductor contacts rollers, guide rods, or other equipment. The polymer insulation layer can also deform when two conductors are connected to form an untwisted pair.

[0271] Many cables contain more than one twisted pair. In order to reduce electrical interference between twisted pairs, each twisted pair in a cable can have different lay lengths or different twists per meter. The difference in lay length and other differences in twisted pairs can cause some twisted pairs to have faster or slower signal speeds. One factor that can cause a twisted pair to have faster or slower signal speeds is the amount of air in the gap between the two insulated conductors of the twisted pair. The more the conductors in the twisted pair are deformed by the compression force of twisting, the less air is left in the gap. The less the conductors in the twisted pair are deformed by the compression force of twisting, the more air is left in the gap, the lower the dielectric constant of the twisted pair, and the faster the signal speed of the twisted pair. In addition to air being contained in the gap of the twisted pair, air can also be contained between various components in the cable. In some cable embodiments, air pockets can be formed between twisted pairs, between twisted pairs and cross members, between twisted pairs and filler tubes, and / or in hollow tubes. Generally, the more air is contained in the cable, the better the electrical properties of the cable.

[0272] In some applications, multiple twisted pairs in a single cable can be used to transfer data. In order to correctly process the data, data must be sent through the twisted pair and received from each twisted pair at a specific time. In some embodiments, different lay lengths are used to reduce the electrical noise between different twisted pairs. Four twisted pairs are usually used to transmit signals. Using different lay lengths for each twisted pair in these four twisted pairs can cause the conductor path of one twisted pair to be shorter or longer than the conductor path of another twisted pair. For example, a twisted pair with a longer lay length and fewer twists per inch will have a shorter conductor path than a twisted pair with a shorter lay length and more twists per inch.

[0273] In many applications, it is important that the signals on the various twisted pairs arrive at approximately the same time. Different conductor lengths may cause the signals to arrive at different times. This can produce an effect known as delay differences. In some embodiments, it is beneficial to slow down or not modulate the signal that arrives first (shortest conductor pair path) and speed up the signal that naturally arrives last (longest conductor pair path).

[0274] The difference between the signal received from the twisted pair with the fastest signal speed and the signal received from the twisted pair with the slowest signal speed is called the delay difference. It is desirable to have a delay difference of less than 25ns. In some applications, a delay difference of less than 50ns is acceptable.

[0275] As discussed, deformation of the polymer insulation in a twisted pair can affect the electrical properties of the twisted pair, including signal speed. The tighter the twist, or the shorter the lay of the twisted pair, the greater the compressive forces applied during twisting, and generally the greater the degree of deformation of the polymer insulation and the subsequent reduction in the air dielectric between the insulated conductors.

[0276] In some embodiments, multiple twisted pairs can be exposed to cryogenic fluids for different amounts of time in order to adjust the signal speed and reduce the delay difference of the resulting cable. By exposing the polymer insulated conductors to the cryogenic fluid for different amounts of time, the desired amount of deformation of the polymer layer can be introduced. By controlling the degree of polymer deformation, the desired amount of air in the twisted pair gap can be controlled. Although deformation generally has a negative impact on the electrical properties of the resulting twisted pair, by being able to control the degree of the negative impact, the signal speed across multiple twisted pairs can be standardized, and a cable with a reduced delay difference across multiple twisted pairs can be formed.

[0277] In a non-limiting example, four twisted pairs are manufactured to be incorporated into a single Ethernet cable. The polymer insulated conductors forming each twisted pair in these four twisted pairs can be exposed to a cryogenic fluid before being twisted. The polymer insulated conductors forming the twisted pair with the longest lay length can be exposed to a cryogenic fluid for about, for example, two seconds, so as to reduce the degree of deformation of the polymer insulation layer. The polymer insulated conductors forming the twisted pair with the shortest lay length can be exposed to a cryogenic fluid for about, for example, ten seconds, so as to reduce the degree of deformation of the polymer insulation layer, and keep most of the air dielectric between the insulated conductors. The polymer insulated conductors forming the twisted pair with more medium lay lengths can be exposed to a cryogenic fluid for the period between 2 seconds to 10 seconds. By exposing the wires constituting different twisted pairs to cryogenic fluids for different amounts of time, the signal speed of the resulting twisted pair can be tuned, and the delay difference of the resulting cable can be reduced.

[0278] While the dielectric constant of a given polymer may be known, the total amount of insulation and air space surrounding the conductors within a twisted pair is a function of the original polymer insulated conductors, the cable design, and the degree of deformation of the various cable components introduced during the manufacturing process. In the case of a foamed polymer insulation layer, the amount of air space surrounding the conductors can be closely related to the degree of deformation of the polymer insulation layer.

[0279] For a given conductor, the dielectric constant is inversely proportional to the propagation speed. Therefore, the time it takes for a signal to travel along a given length of a twisted pair is also related to the dielectric constant. The higher the total dielectric constant (insulation layer combined with air space) surrounding the conductor, the longer the signal will take to pass through the twisted pair. By controlling the degree of deformation of various cable components (for example, including: insulation layer, twisted pair, hollow tube, filler tube, and / or jacket), the electrical properties of the twisted pair and / or cable can be modulated. This is partly due to the amount of air retained around or inside the cable assembly. By combining twisted pairs with known or controlled signal speeds, cables with reduced delay differences can be manufactured.

[0280] The propagation velocity of a twisted pair can be measured directly using commercially available instruments. The measured value of the propagation velocity can be used to determine the combined dielectric constant (ε) using the following equation.

[0281]

[0282] By measuring the propagation velocity directly, the combined dielectric constant (ε) can be calculated to account for the dielectric effects of both the polymer insulation and the air space surrounding the conductor.

[0283] In a non-limiting example, it is assumed that the propagation speed of the twisted pair is measured to be 68%. Based on the above formula, the combined dielectric constant is calculated to be 2.16. Using the time delay calculation provided above, the time delay of the signal traveling through the twisted pair will be equal to about 1.5 nanoseconds per foot. If a second twisted pair is made, and the polymer insulated conductor is exposed to a cryogenic fluid before the polymer insulated conductor is twisted together, the amount of air space surrounding the conductor can be increased, thereby increasing the propagation speed. If the increased propagation speed is 70%, only 2% is increased, then the resulting combined dielectric constant is calculated to be 2.04, and the calculated time delay is 1.45ns / foot. For a 330-foot length of twisted pair, the difference of 0.05 nanoseconds per foot between the two twisted pairs results in a total signal delay difference of 16.5 nanoseconds. By exposing the polymer insulated conductor to a cryogenic fluid for a specific amount of time, the combined dielectric constant and the propagation speed can be controlled. This allows the development of higher-speed twisted pairs, and also allows the formation of cables with reduced delay differences.

[0284] By exposing the polymer insulated conductors to the cryogenic fluid for varying amounts of time, a desired amount of deformation of the polymer layer can be introduced. While deformation generally has a negative impact on the electrical properties of the resulting twisted pair, by being able to control the extent of the negative impact, signal speeds across multiple twisted pairs can be standardized and cables with reduced delay differences can be formed.

[0285] In some embodiments, the twisting machine can be adjusted to run at a faster or slower line speed to control the amount of time that the insulated conductor is exposed to the cryogenic fluid. In some embodiments, multiple cooling vessels of different lengths can be used to expose the polymer insulated conductor to the cryogenic fluid for different amounts of time. In some embodiments, a displacement block or adjustable baffle can be used to control the portion of the cooling vessel that actually contains the cryogenic fluid, thereby allowing a single cooling vessel to be used to expose the polymer to the cryogenic fluid for different amounts of time. By using a displacement block or adjustable baffle, a portion of the cooling vessel can be retained without the cryogenic fluid, thereby functionally forming a cooling vessel of variable length.

[0286] In some embodiments, one or more groove wheels, wheels, capstans, and / or rollers can be used in the cooling container to redirect the path of the polymer cable assembly in the cooling container. This arrangement allows the polymer cable assembly to remain in the cooling container for a longer period of time without increasing the length of the cooling container or reducing the linear speed of the assembly. In some embodiments, the polymer cable assembly enters the cooling container in the upper vapor region of the container, where the evaporated cryogenic vapor has risen above the cryogenic liquid, and is subsequently redirected to pass through the liquid region of the container (where liquid cryogenic fluid is maintained). This arrangement allows the polymer cable assembly to initially transfer heat to the cryogenic vapor before contacting the cryogenic liquid, thereby reducing the total heat load being transferred to the cryogenic liquid and increasing the total residence time of the polymer cable assembly in the cooling container. In some embodiments, the redirecting wheel (redirecting wheel) can be adjustable, so as to control the total residence time of the polymer cable assembly in the cooling container.

[0287] It should be appreciated that the cable can be made with one or more twisted pairs, including, for example, two, three, four, six, or eight twisted pairs. Each twisted pair in the cable can be exposed to the cryogenic fluid for a unique predetermined amount of time in order to adjust the signal speed. By adjusting the signal speed, the delay difference of the resulting cable can be reduced.

[0288] In some embodiments, a cable jacket is formed around a twisted pair or other cable assembly using an extruder with a forming die. The cable assembly is passed through the extruder die, and a polymer is extruded around the cable assembly to form the jacket. In some embodiments, the cable jacket is exposed to a cryogenic fluid after being extruded around the cable assembly to avoid deformation of the cable jacket.

[0289] In some embodiments, the polymer can be exposed to a cryogenic fluid after being extruded to form a polymer shape, including but not limited to a hollow tube, a solid tube, a rectangular shape, an irregular shape, a shape with a protrusion, an indentation or a cavity, or any other shape design. By exposing the extruded polymer shape to a cryogenic fluid after extruding the shape, the stress / strain response and hardness of the extruded shape can be increased over a relatively short distance. In some embodiments, exposure to a cryogenic fluid can be used to adjust the crystal structure of the extruded shape, and / or control the physical properties of the resulting polymer shape. In some embodiments, the extruded polymer can be exposed to a water bath before being exposed to a cryogenic fluid. By exposing the extruded polymer shape to a cryogenic fluid, the resulting polymer can be more easily handled, ground, machined, or cut. The resulting polymer can resist deformation and / or produce less shavings, dust, chips, or unusable materials during processing. In some embodiments, by adjusting the crystal structure of the polymer cable assembly, improved tensile and elongation properties can be achieved.

[0290] In some embodiments, a cryogenic cooling vessel may be incorporated into a continuous or semi-continuous process in-line. In some embodiments, a twisting machine may be configured to incorporate a cryogenic cooling chamber before, during, and / or after the twisting machine twists the polymer insulated conductors to form twisted pairs. In some embodiments, a cabling machine may be configured to incorporate a cryogenic cooling chamber before, during, and / or after the cabling machine gathers and / or twists the cable components to form a cable core.

[0291] In some embodiments, the cryogenic cooling container comprises: a container configured to hold cryogenic liquid, a liquid level sensor (e.g., such as a float switch), an inlet arrangement arranged to provide cryogenic liquid, and / or a discharge arrangement for removing evaporated cryogenic fluid. In some cryogenic cooling containers, an inlet is provided to allow a polymer component (e.g., such as a polymer insulated conductor) to enter the cooling container, and an outlet is provided to allow the polymer component to leave the cooling container. In some embodiments, the diameter of each of the inlet and outlet is less than 0.3 mm larger than the diameter of the polymer sample. In some embodiments, the inlet and / or outlet are provided with a profiled shape to accommodate various profiled polymer samples, e.g., such as a cross-net. In some embodiments, the cooling container incorporates a sensor and / or a marking device for maintaining consistent wire or cable quality during operation and / or process interruption.

[0292] In some embodiments, a cooling vessel is provided to expose the polymer insulated conductors entering the twister to a cryogenic fluid prior to the first contact between the polymer insulated conductors. The first point of contact may be several feet before the polymer insulated conductors actually enter the twister take-up device. At the first point of contact, there is a compressive force between the polymer insulated conductors, but it may be weak relative to the peak compressive force generated when the polymer insulated conductors are twisted together. In some embodiments, a cooling vessel is provided to expose the polymer insulated conductors to a cryogenic fluid after the first point of contact but before the polymer insulated conductors enter the twister.

[0293] In some embodiments, the automated cryogenic exposure system can be used as part of an online continuous or semi-continuous process. The automated cryogenic exposure system can be used with a twisting process, a cabling process, a sheathing process, and / or any other process in which a polymer component can be compressed or deformed.

[0294] In some embodiments, the cryogenic exposure system includes: a cooling container having a variable length, a variable component path, a multi-component path, one or more sensors configured to determine the diameter of a wire, a twisted pair, a cable core, or a cable, and / or a machine automation controller.

[0295] In one non-limiting example, an optical sensor can be used to measure the diameter of one or two polymer insulated conductors that are unwound at the beginning of the twisting process of the twisted pair. As described herein, the polymer insulated conductors can be passed through a cooling container containing a cryogenic fluid (such as liquid nitrogen) to increase the stress / strain response and hardness of at least a portion of the polymer insulation layer. After passing through the cooling container, the two polymer insulated conductors are twisted together to form a twisted pair. A second optical sensor can be used to measure the width of the final twisted pair.

[0296] By measuring the diameters of the two polymer insulated conductors before they contact each other, the two diameters can be combined to determine the potential width of the resulting twisted pair if the polymer insulation does not experience any compression or deformation. In some embodiments, the potential zero deformation width can also be determined by measuring the diameter of one of the polymer insulated conductors at the beginning of the twisting process and doubling it.

[0297] When measuring the width of the resulting twisted pair, the optical sensor can measure the width of the twisted pair as the twisted pair passes through a light beam (e.g., a beam of photons emitted by the optical sensor). It should be appreciated that when the individual conductors are oriented in a plane perpendicular to the light beam of the optical sensor, the peak width measurement is used to represent the width of the twisted pair. When the two conductors of the twisted pair are stacked in a straight line with the light beam of the optical sensor, the measured width can be approximately equal to the width of one insulated conductor and does not represent the width of the twisted pair. The measured width of the twisted pair can be compared to the theoretical zero-crush width to determine the crush ratio of the twisted pair in real time.

[0298] As part of the twisted pair cable design, a desired crush ratio can be established to achieve desired electrical properties. If the measured crush ratio is determined to be above the desired crush ratio set point, the cooling container can be adjusted to extend the length of the polymer insulated conductor during exposure to the cryogenic fluid. By extending the length of the cooling container containing the cryogenic fluid, the exposure time of the polymer insulated conductor can be increased, and the stress / strain response and hardness of the polymer insulated conductor can be increased before the polymer insulated conductor is exposed to the compressive force of the twisting process. By increasing the stress / strain response and hardness of the polymer insulated conductor before twisting, the crush ratio of the resulting twisted pair can be reduced. In some embodiments, the twisting machine speed can be adjusted to help increase or reduce both the residence time of the insulated conductor in the cryogenic fluid and / or the compressive force generated by the twisting process.

[0299] In some embodiments, the optical sensor and the variable length cooling container can be connected to one or more processors or machine automation controllers to create an automated quality control process. When the measured crush ratio deviates from the desired crush ratio set point, the controller can adjust the position of the redirecting wheel to cause the variable length cooling container to respond by extending or shortening the length of the portion of the cooling container containing the cryogenic fluid, and / or extending or shortening the length of the component path within the cooling container. By automatically adjusting the length of the portion of the cooling container containing the cryogenic fluid, the time that the polymer insulated conductor is exposed to the cryogenic fluid and therefore the stress / strain response and hardness of the polymer insulation layer can be modulated. By modulating the stress / strain response and hardness of the polymer insulation layer, the crush ratio of the twisted pair can be controlled.

[0300] In some embodiments, minor modifications can be made to the variable length cooling vessel on a continuous basis. Granular and / or automated control of the length of the cooling vessel, and therefore the time the polymer insulated conductor is exposed to the cryogenic fluid, allows the crush ratio to be controlled and maintained despite a large number of potentially complicating factors, including but not limited to ambient temperature, ambient sunlight, relative humidity, line speed, lay length, twister parameters, twister design, the type of polymer insulation material used, whether the polymer insulation material is foamed or solid and / or the degree of foaming of the polymer insulation material, variations in the polymer insulated conductor from roll to roll, and the like.

[0301] In some embodiments, multiple cooling containers can be used to control the total exposure time of the polymer insulated conductor to the cryogenic fluid. By using multiple separate cooling containers, different methods of applying the cryogenic fluid to the polymer insulating material can be used on the same polymer insulating material. For example, the first cooling container can immerse the polymer conductor in a cryogenic fluid bath, while the second cooling container can use a cryogenic fluid spray. It should be appreciated that any number of cooling containers can be used in any of a variety of configurations. By changing the configuration of some or all of the cooling containers in the multiple cooling containers, the exposure time of the polymer insulated conductor and the temperature of the polymer insulated conductor when twisted or other compressive forces can be controlled in an adjustable manner.

[0302] Traditionally, obtaining the desired degree of extrusion requires a trial and error process, wherein a roll of twisted pair is manufactured and the resulting roll of twisted pair is tested for electrical properties. If the electrical properties are not within predetermined specifications, the roll of twisted pair is marked as unqualified and one of a number of variables will be changed. Then, another roll of twisted pair will be manufactured and the electrical properties of the roll of twisted pair will be tested. This trial and error process requires a large amount of time and results in material loss. Since it is known that the physical properties of the polymer insulated conductor and the resulting twisted pair affect the electrical properties, by controlling the degree of extrusion in the twisted pair, the electrical properties of the twisted pair can also be controlled. The disclosed continuous and / or automatic process can be used to obtain the desired physical properties, and therefore the desired electrical properties, in less time and with less material waste.

[0303] FIG. 19A to FIG. 19C A schematic diagram of a variable length cooling container according to one embodiment is shown. Fig.19A As shown, the variable length cooling vessel may include a baffle 1630 that is configured to move forward and backward to change the length of the cooling vessel containing the cryogenic fluid 1620. The baffle 1630 may be controlled by an electric motor 1650 connected to a screw or lead screw drive 1660. Fig.19AAs shown, polymer insulated conductor 1610 may enter the cooling container through hole 1640. After passing through the portion of the cooling container that does not contain cryogenic fluid 1620, polymer insulated conductor 1610 may pass through partition 1630 through similar hole 1640. After passing through partition 1630, polymer insulated conductor 1610 may be exposed to cryogenic fluid 1620. Fig.19B and Fig.19C As shown, the position of the partition 1630 can be controlled using a motor 1650 and / or a lead screw drive 1660 to extend or reduce the portion of the cooling container containing the cryogenic fluid 1620. By modulating the length of the portion of the cooling container containing the cryogenic fluid, the time the polymer insulated conductor is exposed to the cryogenic fluid can be controlled. By controlling the time the polymer insulated conductor is exposed to the cryogenic fluid, the crush ratio and final electrical properties of the twisted pair or cable can be controlled.

[0304] In some embodiments, a motor, a screw drive or other mechanism for controlling the position of a baffle in a variable length cooling container may be operably connected to a machine controller. In some embodiments, the machine controller may be used to control the position of a redirecting wheel inside a cooling container to adjust the length of the assembly path in the cooling container. The dynamic assembly path may be controlled to adjust the residence time of the polymer cable assembly in the cooling container. The machine controller may communicate data with one or more processors, which communicate data with a first sensor for determining the diameter of a polymer insulated conductor and a second sensor for determining the width of a twisted pair. The processor and the machine controller may compare the diameter of the polymer insulated conductor and the width of the twisted pair resulting therefrom to determine the crushing ratio and compare the determined crushing ratio with a predetermined desired crushing ratio set point. The machine controller may then guide the motor and / or screw drive to adjust the time that the polymer insulated conductor is exposed to a cryogenic fluid until the determined crushing ratio is approximately equal to the desired crushing ratio set point. Although the above-mentioned low temperature exposure system is described in the context of a twisting system, it should be appreciated that the system may be applied to any other process in which a polymer assembly may be compressed or deformed.

[0305] In some embodiments, the cooling vessel comprises a nozzle configured to spray a cryogenic fluid onto the polymer assembly. In some embodiments, rather than changing the physical dimensions of the cooling chamber containing the cryogenic fluid, some of the plurality of nozzles may be closed, bypassed, or otherwise prevented from spraying the cryogenic fluid. This allows for control of the exposure time of the polymer assembly as discussed above and control of the resulting crush ratio of the polymer assembly.

[0306] FIG. 20A to FIG. 20C A schematic diagram of a variable spray cooling container according to one embodiment is shown. Fig. 20AAs shown, polymer insulated conductor 1710 can enter cooling container through hole 1730. Cryogenic spray nozzle 1720 can be activated to expose polymer insulated conductor 1710 to cryogenic fluid. Fig. 20A As shown, all of the plurality of spray nozzles 1720 may be enabled to expose the polymer insulated conductor to a maximum amount of cryogenic fluid. Fig. 20B As shown, a portion of the plurality of cryogenic spray nozzles 1720 may be deactivated to reduce the time the polymer insulated conductor is exposed to the cryogenic fluid. Fig. 20C As shown, more spray nozzles 1720 can be deactivated to reduce the time that the polymer insulated conductor is exposed to the cryogenic fluid. In some embodiments, the flow rate of the cryogenic fluid through one or more nozzles can also be adjusted to adjust the stress / strain response and hardness of the polymer component passing through the cooling container. In some embodiments, all spray nozzles can be deactivated, and the polymer component may not be exposed to the cryogenic fluid at all. By adjusting the flow rate of at least one of the multiple cryogenic spray nozzles, the time that the polymer insulated conductor is exposed to the cryogenic fluid can be adjusted. In some embodiments, the flow rate of the cryogenic fluid through the nozzle of the cooling container can be adjusted in response to the measured crush ratio in order to precisely control the crush ratio of the twisted pair or the deformation of any other polymer component passing through the cooling container.

[0307] In some embodiments, reducing the extrusion or deformation of polymer insulated conductors, cables, cable jackets, and other cable components allows the use of less polymer material to manufacture those components while maintaining or improving electrical performance. By using less polymer material, the resulting cable has less flammable material and a lower combustible load. Cables with a lower combustible load are more likely to pass the UL 910 Steiner tunnel test.

[0308] In some embodiments, the step of adding additional insulation and / or jacket material to compensate for the expected deformation creates a new set of problems. For example, many cables must pass certain flame and smoke standards, which ensure that the cables are safe for use in buildings or residences. One factor in the propensity of a cable to propagate flames and generate smoke is the amount of material contained within it, commonly referred to as the "combustible load." Typically, when the amount of combustibles (in this case, polymeric insulation or jacket material) increases, the result is more smoke generation or more flame propagation for the cable being tested.

[0309] An example of a combustible load test is the UL 910 Steiner Tunnel Test, which is related to ASTM E84, NFPA 255, UL 723, and ULC S102. In this test, a cable bundle is subjected to a flame in a 24-foot-by-1.8-foot-by-1-foot non-combustible horizontal box or tunnel. The flame intensity is set to 89 kilowatts, and air is moved through the tunnel to simulate a plenum ceiling condition. Materials tested according to these standards are required to exhibit a maximum flame spread distance of 5 feet, a maximum peak optical density of 0.5, and a maximum average optical density of 0.15.

[0310] Design engineers typically select materials that are optimized for cost and meeting required combustible loading standards. Potential problems may arise when additional material is added to compensate for cable deformation caused by forces incurred during the manufacture of these cables. This additional material increases the combustible loading, raises costs, and limits the types of materials that can be used. As an example, some Cat 6A cables have a shorter lay length, which produces higher compressive forces during manufacturing. These cables are typically insulated using FEP and PVC resins due to the higher than normal deformations encountered during the manufacture of these products. On the other hand, some Cat 6 cables utilize a longer lay length and are subject to relatively reduced compressive forces during manufacturing. Therefore, these cables require less additional insulation to compensate for deformation. This lower combustible loading allows other lower cost materials and / or the use of other lower cost materials.

[0311] In some embodiments, the cable is manufactured by temporarily increasing the stiffness of the polymer cable assembly before or during a compression event. The increased stiffness reduces the degree of deformation experienced during the compression event, and therefore, less additional insulation material is required to achieve the desired electrical performance. In some embodiments, increasing the stiffness of the polymer cable assembly allows the total combustible load in the resulting cable to be reduced, thereby allowing the cable to pass the UL 910 Steiner Tunnel Test, while a similar cable that does not experience the increase in stiffness and does not include additional polymer material to compensate for the increased depression will not pass the UL 910 Steiner Tunnel Test.

[0312] In some embodiments, cables with lower combustible loads can be developed with more economical materials that would not pass the UL 910 Steiner Tunnel Test without the reduced combustible load. In some embodiments, cables made using the disclosed technology contain a reduced combustible load and are less likely to propagate flames or smoke.

[0313] In some embodiments, cables formed using the disclosed technology can have a smaller outer diameter. This can allow existing buildings to be retrofitted with modern high-performance cables that have an equal or smaller diameter than the lower-performance cables previously used.

[0314] In some embodiments, the wire and cable products have a certain amount of polymer insulation and / or other polymer cable components that contribute to their combustible load. In some embodiments, the combustible load is designed to produce a flame travel distance equal to or less than about five feet, a smoke peak optical density equal to or less than about 0.5, and / or an average optical density equal to or less than about 0.15 when measured according to the Steiner tunnel test method of ASTM E84 (such as referenced in ASTM E84, UL910, NFPA 255, UL 723, or ULC S102).

[0315] In some embodiments, the polymer cable assembly is cooled and / or hardened before undergoing a compression event. Due to the hardening, the polymer cable assembly is able to provide the desired electrical properties because it does not deform as much as it would if the polymer cable assembly was not cooled and / or hardened before being compressed.

[0316] In some embodiments, because the polymer cable assembly deforms less after it hardens, less total polymer can be incorporated into the wire and cable product, thereby reducing the total combustible load of the wire and cable product. In some embodiments, the wire and cable product with reduced combustible load has a capacitance value of less than about 20 pf / ft. In some embodiments, the wire and cable product with reduced combustible load has an impedance value between about 50 ohms and 150 ohms, or an impedance value between about 75 ohms and 125 ohms, or an impedance value equal to about 100 ohms. In some embodiments, the wire and cable product with reduced combustible load has a propagation velocity between about 62% and 80%, or a propagation velocity between about 66% and 70%.

[0317] In some manufacturing facilities, there is ample space to slowly cool a very hot insulated conductor or other polymer cable component after it is extruded. In some facilities, this initial cooling step involves exposing the recently extruded polymer component to ambient air or water contained in a tank for an extended period of time. Since wire and cable manufacturing is typically a continuous process in which the cable components travel rapidly, each of these cooling methods may require a large amount of space, for example, greater than about 40 feet. The long distances required to cool the extruded polymer components require a large amount of production floor space. In addition, these cooling methods typically do not reduce the temperature of the polymer cable component below the ambient temperature.

[0318] In some embodiments, the faster reduction in temperature is beneficial to both saving time and reducing the floor space of the extruder manufacturing operation. In some embodiments, a cooling chamber with a refrigerated fluid or a cryogenic fluid can be used to quickly cool the polymer cable assembly shortly after the polymer cable assembly is extruded. In some embodiments, the cooling chamber after the extruder is less than about 10 feet long, or less than about 8 feet long, or less than about 5 feet long, or less than about 3 feet long.

[0319] In one non-limiting example, the Shore D hardness of a solid FEP plate was measured as follows. An injection molded plate of a solid FEP polymer was used throughout the example. The plate had a length of 61 mm, a width of 61 mm, and a height of 2 mm. The Shore D hardness of the solid FEP plate was measured at an ambient temperature of about 20° C. The plate was then exposed to liquid nitrogen for different lengths of time by immersing the plate in a liquid nitrogen pool. The Shore D hardness of the plate was measured after different exposure times. Fig.21 The data is shown.

[0320] If you can Fig.21 As can be seen from the graph, the Shore D hardness of the FEP plate increases from about 60 to about 83 after being exposed to liquid nitrogen for about 10 seconds. After being exposed to liquid nitrogen for about 10 seconds, the FEP plate reaches a maximum hardness of about 83. Continuing exposure to liquid nitrogen for more than 10 seconds does not continue to increase the hardness of the FEP plate.

[0321] In the following examples, the Shore D hardness of a solid FEP plate was measured as the plate returned to ambient temperature after being exposed to liquid nitrogen for a specific period of time. The plate was immersed in liquid nitrogen for 6 seconds, 10 seconds, or 30 seconds and then removed from the liquid nitrogen. For each of the three tests, the Shore D hardness of the plate was measured at specific time intervals until the plate returned to ambient temperature.

[0322] Fig. 22 The Shore D hardness is shown as the panels return to ambient temperature after being immersed in liquid nitrogen for 6 seconds, 10 seconds, or 30 seconds. Fig. 22 As shown in Figure 2, the difference in hardness change over time between the sample exposed to liquid nitrogen for 10 seconds and the sample exposed to liquid nitrogen for 30 seconds is relatively small. Fig.21 The data shown correlates, indicating that the FEP plaque reaches its maximum hardness after about 10 seconds of exposure to liquid nitrogen. Plaques exposed to liquid nitrogen for 6 seconds likely reach a lower initial Shore D hardness of about 76, which decreases as the plaque is exposed to ambient conditions.

[0323] In the following examples, a solid FEP plaque was immersed in liquid nitrogen for 10 seconds and then removed. As the plaque returned to ambient temperature, the plaque's Shore D hardness and temperature (in °C) were measured. FIG. 23A to FIG. 23C This data is shown for different time periods.

[0324] Fig.23A The Shore D hardness drop and temperature rise of the solid FEP plate are shown over about 390 seconds. Fig. 23B The Shore D hardness drop and temperature rise of the solid FEP plate are shown over about 180 seconds. Fig.23C The figure shows the decrease in Shore D hardness and the increase in temperature of the solid FEP plate within about 30 seconds. FIG. 23A to FIG. 23C Temperature data below -60°C are projections rather than direct measurements.

[0325] In another non-limiting example, the Shore D hardness of the foamed FEP is measured. To make the foamed FEP sample, the FEP foam insulated wire is tightly wrapped around a solid FEP plate. The Shore D hardness of the foamed FEP insulated wire is measured at an ambient temperature of about 20° C. The FEP foam insulated wire is then exposed to liquid nitrogen for different lengths of time by immersing the FEP foam insulated wire in a pool of liquid nitrogen. The Shore D hardness of the foamed FEP is measured after different exposure times. Fig.24 The data is shown.

[0326] like Fig.24 As shown, the Shore D hardness of the FEP foam is about 29 at ambient temperature and rises to about 63 after being exposed to liquid nitrogen for about 15 seconds. Once the foamed FEP reaches a Shore D hardness of about 63, the Shore D hardness reaches a plateau and does not increase significantly after additional exposure time to liquid nitrogen.

[0327] Fig.25 The Shore D hardness of a FEP foam insulated wire is shown as it returns to ambient temperature after being immersed in liquid nitrogen for 10 seconds. As the foamed FEP is exposed to ambient temperature for a longer period of time, the Shore D hardness decreases until it reaches a Shore D hardness of about 29 at ambient temperature.

[0328] In the following example, a foamed FEP insulated wire was immersed in liquid nitrogen for 10 seconds and then removed. As the foamed FEP returned to ambient temperature, the Shore D hardness and temperature of the foamed FEP insulated wire were measured. Fig.26 This data is shown over a certain period of time.

[0329] Fig.26The Shore D hardness drop and temperature rise of the solid FEP plaque are shown over about 390 seconds. Note that no initial temperature data below about -55°C were collected.

[0330] Fig. 27 The Shore D hardness of both solid FEP and foamed FEP when exposed to liquid nitrogen over time is shown. Fig. 27 It can be seen that the Shore D hardness of solid FEP generally stops increasing after about 10 seconds. The Shore D hardness of foamed FEP generally stops increasing after about 15 seconds.

[0331] Fig.28 The Shore D hardness of both solid FEP and foamed FEP when exposed to ambient conditions after being exposed to liquid nitrogen for 10 seconds is shown. It is noteworthy that at ambient temperature, the Shore D hardness of foamed FEP decreases more slowly and takes more than three minutes longer to recover to its Shore D hardness than solid FEP.

[0332] Fig.29 The temperatures of solid FEP and foamed FEP when exposed to ambient conditions after being exposed to liquid nitrogen for 10 seconds are shown. The temperature of the foamed FEP increases more slowly and takes longer than the solid FEP to return to ambient temperature, more than ten minutes.

[0333] Without wishing to be bound by theory, it is believed that the air pockets within the foamed FEP change temperature more slowly than solid FEP. Therefore, when exposed to liquid nitrogen, the foamed FEP insulation material takes longer to reach its minimum temperature and associated increased hardness. The foamed FEP also takes longer to return to its ambient temperature and associated hardness after being removed from the liquid nitrogen.

[0334] Although the above examples are described in terms of solid FEP and foamed FEP, it should be appreciated that similar data can be easily collected for any form and type of polymer. Once the rate at which the hardness of a polymer recovers to the ambient hardness is understood, the hardness of a polymer cable assembly when subjected to a compression event can be controlled by modulating the amount of time the polymer assembly is exposed to ambient temperature after leaving the cooling container. In some embodiments, the distance between cooling containers and / or the line speed of the production line can be adjusted to achieve the desired hardness of the polymer cable assembly at the compression or deformation point.

[0335] It will similarly be appreciated that the amount of cooling time (eg, exposure time to a cryogenic fluid or other cooling medium) may alternatively or additionally be adjusted to achieve a desired stiffness of the polymeric cable assembly when subjected to compressive or other deforming forces.

[0336] In some embodiments, the methods for increasing stiffness described herein produce at least about a 10% increase in Shore D stiffness of a polymeric cable assembly relative to a similar assembly at ambient temperature before or while the polymeric cable assembly is subjected to a compressive force.

[0337] In some embodiments, the methods described herein for increasing stiffness produce at least about a 10% increase in Shore D stiffness at 20°C in a polymeric cable component relative to a similar component made from the same polymer. In some embodiments, the methods described herein for increasing stiffness produce at least about a 10% increase in Shore D stiffness at 20°C in a polymeric cable component relative to a similar component and reduce deformation caused by a compression event by at least about 0.0005 inches.

[0338] In some embodiments, use of a cooling chamber having a length of less than about 10 feet produces an increase in Shore D hardness of at least about 10% relative to a similar component at ambient temperature.

[0339] It will be appreciated that for all cases a 10% increase in Shore D hardness can be converted to other hardness tests such as Britnell, Meyer, Vickers, Rockwell, and other Shore durometer scales such as Shore A.

[0340] For reference, the Shore D durometer test is described in ASTM D2240 and ISO 868. The hardness value is determined by piercing the sample with a durometer indenter foot. The Shore hardness measurement is dimensionless and ranges from 0 to 100. The higher the Shore hardness number, the harder the material and the greater the resistance to deformation. In some embodiments, the disclosed method for increasing hardness is most advantageous for base materials that exhibit a Shore hardness between 40 and 80.

[0341] The methods, systems, and embodiments described herein generally relate to adjusting the stress / strain response and hardness of polymer components. The polymers considered herein include, but are not limited to, thermoplastics, thermosetting plastics, rubbers, and / or elastomers, each of which can be foamed or solid and can contain a variety of additives and / or flame retardants. Specific polymers considered include, but are not limited to: linear low-density polyethylene-LLDPE, high-density polyethylene-HDPE, polyethylene-PE, perfluoroalkoxyalkane-PFA, polytetrafluoroethylene-PTFE, polyvinylidene fluoride-PVDF, ethylene chlorotrifluoroethylene-ECTFE, tetrafluoroethylene, perfluoromethyl vinyl ether-MFA, polyphenylene sulfide-PPS, polyetherketone-PEEK, polyetherketone-PEK, polyethyleneimine-PEI, fluorinated ethylene propylene-FEP, ethylene propylene tetrafluoroethylene-E TFE, ethylene fluoride ethylene propylene - EFEP, polypropylene - PP, nylon - PA, polyvinyl chloride - PVC, polycarbonate - PC, acrylonitrile butadiene styrene - ABS, polystyrene - PS, polyesters such as polyethylene terephthalate (PET), polyimide - PI, polyamide, polyimide, polyamide-imide - PAI, natural rubber, synthetic rubber, fluoroelastomer - FKM, silicone (such as dimethyl polysiloxane), PVdF, PEBA, their foams, their blends and their alloys.

[0342] The conductivity of the conductor is measured using one or more properties of the conductor, such as impedance. As previously described, the impedance of a twisted pair of insulated conductors depends on the hardness or softness of the polymer insulation. For example, the impedance of a twisted pair of insulated conductors increases as the hardness of the polymer insulation increases. The harder the polymer insulation, the greater the amount of air that will be retained within the gaps in the twisted pair.

[0343] In another embodiment, foamed polymer insulation can be used to insulate the wires of twisted pairs. Foaming the polymer can be achieved by techniques such as, but not limited to, extrusion, compression molding, injection molding, reaction injection molding, solid-state methods, or adding a blowing agent to a molten polymer, wherein the blowing agent decomposes to release gas, and then the polymer is foamed by pressurization and heating. Foaming introduces air pockets or air gaps into the polymer insulation when insulating the wire. The air pockets or air gaps help increase the effectiveness of an insulating layer of a given thickness. Because foamed insulation provides better electrical insulation than solid insulating materials, thinner insulating layers can be used.

[0344] A twisted pair of insulated conductors can be produced by twisting two insulated conductors in a spiral form. Other means for twisting insulated conductors may also be available, such as SZ twisting, in which the twisted pair lay direction changes from left to right, etc. A twisted pair of insulated conductors or twisted pair includes two separate insulated conductors that are twisted together at a level of looseness or tightness required for the purpose for which they are used. For example, some twisted pairs can be used for high-speed data communications relative to other twisted pairs. When the separate insulated conductors are twisted, the polymer insulation on each insulated conductor is pressed to a certain degree of tightness against the polymer insulation on the other insulated conductor. The pressure generated by this twisting action causes deformation of the polymer insulation layer. This is called crushing. The greater the degree of deformation or crushing, the shorter the distance between the wires. This results in a reduced impedance between the twisted pairs. The goal is to control the amount of crushing of the polymer insulation.

[0345] The crushing of the polymer insulation that occurs when the individual insulated conductors are twisted together is proportional to the hardness level of the polymer insulation. When the polymer insulation is softer, the crushing or deformation is higher. When heat acts on the polymer insulation, the polymer insulation becomes softer. As mentioned earlier, the impedance of the twisted pair depends on the hardness level of the polymer insulation during the crushing.

[0346] In another embodiment, several twisted pairs can be used to form a single cable. In a cable, each twisted pair can have a different delay, or the time it takes for an electrical signal to travel a given length of the twisted pair. Delay is usually measured in nanoseconds / 100 meters. The difference in delays of multiple twisted pairs in a cable is the delay difference. In order to minimize the delay difference, the delay of each twisted pair in the cable must be similar for every 100 meters. A delay difference of less than 50ns or less than 25ns is preferred. For a twisted pair with a tighter twist, the total distance that the electrical signal must travel is longer relative to a twisted pair with a looser twist. This is because the individual insulated conductors that constitute the twisted pair with a tighter twist must be longer than the individual insulated conductors that constitute the twisted pair with a looser twist. Therefore, it is desirable to have faster signal transmission in a twisted pair with a tighter twist relative to a twisted pair with a looser twist. One of the ways to achieve the desired delay difference of the twisted pairs in the cable is by precisely adjusting the temperature of the polymer insulation material during twisting.

[0347] A twisting machine or twisting unit may be used to twist insulated conductors into twisted pairs. Twisting the individual insulated conductors typically occurs at high speed using a twisting machine having a bow. The bow is a bending device into which the individual conductors may be fed. The bow is set to rotate or swivel at high speed in order to perform a twisting action on the individual conductors as the bow receives them, thereby producing a twisted pair of insulated conductors.

[0348] In another embodiment, in addition to or as an alternative to regulating the temperature of the fluid surrounding the bow frame or immersing the polymer assembly in a cryogenic or cooling fluid, regulation of the temperature of the polymer insulation material can also be achieved by shielding the polymer assembly of the insulated conductors from convective heat transfer.

[0349] In some embodiments, the rotating gantry can be used under normal atmospheric conditions, i.e., the air surrounding the gantry, without regulating the temperature of the atmosphere within the twisting machine. If the fluid is hotter than the polymer assembly, convective heat transfer from the fluid may soften the polymer insulating material, resulting in increased deformation or crushing. If the fluid is cooler than the polymer assembly, convective heat transfer to the fluid may harden the polymer insulating material, resulting in reduced deformation or crushing. In some embodiments, the rotating gantry can be used in a temperature controlled atmosphere, which can be warmer or cooler than ambient conditions. For example, the air within the twisting unit can be cooled by a refrigeration device. In some embodiments, the atmosphere within the twisting unit can be cold nitrogen vapor or another vapor that is cooler than the ambient temperature.

[0350] In some embodiments, the yoke may include means for shielding the insulated conductors from convective heat transfer from the fluid as the yoke rotates or swivels. In other embodiments, the rotating or swivel yoke may be shielded from convective heat transfer from the surrounding fluid by shielding the insulated conductors in longitudinal tubes sized to accommodate the insulated conductors. The longitudinal tubes may be made of any suitable material, such as a polymeric insulating material, which in turn reduces the amount of heat transferred to the insulated conductors.

[0351] In some embodiments, the rotating bow may be shielded from convective heat transfer from the surrounding fluid by shielding the insulated conductors in longitudinal grooves on the bow designed to accommodate the insulated conductors. In other embodiments, the rotating or swivel bow may use means for shielding the insulated conductors from convective heat transfer from the surrounding fluid by using a windshield on the windward side of the bow.

[0352] In other embodiments, as described above, a rotating or swivel yoke may utilize means for shielding the insulated conductors from convective heat transfer from the fluid including one or more adjustable vents.

[0353] Further described herein is a method for manufacturing a twisted pair of insulated conductors having a predetermined impedance. Such a method may include feeding two separate insulated conductors into a rotating or swiveling bow frame as part of a twisting machine in the presence of a fluid. Then, the convective heat transfer from the fluid to the insulated conductors is controlled so as to control their temperature to achieve a specific level of hardness. The insulated conductors are then twisted using the bow frame to form a twisted pair, wherein the insulated conductors undergo an amount of deformation during twisting based on the hardness level of the polymer insulation material of a given set of twisting machine parameters. A method for manufacturing a twisted pair of insulated conductors within a predetermined tolerance range of impedance is also described. One of the methods includes sensing a pair of insulated conductors into a rotating bow frame in the presence of a fluid, controlling the convective heat transfer from the fluid to the insulated conductors and twisting them to form a twisted pair. Once the twisted pair is produced, the method includes measuring the impedance of the twisted pair and, if necessary, adjusting the amount of convective heat transfer from the fluid to the insulated conductors based on a comparison of the measured impedance of the twisted pair with a predetermined tolerance range.

[0354] Example

[0355] In the working examples, multiple twisted pairs were produced using FEP insulated conductors. For all tests, the diameter of the copper conductor was approximately 0.0216 inches and the outer diameter of the FEP insulated conductor was approximately 0.0419". The lay length of all twisted pairs in this example was 6.20 mm / twist. The samples were twisted at approximately 2750 twists / minute (TPM) with 18% backtwist. Control tests were performed without any temperature or hardness manipulation. The control monomers were twisted at ambient temperature using an unshielded bow frame. In the remaining tests, the insulating monomers were exposed to liquid nitrogen before being twisted together. FIG. 45A to FIG. 45E As shown, each sample was twisted using a modified bow that was shielded from 0%, 25%, 50%, 75%, or 100% convective heat transfer. In this embodiment, the bow was shielded by a single continuous section rather than separate sections. It should be understood that the shielding can be performed in a single continuous section or using a method such as Fig.35 The multiple separated sections shown in shield the bow frame with the same percentage. An embodiment of the bow frame with a single shielding section may include a shielding section that covers the most upstream inlet of the bow frame, the most downstream outlet of the bow frame, or any intermediate portion of the bow frame. Each such arrangement can have a different effect on the degree of convective heat transfer between the twisted pairs within the bow frame and the atmosphere of the twisting machine, thereby allowing greater control over the degree of heat transfer. In this embodiment, two twisted pair samples are prepared for each test. The impedance of each twisted pair is measured for each sample. As shown in the data below, the impedance increases with the increase in the shielding degree of the bow frame. In addition, the twisted pairs exposed to liquid nitrogen and twisted with 0% shielding of the bow frame have higher impedance relative to the control samples without any temperature or hardness adjustment.

[0356]

[0357] The above data (in Fig.46 ) shows that the impedance can be adjusted by controlling the extent to which the bow is shielded from convective heat transfer during the twisting process.

[0358] In another working example, multiple twisted pairs were produced using FEP insulated conductors. For all tests, the diameter of the copper conductor was approximately 0.0216 inches and the outer diameter of the FEP insulated conductor was approximately 0.0419". The lay length of all twisted pairs in this embodiment was 6.20 mm / twist. The samples were twisted at approximately 2750 twists / minute (TPM) with 18% back twist. Control tests were conducted without any temperature or hardness manipulation. The control unit was twisted at ambient temperature using an unshielded bow. The remaining tests were exposed to liquid nitrogen before twisting together. Each sample was twisted using a modified bow that was shielded from 0%, 25%, 50%, 75% or 100% convective heat transfer. Two twisted pair samples were prepared for each test. The delay (the time it takes for an electrical signal to travel 100 m) was measured for each twisted pair. As shown in the data below (and in Fig.47 The delay increases with the degree of shading of the arch.

[0359] Table 8

[0360]

[0361]

[0362] Disclosed embodiments include a method of reducing the effects of compressive forces on a polymer cable assembly, the method comprising the steps of providing a polymer cable assembly having a first stiffness, wherein the first stiffness is the stiffness of the polymer cable assembly under ambient conditions; temporarily changing the stiffness of the polymer cable assembly to a second stiffness, wherein the second stiffness is different from the first stiffness; subjecting the polymer cable assembly to a compressive force; and returning the polymer cable assembly to the first stiffness. In some embodiments, the polymer cable assembly is subjected to the compressive force while the polymer cable assembly is at the second stiffness. In some embodiments, the compressive force causes the polymer cable assembly at the second stiffness to deform less than the polymer cable assembly at the first stiffness. In some embodiments, the second stiffness is greater than the first stiffness. In some embodiments, the step of temporarily changing the stiffness of the polymer cable assembly comprises cooling the polymer cable assembly. In some embodiments, the step of cooling the polymer cable assembly comprises exposing the polymer cable assembly to a cryogenic fluid. In some embodiments, the step of cooling the polymer cable assembly comprises exposing the polymer cable assembly to a frozen solid surface. In some embodiments, the frozen solid surface is rotated. In some embodiments, the step of cooling the polymer cable assembly comprises exposing the polymer cable assembly to a cryogenic liquid. In some embodiments, the polymer cable assembly is exposed to a cryogenic liquid for about ten seconds or less. In some embodiments, the polymer cable assembly is exposed to a cryogenic liquid for between six seconds and ten seconds. In some embodiments, the step of cooling the polymer cable assembly includes: exposing the polymer cable assembly to a refrigerated gas. In some embodiments, the refrigerated gas is between 15°C and -10°C. In some embodiments, the polymer cable assembly includes an outer surface, an inner body, and an inner surface, and wherein the step of cooling the polymer cable assembly includes: cooling the outer surface of the polymer cable assembly. In some embodiments, the polymer cable assembly is a polymer insulation material surrounding the periphery of the conductor. In some embodiments, the polymer cable assembly is a fluoropolymer insulation material surrounding the periphery of the conductor. In some embodiments, the polymer cable assembly is no longer cooled for less than or equal to ten seconds before being subjected to a compressive force. The method of some embodiments also includes the following steps: before subjecting the polymer cable assembly to a compressive force, stopping cooling the polymer cable assembly for less than or equal to five seconds.

[0363] Additional disclosed embodiments include a method of manufacturing a communication cable, the method comprising the steps of providing a polymer cable assembly having a first cross-sectional radius and a second cross-sectional radius, wherein the first cross-sectional radius is the maximum distance along the cross-section from the center of the polymer cable assembly to the edge of the polymer cable assembly, and the second cross-sectional radius is the minimum distance along the cross-section from the center of the polymer cable assembly to the edge of the polymer cable assembly, and wherein the first cross-sectional radius is approximately equal to the second cross-sectional radius + / - 3%, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; subjecting the polymer cable assembly to a compressive force, wherein after the compressive force, the first cross-sectional radius is approximately equal to the second cross-sectional radius + / - 10%. In some embodiments, the compressive force causes the polymer cable assembly at the second hardness to deform less than the polymer cable assembly at the first hardness. In some embodiments, the step of temporarily changing the hardness of the polymer cable assembly comprises cooling the polymer cable assembly. In some embodiments, the step of cooling the polymer cable assembly comprises exposing the polymer cable assembly to a cryogenic fluid. In some embodiments, the step of cooling the polymer cable assembly comprises exposing the polymer cable assembly to a cryogenic liquid. In some embodiments, the step of cooling the polymer cable assembly comprises: exposing the polymer cable assembly to a refrigerated gas. In some embodiments, the polymer cable assembly is no longer cooled for less than or equal to ten seconds before being subjected to the compressive force. The method of some embodiments also includes the step of stopping cooling the polymer cable assembly for less than or equal to five seconds before subjecting the polymer cable assembly to the compressive force. In some embodiments, the polymer cable assembly is a polymer insulation material surrounding the periphery of the conductor. In some embodiments, the polymer cable assembly is a fluoropolymer insulation material surrounding the periphery of the conductor. Additional disclosed embodiments include a method of manufacturing a communication cable, the method comprising the steps of: providing a polymer cable assembly having a first diameter and a second diameter, wherein the first diameter and the second diameter are perpendicular to each other, and wherein the first diameter is approximately equal to the second diameter + / -3%, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; subjecting the polymer cable assembly to a compressive force, wherein, after the compressive force, the first diameter is approximately equal to the second diameter + / -10%; restoring the polymer cable assembly to the first hardness. In some embodiments, the polymer cable assembly is subjected to a compressive force when the polymer cable assembly is at the second hardness. In some embodiments, the compressive force causes the polymer cable assembly at the second hardness to deform less than the polymer cable assembly at the first hardness.In some embodiments, the second hardness is greater than the first hardness. In some embodiments, the step of temporarily changing the hardness of the polymer cable assembly includes: cooling the polymer cable assembly. In some embodiments, the step of cooling the polymer cable assembly includes: exposing the polymer cable assembly to a frozen solid surface. In some embodiments, the frozen solid surface is rotated. In some embodiments, the step of cooling the polymer cable assembly includes: exposing the polymer cable assembly to a cryogenic liquid. In some embodiments, the step of cooling the polymer cable assembly includes: exposing the polymer cable assembly to a refrigerated gas. In some embodiments, the refrigerated gas is between 15°C and -10°C and may include a variety of substitutes, such as cryogenic fluids, inert gases (such as helium, nitrogen, argon, krypton, radon, neon, xenon, and combinations thereof). In some embodiments, the fluid in the twister or cooling chamber may include cooled air produced by an air conditioner or refrigeration device, a fluorocarbon solution, a saline solution, a gas obtained by vaporizing a solid or liquid with a vaporization temperature of 0 degrees Celsius or less (such as dry ice or liquid nitrogen), a liquid with a freezing point of 0 degrees Celsius or less, cooled acetone, and combinations thereof.

[0364] Additionally disclosed embodiments include a method of manufacturing a communication cable, the method comprising the steps of: providing a first pair of polymer insulated conductors, a second pair of polymer insulated conductors, a third pair of polymer insulated conductors, and a fourth pair of polymer insulated conductors, wherein each pair of polymer insulated conductors includes two polymer insulated conductors, and wherein each polymer insulated conductor has a first hardness, wherein the first hardness is the hardness of the polymer insulated conductor under environmental conditions; temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, and the third pair of polymer insulated conductors to a second hardness, wherein the second hardness is different from the first hardness ... The polymer insulated conductors are twisted together to form a first twisted pair, the first twisted pair having a first propagation delay for 100 meters; the second pair of polymer insulated conductors are twisted together to form a second twisted pair, the second twisted pair having a second propagation delay for 100 meters; the third pair of polymer insulated conductors are twisted together to form a third twisted pair, the third twisted pair having a third propagation delay for 100 meters; the fourth pair of polymer insulated conductors are twisted together to form a fourth twisted pair, the fourth twisted pair having a fourth propagation delay for 100 meters, wherein for the first propagation delay, the second propagation delay, the third propagation delay, and the fourth propagation delay for 100 meters, the propagation delay difference for 100 meters is within 50 nanoseconds of each other. In some embodiments, the first propagation delay, the second propagation delay, the third propagation delay, and the fourth propagation delay for 100 meters have a delay difference of less than about 25 nanoseconds. In some embodiments, the step of temporarily changing the stiffness of the polymer insulated conductors includes cooling the polymer insulated conductors. In some embodiments, the step of temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and the fourth pair of polymer insulated conductors comprises: cooling the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and the fourth pair of polymer insulated conductors for a first time period, a second time period, a third time period, and a fourth time period, respectively. In some embodiments, the first time period is longer than the second time period, and the second time period is longer than the third time period. In some embodiments, the first time period is between about 8 seconds and 10 seconds, the second time period is between about 6 seconds and 8 seconds, and the third time period is between about 4 seconds and 6 seconds. In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and the fourth twisted pair have a first lay, a second lay, a third lay, and a fourth lay, respectively, the first lay is shorter than the second lay, and the second lay is shorter than the third lay. In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and the fourth twisted pair have a first lay length, a second lay length, a third lay length, and a fourth lay length, respectively, the first lay length is shorter than the second lay length, and the second lay length is shorter than the third lay length, and wherein the first time period is longer than the second time period, and the second time period is longer than the third time period.In some embodiments, the polymer insulated conductors in the first twisted pair, the second twisted pair, the third twisted pair, and the fourth twisted pair have a first crush ratio, a second crush ratio, a third crush ratio, and a fourth crush ratio, respectively. In some embodiments, the first crush ratio is less than the second crush ratio, and wherein the second crush ratio is less than the third crush ratio. In some embodiments, the first twisted pair, the second twisted pair, the third twisted pair, and the fourth twisted pair have a first signal speed, a second signal speed, a third signal speed, and a fourth signal speed, respectively. In some embodiments, the first signal speed is greater than the second signal speed, and wherein the second signal speed is greater than the third signal speed. In some embodiments, the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and the fourth pair of polymer insulated conductors each have a different second hardness. In some embodiments, the second hardness of the first pair of polymer insulated conductors is greater than the second hardness of the second pair of polymer insulated conductors, and wherein the second hardness of the second pair of polymer insulated conductors is greater than the second hardness of the third pair of polymer insulated conductors. Additional embodiments relate to a method of manufacturing a communication cable, the method comprising the steps of: providing a first pair of polymer insulated conductors and a second pair of polymer insulated conductors, wherein each pair of polymer insulated conductors includes two polymer insulated conductors, and wherein each polymer insulated conductor has a first stiffness, wherein the first stiffness is the stiffness of the polymer insulated conductor under ambient conditions; temporarily changing the stiffness of the polymer insulated conductors in the first pair of polymer insulated conductors to a second stiffness, wherein the second stiffness is different from the first stiffness; twisting the first pair of polymer insulated conductors together to form a first twisted pair, the first twisted pair having a first propagation delay for 100 meters; twisting the second pair of polymer insulated conductors together to form a second twisted pair, the second twisted pair having a second propagation delay for 100 meters, wherein the first propagation delay for 100 meters and the second propagation delay for 100 meters are within 25 nanoseconds of each other. In some embodiments, the step of temporarily changing the stiffness of the polymer insulated conductors in the first pair of polymer insulated conductors and the second pair of polymer insulated conductors comprises: cooling the first pair of polymer insulated conductors and the second pair of polymer insulated conductors.

[0365] Some disclosed embodiments relate to a system for manufacturing wire and cable products, the system comprising: a payout device, the payout device being configured to pay out a polymer cable assembly; a cooling container, the cooling container being configured to receive the polymer cable assembly, wherein the cooling container contains a refrigerated fluid; and a take-up device, the take-up device being configured to tighten the polymer cable assembly. In some embodiments, the cooling container contains liquid nitrogen. The system of some embodiments also includes a secondary structure, the secondary structure being configured to receive the polymer cable assembly, wherein the interior of the secondary structure is in fluid communication with the interior of the cooling chamber. In some embodiments, the cooling container contains liquid nitrogen, and wherein nitrogen vapor travels from the interior of the cooling container to the interior of the secondary structure. In some embodiments, the secondary structure is a hollow tube. In some embodiments, the atmosphere within the cooling container is at a temperature lower than the ambient temperature. In some embodiments, the cooling container is thermally insulated. The system of some embodiments also includes a refrigeration device, and wherein the refrigeration device is configured to provide refrigerated air to the cooling container. In some embodiments, the polymer cable assembly is a polymer insulated conductor, and the system also includes a twisting machine, the twisting machine being configured to receive a first polymer insulated conductor and a second polymer insulated conductor and form a twisted pair. In some embodiments, the atmosphere within the twisting machine is at a temperature lower than the ambient temperature. The system of some embodiments also includes a secondary structure, the secondary structure is configured to receive the polymer cable assembly, wherein the interior of the secondary structure is in fluid communication with the interior of the cooling chamber, and wherein the secondary structure is in fluid communication with the interior of the twisting machine. Additional embodiments are directed to a system for manufacturing wire and cable products, the system comprising: a payout device, the payout device is configured to pay out the polymer cable assembly; and a take-up device, the take-up device is configured to tighten the polymer cable assembly. The system of some embodiments also includes a plurality of freezing rollers.

[0366] Still more disclosed embodiments are directed to a method of manufacturing a low combustible loading wire and cable product, the method comprising the steps of: establishing desired electrical characteristics of the wire and cable product, wherein the wire and cable product comprises a polymeric cable assembly, wherein the polymeric cable assembly has a first combustible loading and a first stiffness, and wherein when the polymeric cable assembly is subjected to a first combustible loading test according to ASTM The polymer cable assembly has a flame travel distance equal to or less than about five feet, a peak optical density of smoke equal to or less than about 0.5, and an average optical density equal to or less than about 0.15 when measured by the Steiner Tunnel Test Method of E84, and wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; causing a first amount of deformation to the polymer cable assembly by subjecting the polymer cable assembly to a compressive force when the polymer cable assembly is at the second hardness, and using the polymer cable assembly to form a wire and cable product, wherein the wire and cable product meet the established desired electrical characteristics when the polymer cable assembly is deformed by the first amount of deformation, but will not meet the desired electrical characteristics if the polymer cable assembly is deformed by a second amount of deformation, wherein the second amount of deformation is the amount that the polymer cable assembly will deform when subjected to the compressive force when the polymer cable assembly is at the first hardness. In some embodiments, the polymer cable assembly is a polymer insulation layer surrounding the wire. In some embodiments, the wire and cable product is a twisted pair wire. In some embodiments, the wire and cable products produce a flame travel distance of less than four feet when measured by the Steiner Tunnel Test Method of ASTM E84. In some embodiments, the wire and cable products produce a smoke peak optical density of less than 0.4 when measured by the Steiner Tunnel Test Method of ASTM E84. In some embodiments, the wire and cable products produce an average optical density of less than 0.15 when measured by the Steiner Tunnel Test Method of ASTM E84. In some embodiments, the desired electrical characteristic of the wire and cable products is a capacitance value of less than about 20pf / ft. In some embodiments, the desired electrical characteristic of the wire and cable products is an impedance value between about 75 ohms and 125 ohms. In some embodiments, the desired electrical characteristic of the wire and cable products is a propagation velocity between about 62% and 80%.

[0367] Additional disclosed embodiments relate to a method of forming a twisted pair, the method comprising the following steps: operating a cable twisting apparatus at a first speed to produce a first twisted pair having a first crush ratio; providing a first polymer insulated conductor, the first polymer insulated conductor comprising a first conductor electrically insulated by a first polymer insulation layer; providing a second polymer insulated conductor, the second polymer insulated conductor comprising a second conductor electrically insulated by a second polymer insulation layer; exposing at least the first polymer insulated conductor to a cryogenic fluid; and operating the cable twisting apparatus at a second speed to produce a second twisted pair having a second crush ratio, wherein the second twisted pair comprises the first polymer insulated conductor and the second polymer insulated conductor, and wherein the second speed is faster than the first speed. In some embodiments, the second crush ratio is within 10% of the first crush ratio. In some embodiments, the second crush ratio is less than the first crush ratio. In some embodiments, the second speed is at least 15% faster than the first speed. In some embodiments, the second speed is at least 25% faster than the first speed. In some embodiments, the first speed is the rated speed of the cable twisting apparatus for wire and cable products, and wherein the second speed is at least 10% faster than the first speed. In some embodiments, the second speed is at least 10% faster than the first speed, and wherein the second crush ratio is less than the first crush ratio. In some embodiments, the first speed is at least 60 feet per minute, and wherein the second speed is at least 70 feet per minute. In some embodiments, the first speed is at least 160 feet per minute, and wherein the second speed is at least 180 feet per minute. In some embodiments, the first speed is at least 220 feet per minute, and wherein the second speed is at least 275 feet per minute. In some embodiments, the cryogenic fluid is liquid nitrogen.

[0368] Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present disclosure. All such improvements and modifications are considered to be within the scope of the concepts disclosed herein and the appended claims. It is to be understood that any given element of the disclosed embodiments of the present invention may be embodied in a single structure, a single step, a single substance, etc. Similarly, a given element of the disclosed embodiments may be embodied in multiple structures, steps, substances, etc.

[0369] The above description and the accompanying drawings illustrate and describe certain processes, machines, products and material compositions, some of which embody the present invention. Such descriptions or illustrations are not intended to limit the scope of the rights that can be claimed, but are set to help understand the claims, help implement and use the content of the claimed rights, and teach the best way to use the present invention. If this description and the accompanying drawings are interpreted as only disclosing a certain specific embodiment or several embodiments, it should not be understood as limiting the scope of the rights that can be claimed to that specific embodiment or several embodiments. Any example or embodiment of the present invention described herein is not intended to indicate that the scope of the rights claimed must be completely consistent with the example or embodiment. When it is mentioned that the present invention or its embodiment achieves one or more goals, it is not intended to limit the scope of the rights that can be claimed to the scheme that can achieve all these goals. Any statement criticizing the prior art in this specification is not intended to limit the scope of the rights claimed to exclude any aspect of the prior art.

[0370] In addition, the present disclosure shows and describes certain embodiments of the disclosed processes, machines, manufacture, compositions of matter, and other teachings, but it is to be understood that the teachings of the present disclosure are capable of being used in various other combinations, modifications, and environments, and are capable of changes or modifications within the scope of the teachings as expressed herein.

[0371] Any section headings herein are provided solely to provide an organizational arrangement consistent with the recommendations of 37 CFR § 1.77 or otherwise. Such headings shall not limit or characterize the inventions described herein.

Claims

1. A method of manufacturing a twisted pair of insulated conductors having improved resistance to crushing, the method comprising the steps of: cooling the first insulated conductor to increase the stiffness of the first insulated conductor; cooling the second insulated conductor to increase the stiffness of the second insulated conductor; feeding the first insulated conductor and the second insulated conductor into a bow of a twisting unit in the presence of a fluid; and at least partially shielding the insulated conductors from convective heat transfer from the fluid when the yoke rotates.

2. A method for manufacturing a twisted pair of insulated conductors having a predetermined impedance, the method comprising the following steps: a. feeding a first insulated conductor and a second insulated conductor into a rotating bow as part of a twisting machine in the presence of a fluid, wherein the first insulated conductor comprises a first conductor surrounded by a first insulator, and wherein the second insulated conductor comprises a second conductor surrounded by a second insulator; b. controlling convective heat transfer between the first insulated wire and the second insulated wire and the fluid to control the temperature of the first insulator and the second insulator, thereby imparting hardness to the first insulator and the second insulator; and c. twisting the first insulated conductor with the second insulated conductor to form a twisted pair, wherein the first insulated conductor and the second insulated conductor experience an amount of deformation during twisting that is a function of stiffness, wherein an impedance of the twisted pair is a function of the degree of deformation.

3. A method for manufacturing a twisted pair of insulated conductors within a predetermined impedance tolerance range, the method comprising the steps of: a. feeding a first insulated conductor and a second insulated conductor into a rotating bow as part of a twisting machine in the presence of a fluid, wherein the first insulated conductor comprises a first conductor surrounded by a first insulator, and wherein the second insulated conductor comprises a second conductor surrounded by a second insulator; b. controlling convective heat transfer from the fluid to the first insulated conductor and the second insulated conductor; and c. twisting the first insulated conductor with the second insulated conductor to form a twisted pair, wherein the first insulated conductor and the second insulated conductor undergo an amount of deformation during twisting; d. measuring the impedance of the twisted pair; and e. If the impedance of the twisted pair is outside of a predetermined tolerance range, regulating convective heat transfer from the fluid to the first insulated conductor and the second insulated conductor.

4. The method according to any one of claims 1 to 3, wherein: The fluid is selected from the group consisting of: air, N2, CO2, argon, helium, neon, krypton, xenon and radon.

5. A twisted pair of insulated conductors having increased resistance to deformation, the twisted pair of insulated conductors being the product of the method according to claim 1.

6. A twisted pair of insulated conductors having a predetermined impedance, the twisted pair of insulated conductors being the product of the method according to claim 2.

7. A twisted pair of insulated conductors having an impedance within a predetermined tolerance range, the twisted pair of insulated conductors being the product of the method of claim 3.

8. The twisted pair cable according to any one of claims 5 to 7, wherein: The twisted pair has an impedance of at least 101.8Ω.

9. The twisted pair cable according to any one of claims 5 to 7, wherein: The twisted pair has an impedance of at least 102Ω.

10. The twisted pair cable according to any one of claims 5 to 7, wherein: The twisted pair has an impedance of at least 103Ω.

11. The twisted pair cable according to any one of claims 5 to 7, wherein: The twisted pair has a delay of at least 491.5 ns / 100 ft.

12. The twisted pair cable according to any one of claims 5 to 7, wherein: The twisted pair has a delay of at least 492ns / 100ft.

13. A cable comprising the twisted pair wire according to any one of claims 5 to 12.

14. A method for reducing the effects of compressive forces on a polymer cable assembly, the method comprising the steps of: Providing a polymer cable assembly having a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; subjecting the polymer cable assembly to a compressive force in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow; and allowing the polymer cable assembly to return to the first hardness.

15. A method for reducing the effects of compressive forces on a polymer cable assembly, the method comprising the steps of: a. providing a polymer cable assembly having a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is different from the first hardness; b. subjecting the polymer cable assembly to a compressive force in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow; and c. allowing the polymer cable assembly to return to the first stiffness.

16. A method for manufacturing a communication cable, the method for manufacturing a communication cable comprising the following steps: a. Providing a polymer cable assembly having a first cross-sectional radius and a second cross-sectional radius, wherein the first cross-sectional radius is a maximum distance along the cross-section from a center of the polymer cable assembly to an edge of the polymer cable assembly, and the second cross-sectional radius is a minimum distance along the cross-section from the center of the polymer cable assembly to an edge of the polymer cable assembly, and wherein the first cross-sectional radius is approximately equal to ±3% of the second cross-sectional radius, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; b. temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; and c. subjecting the polymer cable assembly to a compressive force in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow, wherein, after the compressive force, the first cross-sectional radius is approximately equal to the second cross-sectional radius ±10%.

17. A method for manufacturing a communication cable, the method for manufacturing a communication cable comprising the following steps: a. providing a polymer cable assembly having a first diameter and a second diameter, wherein the first diameter and the second diameter are perpendicular to each other, and wherein the first diameter is approximately equal to the second diameter ±3%, and wherein the polymer cable assembly has a first hardness, wherein the first hardness is the hardness of the polymer cable assembly under ambient conditions; b. temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; c. subjecting the polymer cable assembly to a compressive force in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow, wherein after the compressive force, the first diameter is approximately equal to the second diameter ±10%; and d. allowing the polymer cable assembly to return to the first hardness.

18. A method for manufacturing a communication cable, the method for manufacturing a communication cable comprising the following steps: a. providing a first pair of polymer insulated conductors, a second pair of polymer insulated conductors, a third pair of polymer insulated conductors, and a fourth pair of polymer insulated conductors, wherein each pair of polymer insulated conductors comprises two polymer insulated conductors, and wherein each polymer insulated conductor has a first hardness, wherein the first hardness is the hardness of the polymer insulated conductor under ambient conditions; b. temporarily changing the hardness of the polymer insulated conductors in the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors, and the fourth pair of polymer insulated conductors to a second hardness, wherein the second hardness is different from the first hardness; c. twisting the polymer insulated conductors of the first pair of polymer insulated conductors together to form a first twisted pair, the first twisted pair having a first propagation delay over 100 meters; d. twisting the polymer insulated conductors of the second pair of polymer insulated conductors together to form a second twisted pair, the second twisted pair having a second propagation delay over 100 meters; e. twisting the polymer insulated conductors of the third pair of polymer insulated conductors together to form a third twisted pair having a third propagation delay over 100 meters; and f. twisting the polymer insulated conductors of the fourth pair of polymer insulated conductors together to form a fourth twisted pair, the fourth twisted pair having a fourth propagation delay over 100 meters, wherein for the first propagation delay, the second propagation delay, the third propagation delay, and the fourth propagation delay over 100 meters, the propagation delay differences over 100 meters are within 50 nanoseconds of each other; Wherein, the step of twisting at least one pair of the polymer insulated conductors among the first pair of polymer insulated conductors, the second pair of polymer insulated conductors, the third pair of polymer insulated conductors and the fourth pair of polymer insulated conductors comprises: feeding the polymer insulated conductors into a bow frame of a twisting unit, wherein the polymer insulated conductors are at least partially shielded from the influence of convective heat transfer in the bow frame.

19. A method for manufacturing a communication cable, the method for manufacturing a communication cable comprising the following steps: a. providing a first pair of polymer insulated conductors and a second pair of polymer insulated conductors, wherein each pair of polymer insulated conductors comprises two polymer insulated conductors, and wherein each polymer insulated conductor has a first hardness, wherein the first hardness is the hardness of the polymer insulated conductor under ambient conditions; b. temporarily changing the hardness of the polymer insulated conductor in the first pair of polymer insulated conductors to a second hardness, wherein the second hardness is different from the first hardness; c. twisting together the polymer insulated conductors of the first pair of polymer insulated conductors in a bow of a twisting unit, wherein the polymer insulated conductors are at least partially shielded from convective heat transfer in the bow to form a first twisted pair having a first propagation delay over 100 meters; and d. twisting the polymer insulated conductors of the second pair of polymer insulated conductors together to form a second twisted pair having a second propagation delay over 100 meters, wherein the first propagation delay over 100 meters and the second propagation delay over 100 meters are within 25 nanoseconds of each other.

20. A system for manufacturing a wire and cable product, the system for manufacturing a wire and cable product comprising: a payout device configured to pay out the polymer cable assembly; a cooling container configured to receive the polymeric cable assembly, wherein the cooling container contains a cryogenic fluid; A wire take-up device configured to tighten the polymer cable assembly; and a twisting machine configured to receive a first polymer insulated conductor and a second polymer insulated conductor and form a twisted pair, the twisting machine including a bow in a fluid, the bow including a device for shielding the insulated conductors from the effects of convective heat transfer with the fluid when the bow rotates.

21. A system for manufacturing a wire and cable product, the system for manufacturing a wire and cable product comprising: a payout device configured to pay out the polymer cable assembly; a cooling surface configured to contact the polymeric cable assembly; and a wire take-up device configured to tighten the polymer cable assembly; and a twisting machine configured to receive a first polymer insulated conductor and a second polymer insulated conductor and form a twisted pair, the twisting machine including a bow in a fluid, the bow including means for shielding the insulated conductors from convective heat transfer with the fluid when the bow rotates.

22. A method of manufacturing a low combustible loading wire and cable product, the method comprising the steps of: a. establishing desired electrical properties of a wire and cable product, wherein the wire and cable product comprises a polymeric cable assembly, wherein the polymeric cable assembly has a first combustible load and a first stiffness, and wherein the polymeric cable assembly has a flame travel distance equal to or less than about five feet, a smoke peak optical density equal to or less than about 0.5, and an average optical density equal to or less than about 0.15 when measured in accordance with the Steiner Tunnel Test Method of ASTM E84, and wherein the first hardness is the hardness of the polymeric cable assembly under ambient conditions; b. temporarily changing the hardness of the polymer cable assembly to a second hardness, wherein the second hardness is greater than the first hardness; c. causing a first amount of deformation to the polymer cable assembly by subjecting the polymer cable assembly to a compressive force while the polymer cable assembly is at the second stiffness in a bow of a twisting unit, wherein the polymer cable assembly is at least partially shielded from convective heat transfer in the bow; and d. using the polymer cable assembly to form the wire and cable product, wherein the wire and cable product satisfies the established desired electrical properties when the polymer cable assembly is deformed by the first deformation amount, but the wire and cable product will not satisfy the desired electrical properties if the polymer cable assembly is deformed by a second deformation amount, wherein the second deformation amount is the amount by which the polymer cable assembly will deform when subjected to the compressive force when the polymer cable assembly is at the first hardness.

23. A rotating bow for use in a twisting unit for manufacturing a twisted pair of insulated conductors, wherein: The bow is for use in a fluid, the bow comprising means for shielding the insulated conductors from convective heat transfer with the fluid when the bow is rotated.

24. The rotating bow according to claim 23, wherein: The means for shielding the insulated conductors from convective heat transfer is a longitudinal tube sized to at least partially contain the insulated conductors.

25. The rotating bow according to claim 23, wherein: The means for shielding the insulated conductors from convective heat transfer is a longitudinal groove in the yoke, the longitudinal groove being dimensioned to at least partially accommodate the insulated conductors.

26. The rotating bow according to claim 23, wherein: The means for shielding the insulated conductors from convective heat transfer is a plurality of wind deflectors positioned on the windward side of the insulated conductors.

27. The rotating bow according to claim 23, wherein: The means for shielding the insulated conductors from convective heat transfer includes vents of adjustable size.

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