CA1277731C - Primary transmission line cable - Google Patents

Primary transmission line cable

Info

Publication number
CA1277731C
CA1277731C CA000533900A CA533900A CA1277731C CA 1277731 C CA1277731 C CA 1277731C CA 000533900 A CA000533900 A CA 000533900A CA 533900 A CA533900 A CA 533900A CA 1277731 C CA1277731 C CA 1277731C
Authority
CA
Canada
Prior art keywords
primary conductor
mils
conductor
diameter
wire
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000533900A
Other languages
French (fr)
Inventor
Paul Everett Hubis
Stephen Charles Miller
James George Vana
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
WL Gore and Associates Inc
Original Assignee
WL Gore and Associates Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by WL Gore and Associates Inc filed Critical WL Gore and Associates Inc
Application granted granted Critical
Publication of CA1277731C publication Critical patent/CA1277731C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00Communication cables or conductors
    • H01B11/02Cables with twisted pairs or quads
    • H01B11/12Arrangements for exhibiting specific transmission characteristics
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/0009Details relating to the conductive cores

Landscapes

  • Communication Cables (AREA)
  • Detergent Compositions (AREA)
  • Non-Insulated Conductors (AREA)
  • Insulated Conductors (AREA)
  • Acyclic And Carbocyclic Compounds In Medicinal Compositions (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
  • Laying Of Electric Cables Or Lines Outside (AREA)
  • Vehicle Body Suspensions (AREA)
  • Near-Field Transmission Systems (AREA)

Abstract

ABSTRACT
The present invention relates to single and twisted pair transmission line wires wherein the effective electrical diameter of the primary conductor is increased. This is accomplished by wrapping conductive foil or conductive foil laminated to a substrate layer onto a primary conductor with a diameter less than 20 mils wherein the foil is in contact with the conductor and has an outer insulating cover.
This may be done by either spiral wrapping or by longitudinal wrapping around the electrical conductor. This invention provides a desired characteristic impedance along the length of the wire(s) and allows easy removal for standard termination and increased cut-through resistance.

Description

12~7'731 BACKGROUND OF THE INVENTION
This invention relates to the manufacture of twisted pair and single transmission line wires wherein the effective electrical diameter of the primary conductor is increased thereby providing a desired characteristic impedance along the length of the wire and allowing the wires to be terminated using standard termination equipment. This invention is particularly useful for solderless wrap connections to printed circuit boards or panels and for twisted wire and single, wire interconnections.
Prior to this invention, transmission wire with a low impedance (less than 100 ohms) was not available for use with standard ter~ination equipment. Typically, a primary conductor with a diameter greater than 20 mils had to be selected in order to achieve a low characteristic impedance. Only a thin wall of insulation could be wrapped around the primary conductor without increasing the characteristic impedance.
Since only a thin wall of insulation could be used, there was poor cut-through resistance of this outer wall of insulation and other stripping difficulties.
Because of the low cut-through and abrasion resistance of these thin outer insulation walls. it was often necessary to apply a protective jacket over the wire. This further aggravated the stripping problem as the jacket first had to be removed during termination. During removal, the primary conductor is frequently damaged by the stripping blades. These difficulties have been substantially eliminated by the present invention.
SUMMARY OF THE INVENTION
The present invention relates to single and twisted pair transmission line wires wherein the effective electrical ~7~

diameter of the pcimary conductor is increased. This is accomplishea by wrapping conductive foil oc a conductive foil laminated to a substrate layer onto a primary conductor with a diameter less than 20 mi}s wherein the conductive foil is in contact with the conductor. An outer layer of insulation may then be applied over the foil and primary conductor.
The foil or foil laminate may be applied by either spiral wrapping or by longitudinal wrapping around the primary conductor. This invention provides a desired characteristic impedance along the length of the wire and allows easy removal foc standacd termination and increased cut-thcouqh resistance.
~RIEF DESCRIPTION OF THE DRAWINGS
Pigure l is a schematic representation of a cross-section of a single insulated wire according to the invention.
Figure 2 is a schematic cepresentation of a cross-section of a twisted pair of insulated wires according to the invention.
Fiqure 3 is a graphical representation depicting the relation between impedance and the ratio D/d where D is the diameter of the insulated wire and d is the actual diameter o~
the conductor.
DESCRIPTION OF THE PREF~RRED EMBODIMENTS
The present invention requires that the effective electrical diameter of the primary conductor be increased by wrapping conductive foil or conductive foil laminated to a substcate onto a primary conductoc of less than 20 mils wheceln the foil i8 in contact with the conductor. This may be accomplished by conventional wire wrappin~ techniques and equipment.
The primary conductor with conductive foil oc laminate in contact with it is able to maintain a low characterigtic 3~

impedance and still be compatible with standard termination equipment and peinted circuit boards.
A thicker layer of outer insulation may be applied over this invention and will not affect the characteristic impedance. This provides increased cut-through resistance.
Conventional stripping equipment may be used with the present invention and the thicker layer of outer insulation is easily removed for termination. Standard stripping equipment is available from E.P.E. Technology of Manchester, New Hampshire, and Eubanks of Monrovia, California.
This invention also provides benefits for applications in state of the art electronic equipment. The primary conductor with a diameter of less than 20 mils is compatible with terminal and grid spacings of printed circuit boards (0.025 square inch terminal with grid spacing O.lO0 inches).
~n inventive embodiment may be used either as a single insulated wire or two insulated wires may ~e twisted together and be used as a pair of twisted wires.
Referring to the cro~s-sectional view of a single insulated wire depicted in Figure 1, conductive metal foil laminate l is spirally wrapped around primary conductor 3 with the metal ~oil 2 facing into and in continuous contact with the primary - conductor 3 making electrical contact between primary conductoc 3 and foil 2. The preferred metal foil laminate comprises aluminum foil bonded to polyester or polyimide base film l oc aluminum foil bonded to a film of expanded polytetrafluoro-ethylene l. The primary conductor may have a single wrappin~
of metal foil or it may have a plurality of wrappings, depending on the desired thicknes6 of the wall, as depicted in i2~7~31 Figure 1. Additional insulation 4 is applied over the top of th,e metal foil laminate wrapping.
Figure 2 shows a cross-sectional view of a twisted pair of insulated wices in which conductive metal foil laminate LO is spirally wrapped around each primary conductor 13 with the metal foil 12 facing into the wires and in continuous contact with primary conductors 13 making electrical contact between the primary conductors L3 and laminate 12. Additional insulation 14 is applied over the top of the metal foil laminate wrapping.
Figure 2 also shows the initial diameter of the primary conductor 13 as being dl. As the conductive metal foil is wrapped around each conductor, the size of the ef~ective electrical diameter is increased and i& measured as deff. If the invention is not used, the primary conductor diameter d becomes deff. Additional insulation 14 may be applied over the top of the metal foil laminate wrapping. The total diameter of the conductor 13, wrapped conductive foil 12 and outer insulation covering 14 is measured as D. The characteristic impedance ~ is logarithmically related to the diameter of the insulated wire by the ratio D/d. Where the invention is used, the diameter of the primary conductor (d) is substituted by deff. Thus, by using the invention, the characteristic impedance is reduced because the effective electrical diameter of the primary conductor is increased.
In a preferred embodiment, the additiGnal insulation 14 may be a polyester film or polyimide based film insulation. This additional insulation may be applied by extrusion or by additional wrapping to a desired outside diameter. Cut-thcough resistance i6 increased by the addition of this insulation.

~2~773~

Existing solderless wrap on a primary conductor and the present invention for a single 50 ohm insulated wire are contrasted. A final outer diameter of wire of 19.6 mils is desired as this is the optimum size for automatic wire stripping equipment.
Using conventional technology, a single 28(L) AWG primacy conductor with an actual diameter of 12.6 mils, dielectric constant E=3.1 and a characteristic impedance of 50 ohms, was covered by an outer layer of polyester film insulation. Here, the ~inal diameter of 14.1 mils was attained without increasing the characteristic impedance. A D/d ratio of 1.12 was calculated by referring to Figure 3.
Using the present invention, a single 28(1) AWG primary conductor of actual diameter 12.6 mils was wrapped with three layers of aluminum foil laminated tape whereby the foil was in constant ehysical contact with the primary conductor. An outer layer of polyester film insulation was applied over the primary conductor foil combination. The final diameter of this embodiment was 19.6 mils.
By wrapping the foil around the primary conductor, the diameter of the primary conductor of 12.6 mils was increased tO
~ .
an effective electrical diameter of 17.5 mils. The characteristic impedance was maintained at SO ohms and the eesulting wire had a calculated D/d ratio of 1.13.
The following chart summarizes results of the calculated outer wall thickness and cut-through radius of curvature ~o~
both conventional solderless wrap on a primary conductor and the present invention.

i~7~

CHART I
Comparison Of 28(1) AWG Primar~ Conductors Using Existing Technol9V And The Present Invention For 50 ohms Impedanoe S OuterCut-through ~o d deff D WallRadius Of ohms milsmi 15 D/d D/deffmils mils Cur~ature mils Conventionai Technology 50 12.6 - I.12 - 14.1 0.75 7.05 Foil-Wrapped 50 12.6 17.5 - I.13 19.6 1.05 9.8 1 0 ~ D J).'2 Cut-through radius of curvature = D.'2 An insulated wire with an outer wall thickness of 0.75 mils does not fit standard automated stcipping machines. The standard wire cutting equipmen~ is not able to cut into, grab, and pull off the outer wrapping without injury to the primary conductor. Further, a radius of curvature of 7.05 does not meet conventional wire cut-throuqh requirements.
In contrast, the present invention provided a primary conductor with an increased electrical diameter and increased outer wall diameter and cut-through radius of curvature so that standard automated stripping machines could be used.

A comparison similar to that desccibed in Example 1 was also made with a 28(1) AWG primary conductor with an actual diameter of 12.6 mils, dielectric constant E=3.1 and a characteristic impedance of 55 ohms. Here the D/d ratio was found to be 1.15 by referring to Figure 3.
Test data was accumulated and calculations made were similac to those as described in Example 1. Test cesults ace summarized in Chart 2 shown below.

i27~73~

Comparison of 28(1) AWG Primury Conductors Using Existing Technolog~ And The Present Invention For Wire With A Characteristic Impedance of 55 oh~s Outer Cut-through ~ d deff D WallRadius Of ohms mils mils D/d D/dpffmils ~ils Curvature mils CCnVCntiO11AI Technology 55 12.6 - I.15 - 14.5 0.95 7.25 Foil-~rapped 55 12.6 17.5 - 1.15 2~.1 1.3010.1 1 0 ~all = ~D-d),'2 C~t-thro~gh radius of curvature = D.2 Here again, one skilled in the art can see that the inventive entity allows the impedance to remain at 55 ohms but the outer wall and cut-through radius are increased (by 39%) and can be used with existing wire stripping equipment.

Existing solderless w~ap of primary conductors and the present invention for a 75 ohm twisted pair of insulated wires are compared. An outside diameter of 19.5 mils is desired as this is the optimum size for the automatic wire-stripping machines.
Using conventional technology, a pair of 30(1) AWG primary conductors with initial diameters of 10.1 mils, dielectric constant of 3.12, a characteristic impedance of 75 ohms is extraeolated from Figure 3 to have a D/d ratio of 1.36.
Similarly, a pair of 30(1) AWG primary conductors are individually wrapped with aluminum foil laminated tape so thac the foil is in constant physical contact with each primary conductor. Here, the outer diameter D is 19.5 mils, the effective electrical diameter deff is 14.4 mils, and the ratio of D/deff is found to be 1.31.
The following chart summarizes physical characteristics o~
a 30(1) AWG twisted pair using existing art and a twisted pair as constructed by the present invention.

,~

1277~

CHART ~
75 ohm Twisted Pair 30(1) AW6 Outer Cut-through ~0 d deff D W~ll Radius Of ohms mils mils D/d D/deff mils mils Cur~ature mils Conventional Technology 75 10.1 - 1.36 - 13.6 1.8 6.8 Foil~Wrapped 75 10.1 14.4 - 1.31 19.5 2.6 ~.75 Wall = (D4)-2 Cut-through radius of curvature = D-.2 In this example, we achieve the desired combination of a 30(1) ~WG twisted pair of wires with an outer diametec of l9.S
mils and maintains the desired impedance of 75 ohms. If one were simply to insulate the 30(1) AWG with polyester film insulation to make an outer diameter of 19.5 mils, the characteristic impedance would be 100 oh~s.
Also, tor a 75 ohm twisted pair 30(1) AWG, thè wall thickness has been increased to add cut-through resistance without increasing the characteristic impedance in this invention. Further, the cut-through radius of curvature is increased by 43S and is easily compatible with existing stripping equipment.
It is to be understood that the foregoing description and the accompanying drawings and examples are illustrative of the invention and are not to be taken as limiting the scope of the appended claims.

Claims (8)

1. An electric transmission wire having a low impedance comprising:
(a) a primary conductor;
(b) said primary conductor wrapped with at least one layer of conductive material; and (c) said primary conductor and wrapped conductive material being further wrapped with at least one layer of an insulating film such that the overall diameter of said wrapped wire is less than 20 mils.
2. An article as described in claim 1 wherein said electric transmission wire is a pair of twisted wires.
3. An article as described in claim 1 wherein said wire maintains a characteristic impedance less than 100 ohms.
4. An article as described in claim 1 wherein said conductive material is an aluminum and polyester laminated film.
5. An article as described in claim 1 wherein said conductive material is an aluminum and expanded PTFE laminate,
6. An article as described in claim 1 wherein said conductive material is an aluminum and polyimide laminated film.
7. An article as described in claim 1 wherein said conductive material is wrapped spirally around said primary conductor.
8. An article as described in claim 1 where said conductive material is wrapped longitudinally around said primary conductor,
CA000533900A 1986-04-07 1987-04-06 Primary transmission line cable Expired - Fee Related CA1277731C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US84888186A 1986-04-07 1986-04-07
US848,881 1986-04-07

Publications (1)

Publication Number Publication Date
CA1277731C true CA1277731C (en) 1990-12-11

Family

ID=25304532

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000533900A Expired - Fee Related CA1277731C (en) 1986-04-07 1987-04-06 Primary transmission line cable

Country Status (12)

Country Link
EP (1) EP0243023B1 (en)
JP (1) JPS63119112A (en)
AT (1) ATE73256T1 (en)
AU (1) AU7052487A (en)
CA (1) CA1277731C (en)
DE (1) DE3776949D1 (en)
DK (1) DK177887A (en)
FI (1) FI871483A (en)
GB (1) GB2188768B (en)
NO (1) NO871432L (en)
PT (1) PT84630B (en)
ZA (1) ZA872487B (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH074411A (en) * 1993-06-16 1995-01-10 Toyoda Gosei Co Ltd Fastener made of synthetic resin

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1151842A (en) * 1966-01-12 1969-05-14 Donald Francis Binns Improvements in Electrical Conductors.
US3412199A (en) * 1967-01-12 1968-11-19 Research Corp Electric power transmission cable
JPS6011401B2 (en) * 1977-02-09 1985-03-26 松下電器産業株式会社 copper foil thread wire
US4414428A (en) * 1979-05-29 1983-11-08 Teledyne Industries, Inc. Expanded metal containing wires and filaments

Also Published As

Publication number Publication date
DE3776949D1 (en) 1992-04-09
NO871432L (en) 1987-10-08
EP0243023A2 (en) 1987-10-28
EP0243023A3 (en) 1988-07-20
ATE73256T1 (en) 1992-03-15
PT84630A (en) 1987-05-01
PT84630B (en) 1989-11-30
FI871483A0 (en) 1987-04-06
DK177887D0 (en) 1987-04-07
JPS63119112A (en) 1988-05-23
GB2188768B (en) 1990-01-24
AU7052487A (en) 1987-10-08
NO871432D0 (en) 1987-04-06
GB2188768A (en) 1987-10-07
DK177887A (en) 1987-10-08
EP0243023B1 (en) 1992-03-04
ZA872487B (en) 1988-03-30
GB8707921D0 (en) 1987-05-07
FI871483A (en) 1987-10-08
JPH0456408B2 (en) 1992-09-08

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