20 AWG PoE Cable and RJ-45 Insert for Extended Reach
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Solution Overview
Problem
Current Power-Over-Ethernet (POE) cables have a limited maximum length of 100 meters, requiring boosters or intermediate distribution frames (IDFs) to extend the distance, which increases complexity and cost, and introduces potential points of failure.
Innovation Solution
A twisted pair cable with 20 AWG solid copper conductors and FEP insulation, using RJ-45 connectors adapted for 20 AWG conductors, allows for extended POE cable lengths up to 292 meters without the need for boosters or IDFs, while maintaining full resolution video transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If standard Cat 5e or Cat 6 POE cable is used, then the cable meets TIA electrical requirements and is compatible with existing infrastructure, but the maximum cable length is limited to 100 meters requiring boosters or IDFs
Solution Approach 1:
The patent changes the conductor gauge parameter from standard 24 AWG (Cat 5e/Cat 6) to 20 AWG, which has lower electrical resistance. This parameter change enables the cable to transmit power and data signals over extended distances (292 meters) without requiring additional infrastructure like boosters or IDFs, thereby reducing system complexity while maintaining TIA electrical requirements
Solution Approach 2:
The patent segments the cable into four twisted pairs of 20 AWG solid copper conductors, each pair optimized for specific signal types. This segmentation allows independent optimization of each pair for power transmission, data signaling, and video transmission, enabling extended cable length while maintaining signal integrity and reducing interference
2Length of stationary object
If boosters or IDFs are added to extend POE cable distance, then the cable reach is extended, but the cost and potential points of failure increase
Solution Approach 1:
The patent extracts and eliminates the need for external boosters or IDFs by incorporating the extended transmission capability directly into the cable itself through the use of 20 AWG conductors. This removes additional hardware components from the system, reducing potential points of failure and improving overall reliability while maintaining extended cable length
3Length of stationary object
If 20 AWG conductors with FEP insulation are used, then the cable achieves extended reach of 292 meters, but the connector requirements become more specialized
Solution Approach 1:
The patent designs RJ-45 connectors with enlarged contact holes that can accommodate both the thicker 20 AWG conductors and maintain compatibility with standard networking infrastructure. This universal design allows the extended-reach cable to interface with existing equipment while supporting the specialized 20 AWG conductor requirements
4Length of stationary object
If mid-span power approach is used with POE injectors every 328 feet, then power can be supplied along the cable, but the installation cost and complexity increase
Solution Approach 1:
Instead of adding power injection points along the cable (mid-span approach), the patent inverts the approach by using lower-resistance 20 AWG conductors that can carry power over the entire extended length from a single endpoint source. This eliminates the need for multiple POE injectors and tamper-proof cabinets, simplifying installation while achieving greater cable length
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cable achieves a 45% improvement in reach compared to conventional Cat 6 cables, meeting TIA electrical requirements and tripling the standard distance without additional infrastructure, making it suitable for video surveillance and other demanding applications.
Implementation Method 1
each conductor has FEP (fluorinated ethylene propylene) insulation and an overall FEP jacket. The insulation thickness is 0.012 inches.
Implementation Method 2
The cable includes an outer jacket which in this embodiment is made of fluorinated ethylene propylene (FEP). The jacket has a wall thickness of about 0.013'' and a diameter of about 0.248''. The color may vary but an example is translucent blue.
Data Source
AI summary
A method of extending the usable length of a power-over-ethernet cable includes the steps of providing twisted pairs of wires with the conductor of each wire being a 20 AWG or 22 AWG conductor and terminating the cable at an RJ-45 style connector. The connector for the 20 AWG conductors has an insert therein with holes that can accommodate 20 AWG conductors. FEP, PVC or PP insulation may surround each conductor.