Embodiments of the disclosure relate generally to communication cables and, more particularly, to twisted pair communication cables having integrated pulling elements that withstand higher pulling forces.
A wide variety of different types of communication cables are utilized to transmit information. For example, twisted pair communication cables are utilized to transmit Ethernet and other data signals in accordance with one or more suitable Category cabling standards. In certain applications, twisted pair cables are utilized to provide both data signals and electrical power to a wide variety of devices, such as lighting devices, wireless access points, etc. Typically, electrical power is provided over twisted pairs in accordance with a Power over Ethernet (“PoE”) standard.
Regardless of the intended application, industry standards limit installation lengths of twisted pair cables to 100 m. However, recent customer expectations have led to an increased desire to install PoE and Category cables at continuous lengths exceeding the industry requirement of 100 m. Although twisted pair cables have been sold that are capable of adequately transmitting signal and power at distances greater than 100 m, these cables have not been designed to mechanically endure the installation process. Indeed, existing twisted pair cable designs may be subject to permanent and irreversible stretching of the twisted pairs in the event that they are installed at lengths over 100 m.
Current twisted pair cabling standards require a maximum pulling force exerted on a cable to not exceed 110 N. For example, the ANSI/TIA 568.2-D standard published by the American National Standards Institute (“ANSI”) in 2018 specifies that a maximum pulling tension for a four twisted pair 100 m cable should not exceed 110 N (or 25 lbf) to avoid stretching the copper pairs during cable installation. Similarly, the Insulated Cable Engineers Association ICEA S-90-661 standard, published by ANSI on Jun. 22, 2012, includes a requirement for a maximum pulling force to not exceed 27 N/pair. In a standard four pair cable, the pulling force cannot exceed 108 N to ensure that the twisted pairs are not stretched during installation. Stretching the twisted pairs during installation, for example, by applying pulling forces to the cable, may damage the conductors and/or negatively impact the electrical performance of the cable.
With extended installation lengths, such as installation lengths over 100 m, longer and heavier cables must be pulled by technicians. As a result, it may be necessary to pull a cable with a force exceeding the 110 N permitted by existing standards. Accordingly, there is an opportunity for improved twisted pair cables that can withstand higher pulling forces. In particular, there is an opportunity for improved twisted pair cables with integrating pulling elements that withstand higher pulling forces and facilitate potential installation at extended distances.
The detailed description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items; however, various embodiments may utilize elements and/or components other than those illustrated in the figures. Additionally, the drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure.
Various embodiments of the present disclosure are directed to twisted pair cables with integrated pulling elements. The pulling elements may allow the twisted pair cables to withstand greater pulling forces than those permitted by existing cabling standards. For example, the pulling elements may allow the cables to withstand pulling forces greater than 110 Newtons, such as pulling forces of 330 N or greater. As a result, the cables may be easily pulled and installed at longitudinal lengths or distances greater than 100 m without the twisted pairs being stretched or elongated. Twisted pair cables with integrated pulling elements may be utilized in a wide variety of suitable applications, such as Category cabling applications, Power over Ethernet (“PoE”) applications, etc.
In one example embodiment, a cable may include a plurality of twisted pairs of individually insulated conductors. Any suitable number of pairs may be utilized, such as four pairs of conductors. Additionally, the conductors incorporated into the pairs may be formed with a wide variety of suitable diameters, gauges, and/or other dimensions. The various pairs may also be twisted with any suitable respective twist lays associated with a desired application. In accordance with an aspect of the disclosure, the cable may also include one or more pulling elements that permit the cable to withstand greater pulling forces without elongating or stretching the pairs. For example, integration of one or more pulling elements may permit the cable to withstand a pulling force of 330 N with an elongation of less than 0.20 percent. A jacket may then be formed around the plurality of twisted pairs and the pulling element.
A wide variety of suitable pulling elements may be incorporated into a twisted pair cable as desired in various embodiments. These pulling elements may be formed from a wide variety of suitable materials and/or with a wide variety of suitable dimensions. In certain embodiments, a metallic pulling element may be utilized. For example, the pulling element may be formed from steel, titanium, another suitable metal, or a metallic alloy. In other embodiments, the pulling element may be formed from other suitable materials, such as dielectric materials (e.g., glass reinforced plastic, aramid, etc.) and/or semi-conductive materials (e.g., carbon fiber, etc.). In certain embodiments, a pulling element (e.g., a metallic pulling element, etc.) may be formed from a material (e.g., a metallic material, etc.) having a higher elastic modulus than that of the copper or other conductive material utilized in the twisted pairs. For example, a pulling element may be formed from a material having an elastic modulus greater than 125 GPa. In this regard, the pulling element may primarily bear the tensile load associated with pulling the cable.
A pulling element may also be formed with a wide variety of suitable dimensions, such as any suitable gauge or cross-sectional area. In certain embodiments, a pulling element may have a cross-sectional area of at least 0.115 mm2. For example, a 26 AWG or larger steel pulling element may be utilized. Additionally, in certain embodiments, a pulling element may be formed from a single component. In other embodiments, a pulling element may be formed from a plurality of components that are stranded or twisted together. For example, a pulling element may be formed from a solid metallic material or with a plurality of metallic strands. Additionally, in certain embodiments, a bare, uninsulated, or uncoated pulling element may be utilized. In other embodiments, suitable insulation or a suitable coating may be formed on a pulling element.
Any number of suitable pulling elements may be incorporated into a cable as desired in various embodiments. In certain embodiments, a single pulling element may be utilized. In other embodiments, a plurality (e.g., two, three, four, etc.) of pulling elements may be incorporated into a cable. In certain embodiments, a plurality of pulling elements may have similar constructions. In other embodiments, at least two pulling elements may be formed with different materials and/or different dimensions. Additionally, one or more pulling elements may be positioned at a wide variety of suitable locations within a cable. For example, one or more pulling elements may be positioned between the twisted pairs and the cable jacket (e.g., around an outer periphery of the twisted pairs, etc.). As another example, a pulling element may be positioned between the plurality of twisted pairs. As yet another example, one or more pulling elements may be embedded within the cable jacket. In other embodiments, a plurality of pulling elements may be positioned at different locations. For example, a first pulling element may be positioned between the plurality of twisted pairs while a second pulling element is positioned outside an outer periphery of the twisted pairs. Regardless of the positioning of a pulling element(s), in certain embodiments, a pulling element may extend in a longitudinal direction parallel to the plurality of the twisted pairs. The pulling element may not be twisted or stranded with the twisted pairs.
As a result of incorporating one or more pulling elements, a greater pulling force may be applied or imparted onto the cable without stretching, elongating, or damaging the twisted pairs. The ability to pull a twisted pair cable with greater force may facilitate easier installation of cable runs at lengths exceeding the 100 m limit established by industry standards. For example, a four pair cable that can withstand a pulling force of 330 N may be installed at lengths up to approximately 300 m. Additionally, in certain embodiments, one or more pulling elements may be incorporated into a twisted pair cable without materially altering an outside diameter of the twisted pair cable. For example, a twisted pair cable incorporating one or more pulling elements may have an outside diameter less than or equal to approximately 10 mm.
Embodiments of the disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which certain embodiments of the disclosure are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
The example cables of
Turning first to
According to an aspect of the disclosure, the cable 100 may include a plurality of twisted pairs of individually insulated conductors. As shown in
In certain embodiments, the cable 100 may include only four twisted pairs of individually insulated conductors 105A-D, one or more pulling elements 110, and no other conductive elements and/or transmission media. For example, the cable 100 may include four pairs 105A-D, one or more pulling elements 110, and no other conductive components that are suitable for transmitting communications and/or power signals. As another example, the cable 100 may include four pairs 105A-D, one or more pulling elements 110, one or more drain wires, and no other conductive components that are suitable for transmitting communications and/or power signals. As another example, the cable 100 may include four pairs 105A-D, one or more pulling elements 110, and no other components (e.g., conductive components, optical fibers, etc.) that are suitable for transmitting communications and/or power signals. As yet another example, the cable 100 may include four pairs 105A-D, one or more pulling elements 110, one or more drain wires, and no other components (e.g., conductive components, optical fibers, etc.) that are suitable for transmitting communications and/or power signals.
In certain embodiments, the electrical conductors 120 may be sized in accordance with a desired application for the cable 100. For example, in typical Category cabling, the electrical conductors 120 may be 23 American Wire Gauge (“AWG”) or 24 AWG conductors. Each twisted pair 105 can carry data or some other form of information, for example in a range of about one to ten Giga bits per second (“Gbps”) or other suitable data rates, whether higher or lower. In certain embodiments, each twisted pair 105 supports data transmission of about two and one-half Gbps (e.g. nominally two and one-half Gbps), with the cable 100 supporting about ten Gbps (e.g. nominally ten Gbps). In certain embodiments, each twisted pair 105 supports data transmission of up to about ten Gbps (e.g. nominally ten Gbps), with the cable 100 supporting about forty Gbps (e.g. nominally forty Gbps).
As desired, larger conductors may be utilized in association with PoE applications in order to satisfy desirable power transmission requirements. For example, the electrical conductors 120 may be 22 AWG, 21 AWG, or 20 AWG conductors in PoE applications. In certain embodiments in which the cable 100 is suitable for use in PoE applications, the electrical conductors 120 of certain twisted pairs (e.g., illustrated twisted pairs 105A-D, etc.) may have a diameter and/or cross-sectional area that is greater than or equal to required minimum dimensions for 22 AWG conductors. For example, electrical conductors 120 may have a diameter that is greater than or equal to approximately 0.0240 inches (0.6096 mm). In various embodiments, electrical conductors 120 may have diameters that are greater than or equal to approximately 0.0240, 0250, 0.0255, 0.0260, 0.0275, 0.0280, 0.0285, 0.0300, 0.0310, 0.0320, or 0.0340 inches, or diameters incorporated in a range between any two of the above values.
Additionally, the electrical conductors 120 and/or certain twisted pairs may be capable of transmitting a desired power signal for PoE applications. For example, a desired number of twisted pairs (e.g., the illustrated four twisted pairs 105A-D, etc.) may be capable of transmitting at least approximately 100 Watts of power at approximately 1.0 ampere per pair over a distance of approximately 100 meters with at least approximately 88% efficiency at a temperature of approximately twenty degrees Celsius (20° C.). In certain embodiments, each example twisted pair 105 may be capable of transmitting a desired portion of the overall power. For example, each set of two twisted pairs (e.g., twisted pairs 105A-B and 105C-D, etc.) may be capable of transmitting at least approximately 50 Watts of power. The power transmitted by each set of twisted pairs may be equal to the current carried by each twisted pair multiplied by the voltage between the two twisted pairs. The current and/or voltage on/between each twisted pair may be adjusted as desired in order to attain a desired power signal. As one example, each conductor of a twisted pair 105 may carry an approximately 0.5 ampere signal. Thus, a combined signal of approximately 1.0 ampere may be transmitted on a twisted pair. Other suitable power transmission requirements may be utilized as desired in other embodiments.
The twisted pair insulation (generally referred to as insulation 125) may include any suitable dielectric materials and/or combination of materials. Examples of suitable dielectric materials include, but are not limited to, one or more polymeric materials, one or more polyolefins (e.g., polyethylene, polypropylene, etc.), one or more fluoropolymers (e.g., fluorinated ethylene propylene (“FEP”), melt processable fluoropolymers, MFA, PFA, ethylene tetrafluoroethylene (“ETFE”), ethylene chlorotrifluoroethylene (“ECTFE”), etc.), one or more polyesters, polyvinyl chloride (“PVC”), one or more flame retardant olefins, a low smoke zero halogen (“LSZH”) material, etc.), polyurethane, neoprene, cholorosulphonated polyethylene, flame retardant PVC, low temperature oil resistant PVC, flame retardant polyurethane, flexible PVC, or a combination of any of the above materials. Additionally, in certain embodiments, the insulation of each of the electrical conductors utilized in the twisted pairs 105A-D may be formed from similar materials. In other embodiments, at least two of the twisted pairs may utilize different insulation materials. In yet other embodiments, the two conductors that make up a twisted pair 105 may utilize different insulation materials. As desired in certain embodiments, insulation may additionally include a wide variety of other materials (e.g., filler materials, materials compounded or mixed with a base insulation material, etc.), such as smoke suppressant materials, flame retardant materials, etc.
In various embodiments, twisted pair insulation 125 may be formed from one or multiple layers of insulation material. A layer of insulation may be formed as solid insulation, unfoamed insulation, foamed insulation, or other suitable insulation. As desired, combination of different types of insulation may be utilized. For example, a foamed insulation layer may be covered with a solid foam skin layer. As desired with foamed insulation, different foaming levels may be utilized for different twisted pairs in accordance with twist lay length to assist in balancing propagation delays between the twisted pairs. In certain embodiments, desired twisted pairs (e.g., twisted pairs 105A-D) incorporated into the cable 100 may have insulation that is formed from or that includes FEP. For example, the conductors of the twisted pairs 105A-D may be insulated with solid FEP insulation. Additionally, the twisted pair insulation 125 may be formed with any suitable thickness, inner diameter, outer diameter, and/or other dimensions.
In various embodiments, a desired number of the twisted pairs may be formed with different respective twist lays. For example, in the illustrated four pair cable, each of the twisted pairs 105A-D may have a different twist lay. The different twist lays may function to reduce crosstalk between the twisted pairs, and a wide variety of suitable twist lay configurations may be utilized. According to an aspect of the disclosure, the respective twist lays for the twisted pairs 105A-D may be selected, calculated, or determined in order to result in a cable 100 that satisfies one or more standards and/or electrical requirements. For example, twist lays may be selected such that the cable 100 satisfies one or more electrical requirements of a Category 5, Category 5e, Category 6, or Category 6A standard, such as the TIA 568.2-D standard set forth by the Telecommunications Industry Association. Twist lays may be selected as desired such that the cable 100 satisfies a wide variety of other electrical requirements, such as a propagation delay skew of less than approximately forty-five nanoseconds (45 ns) per one hundred meters (100 m) and/or a direct current resistance unbalance between any pairs (i.e., any two pairs of the cable 100) of less than approximately one hundred milliohms (100 mil) per one hundred meters (100 m).
In certain embodiments, the twist lays of the various twisted pairs 105A-D may account for a desired installation distance of the cable 100. For example, the twist lays may be selected and optimized to facilitate installation lengths exceeding 100 m. In various embodiments, the twist lays may be selected or optimized to facilitate installation lengths of up to 300 m, such as installation lengths of 150, 200, 250, or 300 m, installation lengths included in a range between any two of the above values, or installation lengths included in a range bounded on a maximum end by one of the above values. Additionally, in certain embodiments, the twist lays may be optimized for maximum installation lengths associated with a pulling force that the cable 100 can withstand. For example, if the cable 100 can withstand a pulling force associated with a 300 m installation length, then the twist lays may be selected to facilitate cable runs of up to 300 m that satisfy desired electrical performance parameters (e.g., Category standards, PoE standards, etc.).
In certain embodiments, the differences between twist lays of twisted pairs that are circumferentially adjacent one another (for example the twisted pair 105A and the twisted pair 105B) may be greater than the differences between twist lays of twisted pairs 105 that are diagonal from one another (for example the twisted pair 105A and the twisted pair 105C). As a result of having similar twist lays, the twisted pairs that are diagonally disposed can be more susceptible to crosstalk issues than the twisted pairs 105 that are circumferentially adjacent; however, the distance between the diagonally disposed pairs may limit the crosstalk. Thus, the different twist lays and arrangements of the pairs can help reduce crosstalk among the twisted pairs 105.
As desired, the plurality of twisted pairs 105A-D may be twisted together with an overall twist or bunch. Any suitable overall twist lay or bunch lay may be utilized, such as a bunch lay between approximately 1.9 inches and approximately 15.0 inches. For example, a bunch lay may be approximately 1.9, 2.0, 2.5, 3.0, 3.5, 3.75, 4.0, 4.25, 4.5, 4.75, 5.0, 5.5, 6.0, 7.0, 7.5, 8.0, 9.0, 10.0, 11.0, 12.0, or 15.0 inches, or any value included in a range between two of the previously listed values (e.g., a bunch lay between approximately 3.5 and approximately 4.5 inches, etc.), or any value included in a range bounded on either a minimum or maximum end by one of the above values (e.g., a bunch lay that is less than or equal to approximately 4.25 inches, etc.).
In certain embodiments, the twisted pairs 105A-D may each be twisted in the same direction (e.g., clockwise, counter-clockwise). An overall twist or bunching may then be formed in the same direction as the twisted pairs 105A-D (which tends to tighten the twist lays of each pair) or, alternatively, in an opposite direction from the twisted pairs (which tends to loosen the twist lays of each pair). In other embodiments, a first portion of the twisted pairs 105A-D may have a twist direction that is the same as the overall twist direction while a second portion of the twisted pairs 105A-D may have a twist direction that is opposite that of the overall twist direction. Any number of twisted pairs may be included in either the first portion or the second portion. Indeed, a wide variety of suitable combinations of twist lays and/or twist directions may be utilized as desired in order to obtain twisted pairs with desired final or resultant twist lays.
As desired in various embodiments, one or more suitable bindings or wraps may be wrapped or otherwise formed around the twisted pairs 105A-D once they are twisted together. Additionally, in certain embodiments, multiple grouping of twisted pairs may be incorporated into a cable. As desired, each grouping may be twisted, bundled, and/or bound together. Further, in certain embodiments, the multiple groupings may be twisted, bundled, or bound together.
With continued reference to
An opening enclosed by the jacket 115 may be referred to as a cable core, and the twisted pairs 105A-D and/or other cable components may be disposed within the cable core. In certain embodiments, one or more pulling elements 110 may be disposed within the cable core. In other embodiments, one or more pulling elements 110 may be embedded within the jacket 115. In yet other embodiments, a cable 100 may include at least one first pulling element embedded in the jacket 115 and at least one second pulling element disposed in the cable core. Although a single cable core is illustrated in the cable 100 of
As desired in various embodiments, a suitable separator, spline, or filler may be positioned between two or more of the twisted pairs 105A-D. Although a separator is not illustrated in
In certain embodiments, the separator may be continuous along a longitudinal length of the cable 100. In other embodiments, the separator may be non-continuous or discontinuous along a longitudinal length of the cable 100. In other words, the separator may be separated, segmented, or severed in a longitudinal direction such that discrete sections or portions of the separator are arranged longitudinally (e.g., end to end) along a length of the cable 100. Use of a non-continuous or segmented separator may enhance the flexibility of the cable 100, reduce an amount of material incorporated into the cable 100, and/or reduce cost.
In certain embodiments, the separator may be characterized as having projections that extend from a central portion or spine. For example, a cross-filler may be viewed as having a plurality of projections that extend in different directions from a central portion, spine, or central point. In certain embodiments, the projections of a separator may be continuous along a longitudinal length of the separator (or a separator section in a severed separator). In other embodiments, one or more projections of a separator may have sections or portions that are spaced along a longitudinal length of the separator, and any suitable longitudinal gap or spacing may be positioned between longitudinally adjacent sections of a projection. Longitudinal gaps utilized between sections of a projection may have any suitable lengths or sized, and gaps may be approximately equal in length and/or spacing (e.g., arranged in accordance with a desired pattern, etc.) or alternatively, arranged in a random or pseudo-random manner. The use of longitudinal spaces between adjacent sections of a projection or between adjacent sets of projections (e.g., spaced grouping of projections or prongs) may facilitate a reduction in material utilized to form the separator and/or may enhance the flexibility of the separator.
In certain embodiments, projections may extend from a central portion in different sets of one or more directions at longitudinally spaced locations. For example, a first set of one or more projections may extend in a first set of respective directions. A second set of one or more projections longitudinally adjacent to the first set may extend in a second set of respective directions, and at least one direction of extension in the second set may be different than the direction(s) of extension included in the first set. Regardless of whether longitudinal gaps are positioned between various sets of longitudinally spaced projections, any suitable number of projections (e.g., one, two, three, four, etc.) may extend at each longitudinally spaced location. In certain embodiments, directions of extension may be varied in order to reduce material utilized to form the separator while still providing a separator with a desired overall cross-sectional shape. For example, a separator may function as a cross-filler that includes projections extending in four directions along a longitudinal length; however, at any given location along the longitudinal length, projections may not extend in all four directions. A wide variety of suitable configurations of projections may be utilized as desired. In certain embodiments, a single projection may extend from each longitudinally spaced location, and the projections may alternate directions of extension, for example, at approximately ninety-degree (90°) angles or in accordance with any other suitable pattern. In other embodiments, two projections may extend from each longitudinally spaced location in opposite directions from a central portion, and the directions of extension may alternate by approximately one hundred and eighty degrees (180°) between adjacent spaced locations. In other embodiments, two projections may extend from each longitudinally spaced location with an approximately ninety-degree (90°) angle between the two projections. The directions of extension for the two projections may then be varied between adjacent longitudinally spaced locations. In yet other embodiments, three projections may extend from each longitudinally spaced location, and a projection that is not present may be alternated or otherwise varied along a longitudinal length. For example, a projection that is not present may be alternated at approximately ninety-degree (90°) angles at adjacent longitudinally spaced locations. Additionally, in certain embodiments, the same number of projections may extend from each of the longitudinally spaced locations. In other examples, different numbers of projections may extend from at least two longitudinally spaced locations. A wide variety of other projection configurations and/or variations may be utilized as desired.
For a cross-filler or other separator that includes projections that extend between adjacent sets of twisted pairs 105A-D, each projection may be formed with a wide variety of suitable dimensions. For example, each projection may have a wide variety of suitable cross-sectional shapes at a given cross-sectional point perpendicular to a longitudinal direction of the separator, cross-sectional shapes taken along the longitudinal direction (e.g., rectangular, square, semi-circular, parallelogram, trapezoidal, triangular, etc.), cross-sectional areas, thicknesses, distances of projection (i.e., length of projection from the central portion), and/or longitudinal lengths. In certain embodiments, each projection may be formed with substantially similar dimensions. In other embodiments, at least two projections may be formed with different dimensions. Similarly, in certain embodiments, each projection may be formed from similar materials. In other embodiments, at least two projections may be formed from different materials.
A wide variety of suitable techniques may be utilized to form a separator. For example, in certain embodiments, material may be extruded, cast, molded, or otherwise formed into a desired shape to form the separator. In other embodiments, various components of a separator may be separately formed, and then the components of the separator may be joined or otherwise attached together via adhesive, bonding (e.g., ultrasonic welding, etc.), or physical attachment elements (e.g., staples, pins, etc.). In yet other embodiments, a tape may be provided as a substantially flat separator or formed into another desired shape utilizing a wide variety of folding and/or shaping techniques. For example, a relatively flat tape may be formed into an X-shape or cross-shape as a result of being passed through one or more dies. In other embodiments, a plurality of tapes may be combined in order to form a separator having a desired cross-sectional shape. For example, two tapes may be folded at approximately ninety-degree angles and bonded together to form a cross-shaped separator. As another example, four tapes may be folded at approximately ninety-degree angles and bonded to one another to form a cross-shaped separator. A wide variety of other suitable construction techniques may be utilized as desired. Additionally, in certain embodiments, a separator may be formed to include one or more hollow cavities that may be filled with air or some other gas, one or more pulling elements 110, moisture mitigation material, a drain wire, shielding, or some other appropriate components.
The separator (and/or various segments, projections, and/or other components of the separator) may be formed from a wide variety of suitable materials and/or combinations of materials as desired in various embodiments. For example, the separator may include paper, metallic material (e.g., aluminum, ferrite, etc.), alloys, semi-conductive materials, ferrite ceramic materials, various plastics, one or more polymeric materials, one or more polyolefins (e.g., polyethylene, polypropylene, etc.), one or more fluoropolymers (e.g., fluorinated ethylene propylene (“FEP”), melt processable fluoropolymers, MFA, PFA, ethylene tetrafluoroethylene (“ETFE”), ethylene chlorotrifluoroethylene (“ECTFE”), etc.), one or more polyesters, polyvinyl chloride (“PVC”), one or more flame retardant olefins (e.g., flame retardant polyethylene (“FRPE”), flame retardant polypropylene (“FRPP”), a low smoke zero halogen (“LSZH”) material, etc.), polyurethane, neoprene, cholorosulphonated polyethylene, flame retardant PVC, low temperature oil resistant PVC, flame retardant polyurethane, flexible PVC, or any other suitable material or combination of materials. As desired, the separator may be filled, unfilled, foamed, solid, homogeneous, or inhomogeneous and may or may not include additives (e.g., flame retardant and/or smoke suppressant materials). In certain embodiments, a separator may include or incorporate one or more shielding materials, such as electrically conductive shielding material, semi-conductive material, and/or dielectric shielding material (e.g., ferrite ceramic material, etc.). As a result of incorporating electrically conductive material, the separator may function as a shielding element.
In certain embodiments, each segment of a severed or subdivided separator may be formed from similar materials. In other embodiments, a separator may make use of alternating materials in adjacent portions or segments. For example, a first portion or segment of the separator may be formed from a first set of one or more materials, and a second portion or segment of the separator may be formed from a second set of one or more materials. As one example, a relatively flexible material may be utilized in every other portion of a separator. As another example, flame retardant material may be selectively incorporated into desired portions of a separator. In this regard, material costs may be reduced while still providing adequate flame retardant qualities.
As desired in various embodiments, one or more shield elements or shielding elements may be incorporated into the cable 100. Each shielding element may incorporate one or more shielding materials, such as electrically conductive shielding material, semi-conductive material, and/or dielectric shielding material (e.g., ferrite ceramic material, etc.). Examples of suitable shield layers that may be utilized as shielding elements include, but are not limited to, an overall shield formed around the twisted pairs 105A-D (as shown in
In certain embodiments, a shield layer, such as an overall shield layer, may be positioned within a cable core. In other embodiments, a shield layer may be incorporated into the outer jacket 115. For example, a shield layer may be sandwiched between two other layers of outer jacket material, such as two dielectric layers. As another example, electrically conductive material or other shielding material may be injected or inserted into the outer jacket 115 or, alternatively, the outer jacket 115 may be impregnated with shielding material. A wide variety of other suitable shielding arrangements may be utilized as desired in other embodiments. Further, in certain embodiments, a cable 100 may include a separate, armor layer (e.g., a corrugated armor, etc.) for providing mechanical protection. In other embodiments, the cable 100 may be formed without a separate armor layer (e.g., corrugated armor, interlocked armor, etc.). As a result of not including an armor layer, an outer diameter of the cable 100 can be reduced.
An example external or overall shield layer (such as those illustrated in
As desired, a wide variety of suitable techniques and/or processes may be utilized to form a shield (or a shield segment). For example, a shield may be formed from continuous electrically conductive material (e.g., an aluminum foil layer, etc.). As another example, a shield may be formed as a braided shield. As yet another example, a base material or dielectric material may be extruded, pultruded, or otherwise formed. Electrically conductive material or other shielding material may then be applied to the base material. In other embodiments, shielding material may be injected into the base material. In other embodiments, dielectric material may be formed or extruded over shielding material in order to form a shield. Indeed, a wide variety of suitable techniques may be utilized to incorporate shielding material into a base material.
In certain embodiments, the shield (or individual shield segments) may be formed as a tape that includes both a dielectric layer and an electrically conductive layer (e.g., copper, aluminum, silver, an alloy, etc.) formed on one or both sides of the dielectric layer. Examples of suitable materials that may be used to form a dielectric layer include, but are not limited to, various plastics, one or more polymeric materials, one or more polyolefins (e.g., polyethylene, polypropylene, etc.), one or more fluoropolymers (e.g., fluorinated ethylene propylene (“FEP”), polyester, polytetrafluoroethylene, polyimide, or some other polymer, combination of polymers, aramid materials, or dielectric material(s) that does not ordinarily conduct electricity. In certain embodiments, a separate dielectric layer and electrically conductive layer may be bonded, adhered, or otherwise joined (e.g., glued, etc.) together to form the shield. In other embodiments, electrically conductive material may be formed on a dielectric layer via any number of suitable techniques, such as the application of metallic ink or paint, liquid metal deposition, vapor deposition, welding, heat fusion, adherence of patches to the dielectric, or etching of patches from a metallic sheet. In certain embodiments, the conductive patches can be over-coated with an electrically insulating film, such as a polyester coating. Additionally, in certain embodiments, an electrically conductive layer may be sandwiched between two dielectric layers. In other embodiments, at least two electrically conductive layers may be combined with any number of suitable dielectric layers to form the shield. For example, a four-layer construction may include respective electrically conductive layers formed on either side of a first dielectric layer. A second dielectric layer may then be formed on one of the electrically conductive layers to provide insulation between the electrically conductive layer and the twisted pairs 105A-D. Indeed, any number of suitable layers of material may be utilized in a shield 130.
Additionally, in certain embodiments, one or more separator elements (not shown) may be positioned between the individual conductors of a twisted pair 105. As desired, shielding material may be optionally incorporated into one or more separator elements positioned between the conductors of respective twisted pairs 105A-D. In certain embodiments, a twisted pair separator may be woven helically with the individual conductors or conductive elements of an associated twisted pair 105. In other words, a separator element may be helically twisted with the conductors of a twisted pair 105 along a longitudinal length of the cable 100.
Each separator element may have a wide variety of suitable constructions, components, and/or cross-sectional shapes. For example, each separator may be formed as a dielectric film that is positioned between the two conductors of a twisted pair 105. In other embodiments, a separator may be formed with an H-shape, an X-shape, or any other suitable cross-sectional shape. For example, the separator may be formed to create or define one or more channels in which the twisted pair conductors may be situated. In this regard, the separator may assist in maintaining the positions of the twisted pair conductors when stresses are applied to the cable, such as pulling and bending stresses. Additionally, in certain embodiments, a separator may include a first portion positioned between the conductors of a twisted pair 105 and one or more second portions that form a shield around an outer circumference of the twisted pair. The first portion may be helically twisted between the conductors, and the second portion(s) may be helically twisted around the conductors as the separator and the pair 105 are twisted together. The first portion or dielectric portion may assist in maintaining spacing between the individual conductors of the twisted pair 105 and/or maintaining the positions of one or both of the individual conductors. The second portion(s) or shielding portions may extend from the first portion, and the second portion(s) may be individually and/or collectively wrapped around the twisted pair conductors in order to form a shield layer.
As set forth above, a wide variety of different components of a cable may function as shielding elements. In certain embodiments, the electrically conductive material or other shielding material incorporated into a shield element may be relatively continuous along a longitudinal length of a cable. For example, a relatively continuous foil shield or braided shield may be utilized. In other embodiments, a shield element may be formed as a discontinuous shield element having a plurality of isolated patches of shielding material. For example, a plurality of discontinuous patches of electrically conductive material may be incorporated into the shield element (or into various components of a shield element), and gaps or spaces may be present between adjacent patches in a longitudinal direction. A wide variety of different patch patterns may be formed as desired in various embodiments, and a patch pattern may include a period or definite step. In other embodiments, patches may be randomly formed or situated on a base or carrier layer.
A wide variety of suitable shielding materials may be utilized to form patches of shielding material. Examples of suitable electrically conductive materials that may be utilized include, but not limited to, metallic material (e.g., silver, copper, nickel, steel, iron, annealed copper, gold, aluminum, etc.), metallic alloys, conductive composite materials, etc. Indeed, suitable electrically conductive materials may include any material having an electrical resistivity of less than approximately 1×10−7 ohm meters at approximately 20° C. In certain embodiments, an electrically conductive material may have an electrical resistivity of less than approximately 3×10−8 ohm meters at approximately 20° C. Electrically conductive material incorporated into a shield may have any desired thickness, such as a thickness of about 0.5 mils (about 13 microns) or greater.
Additionally, for shields that include discontinuous or spaced patches of electrically conductive material, a wide variety of suitable patch lengths (e.g., lengths along a longitudinal direction of a cable) may be utilized. As desired, the dimensions of the segments and/or electrically conductive patches can be selected to provide electromagnetic shielding over a specific band of electromagnetic frequencies or above or below a designated frequency threshold. Individual patches may be separated from one another so that each patch is electrically isolated from the other patches. That is, the respective physical separations between the patches may impede the flow of electricity between adjacent patches. In certain embodiments, the physical separation of patches may be formed by gaps or spaces, such as gaps of dielectric material. In other embodiments, the physical separation of certain patches may result from the overlapping of shield segments. For example, a shield element may be formed from a plurality of discrete segments, and adjacent segments may overlap one another. The respective physical separations between the patches may impede the flow of electricity between adjacent patches. A wide variety of suitable gap distances or isolation gaps may be provided between adjacent patches. Additionally, in certain embodiments, patches may be formed as first patches (e.g., first patches on a first side of a dielectric material), and second patches may be formed on an opposite side of a dielectric base layer. For example, second patches may be formed to correspond with the gaps or isolation spaces between the first patches. As desired, patches may have a wide variety of different shapes and/or orientations. For example, the segments and/or patches may have a rectangular, trapezoidal, parallelogram, triangular, or any other desired shape.
According to an aspect of the disclosure, one or more pulling elements 110 or tensioning elements may be incorporated into the cable 100. The pulling element(s) 110 allow an increased pulling force to be imparted on the cable 100 without elongating the conductors of the twisted pairs 105A-D. In this regard, the cable 100 may be pulled and installed at longitudinal lengths greater than 100 m. When integrated or incorporated into the cable 100, the pulling element(s) 110 may bear a majority of a pulling load or pulling tension imparted onto the cable 100, thereby reducing or limiting the tension placed on the twisted pairs 105A-D. In certain embodiments, the pulling element(s) 110 may be coupled to other components of the cable 100, such as the twisted pairs 105A-D, with regards to bearing a pulling load. When components of the cable 100, such as the twisted pairs 105A-D and the pulling element(s) 110 are coupled together, the components may be pulled at the same rate such that they experience the same elongation. Given the twists imparted on the twisted pairs 105A-D, the pairs 105A-D will elongate less than untwisted or straight components, such as the pulling element(s) 110. Additionally, due to the pulling element(s) 110 having a higher elastic modulus than the other cable components, the pulling element(s) 110 may bear the pulling load or a suitable portion of the pulling load to prevent damage or untwisting of the pairs 105A-D.
As mentioned above, applicable cable standards specify a maximum pulling force for a four-pair cable of 110 N. Similarly, the TANK equation or method is commonly used within the twisted pair cable industry to calculate a maximum pulling force or pulling tension that may be imparted on a cable. The TANK equation, or T=A·N·K states that the maximum allowable pulling tension (T) is equal to the cross-sectional area of the conductor in circular mils (A) multiplied by the number of conductors (N) multiplied by a constant (K). The constant “K” commonly used for copper conductors is 0.008 pounds per circular mil. Additionally, a four pair cable will include eight conductors. Table 1 below sets forth some TANK calculations for four pair cables with common conductor sizes or gauges:
As shown above, the TANK calculation for a 24 AWG cable is similar to the maximum pulling force or tension permitted by applicable cable standards. Although a cable with larger conductors can withstand a slightly higher pulling force, the maximum allowable pulling force for those conductors is still inadequate for longer installations (e.g., installations at lengths exceeding 100 m) and/or for installations in which the cable may encounter higher coefficients of friction. In other words, the twisted pairs may be subject to unwanted elongation in certain installation environments. Unwanted elongation of the twisted pairs 105A-D may result in damage to the pair conductors and/or increase of one or more twist lays that may negatively impact the electrical performance of the cable.
A cable 100 having one or more integrated pulling elements 110 may facilitate pulling loads greater than 110 N (as allowed by applicable standards) or those calculated via use of the TANK equation. In certain embodiments, a cable 100 having one or more pulling elements 110 may withstand a pulling load, force or tension of at least 330 N with an elongation on the cable of less than 0.20 percent. In various embodiments, a cable 100 may withstand a pulling load of at least 220 N, 250 N, 275 N, 300 N, 325 N, 350 N, 375 N, or 400 N, or a pulling load incorporated into a range between any of the above values, with an elongation on the cable of less than 0.20 percent. The maximum cable elongation may define the maximum amount that any components of the cable will stretch or elongate in the longitudinal direction in relation to the original cable length. In certain embodiments, the cable 100 may withstand a pulling load equal to a maximum installation length of the cable 100 multiplied by 110 N per each 100 m of maximum installation length. For example, if the cable 100 is intended for installation at lengths of up to 300 m, then the cable 110 may withstand a pulling load of 300 m×(300/100)×110 or approximately 330 N with a maximum elongation on the cable of less than 0.20 percent. In other embodiments, a cable 100 may be designed to withstand any of the pulling loads set above forth above (e.g., 330 N, etc.) with an elongation on the cable 100 of less than 0.06, 0.075, 0.1, 0.15, 0.25, 0.3, 0.4, 0.5, 0.75, or 1.0 percent, or a maximum elongation included in a range between any of the above values.
In certain embodiments, a cable 100 can withstand a higher pulling load or force (e.g., a force of at least 330N) while still permitting the twisted pairs 105A-D to satisfy desired electrical performance criteria. For example, after pulling, the twisted pairs 105A-D may satisfy desired data transmission and bit error rates associated with an intended application for the cable 100. In certain embodiments, after the cable 100 has been subjected to a pulling load of 330 N, the twisted pairs 105A-D may still satisfy the electrical performance requirements of at least one of IEEE 802.3i for 10BASE-T 10 Mbit/s Ethernet transmission over twisted pairs (as published by IEEE in 1990), IEEE 802.3u for 100BASE-T 100 Mbit/s Ethernet transmission over twisted pairs (as published by IEEE in 1995), IEEE 802.3ab for 1000BASE-T 1 Gbit/s Ethernet transmission over twisted pairs (as published by IEEE in 1999), IEEE 802.3an for 10GBASE-T 10 Gbit/s Ethernet transmission over twisted pairs (as published by IEEE in 2006), or any other suitable standards that establish data transmission, bit error rate, and/or other electrical performance criteria for transmitting Ethernet and/or other signals over twisted pairs.
A pulling element 110 may be formed with a wide variety of suitable constructions as desired in various embodiments. For example, a pulling element 110 may be formed from a wide variety of suitable materials and/or with a wide variety of suitable dimensions. In certain embodiments, a pulling element 110 may be formed from one or more metallic materials. Examples of suitable metal materials include, but are not limited to, steel, ferritic steel, stainless steel, ferritic stainless steel, carbon steel, cold drawn steel, tool steel, titanium, cobalt, chromium, beryllium, any suitable metallic alloy, etc. In general, a metallic material having a higher elastic modulus than the electrically conductive material used in the twisted pair conductors (e.g., copper, etc.) may be utilized. Additionally, the relatively high elastic modulus of a metallic material may permit formation of a pulling element 110 with a relatively small diameter or cross-sectional area. As a result, incorporation of a pulling element 110 into a cable 100 may have a relatively small or no impact on an outside diameter of a cable 100. In other words, relatively small twisted pair cables may be formed that include one or more pulling elements 110.
Additionally, in the event that one or more metallic materials are used to form a pulling element 110, the pulling element 110 may be used as a tracer wire in the cable 100. For example, a metallic pulling element (e.g., a ferritic metallic pulling element, etc.) may be used to trace a buried or in-duct cable 100 utilizing a magnetic flux detector or other suitable device. This eliminates the need of energizing a twisted pair conductor to trace the conductor/cable and allows the pulling element 110 to be differentiated from the twisted pair conductors. Using a twisted pair conductor (e.g., a copper conductor) to perform tracing can interfere with the primary conductor function of transmitting a data signal and/or power. These concerns are alleviated as a result of utilizing a pulling element 110 as a tracer wire.
In other embodiments, a pulling element 110 may be formed from one or more other materials, such as dielectric and/or semi-conductive materials. Examples of suitable dielectric materials that may be utilized include, but are not limited to, fiber reinforced plastic (“FRP”), glass reinforced plastic (“GRP”), aramid materials, basalt fibers, and/or other dielectric or non-conductive materials. Examples of suitable semi-conductive materials that may be utilized include, but are not limited to, carbon fiber, graphene, etc. In certain embodiments, a dielectric or semi-conductive material may have an elastic modulus higher than that of the electrically conductive material used in the twisted pair conductors (e.g., copper, etc.).
Regardless of the material(s) utilized to form a pulling element 110, the pulling element 110 may have any suitable elastic modulus, such as any suitable Young's modulus. In certain embodiments, a pulling element 110 may have an elastic modulus greater than that of the electrically conductive material (e.g., copper, etc.) utilized to form the conductors of the twisted pairs 105A-D. In other words, the electrically conductive material utilized to form the conductors (e.g., conductors 120A, 120B, etc.) of the twisted pairs 105A-D may have a first elastic modulus, and the pulling element 110 may have a second elastic modulus greater than the first elastic modulus. In this regard, the pulling element 110 may primarily bear the tensile load associated with pulling the cable 100. For example, annealed copper typically has an elastic modulus between approximately 110 and approximately 125 GPa. In certain embodiments, a pulling element 110 may have an elastic modulus greater than approximately 125 GPa. In various embodiments, a pulling element 110 may have an elastic modulus greater than approximately 125, 130, 140, 150, 160, 175, 180, 190, 200, 210, 225, 240, 250, 275, or 300 GPa, or an elastic modulus included in a range between any two of the above values.
In other embodiments, the pulling element 110 may have an elastic modulus lower than that of the material used to form the conductors of the twisted pairs 105A-D while permitting the cable 110 to withstand increased pulling loads. For example, aramid or glass fibers may have an elastic modulus lower than that of the conductors. However, a plurality of these fibers may be tightly packed between and/or around the twisted pairs 105A-D (e.g., in the interstices between the pairs 105A-D and/or around outer circumference of the pairs 105A-D) to permit greater pulling loads to be imparted on the cable 100 without damaging the twisted pairs 105A-D.
A pulling element 110 may also be formed with a wide variety of suitable dimensions, such as any suitable gauge or cross-sectional area. In certain embodiments, a pulling element 110 may be formed with a 28 AWG, 27 AWG, 26 AWG, 25 AWG, 24 AWG, 23 AWG, 22 AWG, 21 AWG, or 20 AWG diameter, a diameter included in a range between any two of the above values, or a diameter included in a range bounded on a minimum or maximum end by one of the above values. For example, a pulling element 110 may be formed as a 26 AWG or larger pulling element, such as a 26 AWG or larger steel pulling element. In other embodiments, a pulling element may have a cross-sectional area of approximately 0.050, 0.060, 0.070, 0.080, 0.100, 0.115, 0.125, 0.130, 0.160, 0.200, 0.250, 0.325, 0.400, or 0.500 mm2, a cross-sectional area included in a range between any two of the above values, or a diameter included in a range bounded on a minimum or maximum end by one of the above values. For example, a steel pulling element may have a cross-sectional area of at least 0.115 mm2.
Additionally, in certain embodiments, a pulling element 110 may be formed from a single longitudinally extending component. For example, a single wire or other component may be utilized to form a pulling element. The cable 100 of
In certain embodiments, a pulling element 110 may be formed as a bare, uninsulated, or uncoated pulling element. For example, a pulling element 110 may be formed as a bare metallic or uncoated non-metallic pulling element. As desired, a bare metallic pulling element may be used as a drain wire in the cable 100. In other embodiments, suitable insulation or a suitable coating may be formed around a pulling element 110.
Similarly, one or more suitable coating layers may be formed around a non-metallic pulling element. Examples of suitable materials that may be utilized to form a coating around a pulling element include, but are not limited to, polyethylene (e.g., medium density polyethylene, etc.), polypropylene, one or more other polymeric materials (e.g., such as any of the materials described above with reference to the twisted pair insulation 125 or the jacket, etc.), one or more thermoplastic materials, one or more elastomeric materials, an ethylene-acrylic acid (“EAA”) copolymer, ethyl vinyl acetate (“EVA”), etc.
Additionally, any number of suitable pulling elements may be incorporated into a cable 100 as desired in various embodiments. As shown in
One or more pulling elements 110 may also be positioned at a wide variety of suitable locations within a cable 100. In certain embodiments, one or more pulling elements 110 may be positioned between the twisted pairs 105A-D and the cable jacket 115. For example, as shown in
In certain embodiments, the one or more pulling elements 110 incorporated into a cable 100 may extend in a longitudinally direction parallel to the plurality of twisted pairs 105A-D. In other words, the one or more pulling elements 110 may not be twisted or stranded with the plurality of twisted pairs 105A-D. As a result of extending in a longitudinal direction parallel to the twisted pairs 105A-D, the load borne by the pulling elements 110 may extend along the tensile pulling direction, thereby reducing the strain placed on the twisted pairs 105A-D. Additionally, a longitudinally extending cable element, such as a pulling element 110, may experience greater overall elongation than the twisted pairs 105A-D. Given the higher elastic modulus of the pulling element, this may assist in reducing the strain placed on the twisted pairs 105A-D.
In certain embodiments, incorporation of one or more relatively small pulling elements 110 may result in limited or approximately no change in the outer diameter size of a cable. In other words, a cable 100 may incorporate one or more pulling elements 110 while maintaining a relatively small outer diameter. In certain embodiments, a cable 100 having four twisted pairs 105A-D may have an outer diameter of approximately 10 mm or less. In various embodiments, the cable 100 may have an outer diameter of less than approximately 5, 6, 7, 8, 9, or 10, or an outer diameter included in a range between any two of the above values.
As a result of incorporating one or more pulling elements 110 into a cable 100, the cable 100 may withstand increased pulling forces or pulling loads. The ability to withstand increased pulling loads may facilitate installation of the cable 100 at longer longitudinal lengths or with longer single cable runs. In certain embodiments, the cable 100 may be installed at lengths longer than the 100 m established by industry standards. For example, the cable 100 may be installed at maximum lengths of up to 150, 200, 250, 300, or 350 m, at maximum lengths included in a range between any two of the above values, or at maximum lengths included in a range bounded on a minimum end by one of the above values (e.g., at least 200 m, at least 300 m, etc.).
As desired in various embodiments, a wide variety of other materials may be incorporated into the cable 100. In certain embodiments, the cable 100 may additionally include one or more suitable rip cords and/or drain wires. As desired, a cable 100 may also include a wide variety of water blocking or water swellable materials, insulating materials, dielectric materials, flame retardants, flame suppressants or extinguishants, gels, and/or other materials. The cable 100 illustrated in
In contrast to the cable 100 illustrated in
In contrast to the cable 100 illustrated in
Additionally, the pulling element 310 is illustrated as being positioned within a cable core and outside an overall shield 320. In other words, the pulling element 310 may be positioned between the shield 320 and the jacket 310, and the pulling element 310 may extend parallel to twisted pairs 305A-D without being twisted or stranded with the pairs 305A-D. The pulling element 310 may be positioned at a wide variety of other suitable locations in other embodiments.
Additionally, the pulling element 410 is illustrated as being positioned within a cable core between the plurality of twisted pairs 405A-D. While the twisted pairs 405A-D may be twisted around the pulling element 410, the pulling element will longitudinally extend approximately along a cross-sectional center line of the cable 400. As a result, the pulling element 410 may extend parallel to the twisted pairs 405A-D, thereby permitting the pulling element 410 to bare a pulling load imparted on the cable 400.
In contrast to the cable 100 illustrated in
In certain embodiments, the pulling element 510 may longitudinally extend along a cross-sectional centerline of the plurality of twisted pairs 505A-D and/or the cable 500. Although the twisted pairs 505A-D may be helically twisted with the separator 525, the pulling element 510 may longitudinally extend parallel to the twisted pairs 505A-D, thereby permitting the pulling element 510 to bare a pulling load imparted on the cable 500. Additionally, if the pulling element 510 is free to move within a cavity of the separator 525, a twist will not be imparted on the pulling element 510 when the separator 525 is twisted with the pairs 505A-D.
Additionally, a plurality of pulling elements 610A, 610B may be positioned at a wide variety of suitable locations within the cable 600. For example, the plurality of pulling elements 610A, 610B may be positioned within a cable core. As shown, the pulling elements 610A, 610B may be positioned on opposite sides of the cable core around an outer periphery of the twisted pairs 605A-D. In other embodiments, a first pulling element may be positioned between the plurality of twisted pairs 605A-D, and one or more second pulling elements may be positioned between the twisted pairs 605A-D and the jacket 615. A wide variety of other suitable orientations and configurations may be utilized as desired in other embodiments.
Additionally, the plurality of pulling elements 710A-D may be positioned at a wide variety of suitable locations within the cable 700. For example, the plurality of pulling elements 710A-D may be positioned within a cable core. As shown, the metallic pulling elements 710A, 710B may be positioned on opposite sides of the cable core around an outer periphery of the twisted pairs 705A-D. Similarly, the non-metallic pulling elements 710C, 710D may be positioned on opposite sides of the cable core around an outer periphery of the twisted pairs 705A-D. The metallic pulling elements 710A, 710B and the non-metallic pulling elements 710C, 710D may be offset from one another. In other embodiments, a first pulling element may be positioned between the plurality of twisted pairs 705A-D, and one or more second pulling elements may be positioned between the twisted pairs 705A-D and the jacket 715. A wide variety of other suitable orientations and configurations may be utilized as desired in other embodiments.
As desired in various embodiments, a wide variety of other materials may be incorporated into any of the cables illustrated in
At block 905, a twisted pair cable having one or more integrated pulling elements may be provided. In certain embodiments, the cable may be provided on a reel, box, coil, or other suitable packaging that permits the cable to be pulled and installed by a technician. At block 910, a determination may be made as to whether any additional cables will be pulled or run in conjunction with the provided cable. If it is determined at block 910 that no additional cables will be pulled with the cable, then operation may continue at block 920 below. If, however, it is determined at block 910 that one or more additional cables will be pulled with the cable, then operations may continue at block 915. At block 915, the cable may be combined with one or more additional cables. For example, the cable and the additional cable(s) may be taped, tied, or otherwise joined together. As desired, the cables may be staggered as they are joined together in order to reduce the chances that the cables will snag or catch during pulling. Operations may then continue at block 920.
At block 920, a pull string, Kellems grip, or other suitable pulling device may be added to the cable(s). The pulling device (and tape if multiple cables are joined together) may compress the components of the cable(s) together, thereby essentially coupling the cable conductors and cable pulling elements together. When coupled together, the components of the cable may be pulled at the same rate such that they experience the same elongation. Given the twists imparted on the twisted pairs, the pairs will elongate less than untwisted or straight components, such as the pulling element(s). Additionally, due to the pulling element(s) having a higher elastic modulus than the other cable components, the pulling element(s) may bear the pulling load or a suitable portion of the pulling load to prevent damage or untwisting of the pairs. For example, pulling forces imparted on the cable may be primarily borne by the integrated pulling element(s).
At block 925, the cable may be pulled to a desired termination location. According to an aspect of the disclosure, the integrated pulling elements may permit a pulling force of greater than 110 N to be imparted on the cable. For example, a pulling force of up to 330 N may be imparted on the cable. Additionally, the ability to withstand a higher pulling force may permit the cable to be installed at lengths or with runs exceeding 100 m. For example, the cable may be installed at a length of up to approximately 300 m. Once the cable has been pulled to a desired location, the cable may be terminated at block 930. For example, a technician may terminate the cable utilizing a suitable RJ-45 or other appropriate connector. Additionally, the cable may be connected to a suitable device, such as a PoE device (e.g., a wireless access point, a video camera, etc.), an Ethernet-enabled device, etc. In certain embodiments, the cable may be connected directly to a device. In other embodiments, one o more suitable patch cords may be utilized to connect the cable to a device. Operations may then terminate following block 930.
As desired, the method 900 may include more or less operations than those illustrated in
Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and/or operations. Thus, such conditional language is not generally intended to imply that features, elements, and/or operations are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or operations are included or are to be performed in any particular embodiment.
Many modifications and other embodiments of the disclosure set forth herein will be apparent having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.