Slit-Tape Isolator for Twisted Pair Cable Crosstalk Reduction

Solution Overview

Problem

Existing twisted pair cables face challenges in reducing internal crosstalk and are costly due to the use of expensive isolators that do not wind well on reels, leading to inefficiencies in storage and manufacturing.

Innovation Solution

A new isolator design featuring an extruded flat tape with slits in its thickness, allowing for longer lengths to be wound on a reel with minimal air gaps, and wedges to open the slits during cable assembly, providing effective separation between twisted pairs while reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional isolators are used to separate twisted pairs, then internal crosstalk is reduced, but manufacturing cost increases and storage efficiency decreases

Engineering Contradiction:

Improveinternal crosstalk reductionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The isolator is segmented by introducing slits that divide it into multiple sections. These slits allow the isolator to be compressed during reel winding, eliminating air gaps and enabling longer lengths to be stored on the same reel. The segmentation also reduces material usage while maintaining the separation function between twisted pairs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The isolator design transitions from a solid three-dimensional structure to a two-dimensional flat tape with slits. This dimensional change allows the isolator to be compressed in the thickness direction during winding, enabling longer lengths to fit on reels while maintaining the same reel size. The slits provide compression pathways that reduce volume without compromising the isolator's crosstalk reduction function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If traditional isolators are used to separate twisted pairs, then internal crosstalk is reduced, but reel storage efficiency deteriorates due to air gaps

Engineering Contradiction:

Improveinternal crosstalk reductionVSAvoidlength per reel

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The isolator is segmented by introducing slits that divide it into multiple sections. These slits allow the isolator to be compressed during reel winding, eliminating air gaps and enabling longer lengths to be stored on the same reel. The segmentation also reduces material usage while maintaining the separation function between twisted pairs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The isolator's physical parameters are changed by introducing slits that allow compression in the thickness direction. This parameter change enables the isolator to transition from a rigid structure with fixed volume to a compressible structure that can be densely packed on reels, increasing the length per reel by eliminating air gaps without compromising the isolator's electrical isolation function.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If flat separator tape is used instead of traditional isolators, then cost and storage efficiency improve, but internal crosstalk reduction performance deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidinternal crosstalk reduction

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The isolator is segmented by introducing slits that divide it into multiple sections. These slits allow the isolator to be compressed during reel winding, eliminating air gaps and enabling longer lengths to be stored on the same reel. The segmentation also reduces material usage while maintaining the separation function between twisted pairs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slits in the isolator act as intermediaries that enable compression without compromising the isolation function. The slits provide pathways for compression while the remaining material structure maintains the electrical isolation between twisted pairs, effectively mediating between the need for compression (for cost and storage efficiency) and the need for isolation (for crosstalk reduction).

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20220371252A1Low cost extrudable isolator from slit-tape

Publication Date: 2022.11.24 COMMSCOPE TECHNOLOGIES LLC

AI summary

A dielectric isolator for a twisted pair cable includes a body formed as an elongate strip with a top surface, bottom surface, a first side edge and a second side edge. A first slot is formed in the first side edge and extends at least half way toward the center of the isolator. A second slot is formed in the second side edge and extends at least half way toward the center of the isolator. During cable manufacturing, first and second wedges open the first and second slots. First and second twisted pairs are inserted into the first and second opened slots, respectively. Third and fourth twisted pairs reside at the top and bottom surface, respectively. The isolator has the cost and reel storage savings of a flat separator tape, while simultaneously providing the internal crosstalk performance of the isolator.