EP1364376B1 - Cable de communication, et installation de fabrication idoine - Google Patents

Cable de communication, et installation de fabrication idoine Download PDF

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Publication number
EP1364376B1
EP1364376B1 EP02708331A EP02708331A EP1364376B1 EP 1364376 B1 EP1364376 B1 EP 1364376B1 EP 02708331 A EP02708331 A EP 02708331A EP 02708331 A EP02708331 A EP 02708331A EP 1364376 B1 EP1364376 B1 EP 1364376B1
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EP
European Patent Office
Prior art keywords
cable
extrusion
cavities
insulated conductors
female die
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EP02708331A
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German (de)
English (en)
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EP1364376A2 (fr
Inventor
Giovanni Brandi
Luca Giorgio Maria De Rai
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Prysmian SpA
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Prysmian SpA
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Priority to EP02708331A priority Critical patent/EP1364376B1/fr
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/04—Cables with twisted pairs or quads with pairs or quads mutually positioned to reduce cross-talk
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/02—Stranding-up
    • H01B13/0292—After-treatment

Definitions

  • the present invention generally relates to a communications cable and, more particularly, to a high frequency unshielded telecommunications cable comprising at least one couple of twisted pairs of insulated conductors.
  • This invention also relates to an extrusion apparatus or manufacturing said cable.
  • a communications cable utilizing twisted pair technology must meet stringent requirements with regard to data speed and electrical characteristics, such as a reduced cross-talk and a good electrical stability.
  • cross-talk When twisted pairs are closely bundled such as in a communications cable, disturbance of the .signal transmitted by a twisted pair may occur due to electromagnetic interference between two different twisted pairs. Such phenomenon of signal disturbance, usually referred to as "cross-talk", is highly undesirable and should be at least minimized if not eliminated altogether.
  • NEXT Near End Cross-Talk
  • FEXT Far End Cross-Talk
  • power-sum cross-talk indicates the overall transfer of energy towards one pair from all the other pairs.
  • Cross-talk especially presents a problem in high frequency applications because cross-talk increases logarithmically as the frequency of the transmission increases. At high frequency, furthermore, NEXT is the most relevant cross-talk phenomenon.
  • each twisted pair of a cable has a specified distance between twists along the longitudinal direction, that distance being referred to as lay length.
  • lay length When adjacent twisted pairs have the same lay length and/or twist direction, they tend to lle within a cable more closely spaced than when they have different lay lengths and/or twist direction. Twist direction may also be varied.
  • US patent n. 4,755,629 discloses a communication cable comprising at least two pairs of insulated conductors, each of them being enclosed individually in its own tubular member or tubular buffer portions comprising a plastic material.
  • a metallic shield encloses the tubular members and a jacket encloses the shield. However free spaces are left empty between the tubular portions and the jacket.
  • shielded cables are difficult and time consuming to install and terminate.
  • Shielded conductors are generally terminated using special tools, devices and techniques adapted for the job.
  • Shielding of twisted pairs is costly and complex to process and also susceptible to geometric instability during processing and use.
  • spacing means to space apart the twisted pairs of insulated conductors such as disclosed in US patent n. 5,969,295 .
  • This reference describes a cable obtained by extruding a jacket around twisted pairs of insulated conductors reciprocally spaced by a cross-shaped spacer.
  • the jacket becomes integrally bonded to the radially outer tips of the spacer walls, thus defining a plurality of sector-shaped cavities each housing a respective pair of insulated conductors.
  • the cable disclosed by US 5,969,295 is difficult to manufacture, possesses inhomogeneous mechanical properties and the construction thereof does not allow to prevent possible relative movements, albeit small, between pairs housed in adjacent sector-shaped cavities.
  • the presence of the spacer may increase the stiffness of the cable, thus preventing an easy bending of the same, which bending is
  • the cross-shaped spacer and the cavities thereby formed in the cable of US 5,969,295 are subjected to a helical torsion along the cable length, which requires an additional manufacturing step.
  • EP-A-0 828 259 teaches to embed twisted pairs of insulated conductors within a flexible plastic material so as to stabilize the reciprocal position of the pairs.
  • a cable of this kind while showing, on the one hand, a satisfactory control of the cross-talk phenomenon coupled to a good mechanical resistance, is affected, on the other hand, by electrical and handling problems.
  • a first problem which may occur is the difficulty of stripping the flexible material from the twisted pairs of insulated conductors without causing damage to the structure of the cable.
  • a second problem is related to the possible permanent deformations which may occur whenever the bending radius of the cable is lower than a certain value. Such deformations may cause a variation in the impedance of the conductors, with consequent attenuation of the transmitted signal. Said variation of impedance is related to the "return loss" parameter, i.e.
  • a third problem is related to the rigidity of this kind of cable which may render troublesome the handling and the installation of the same.
  • the Applicant has now found a new communications cable having good transmission parameters, such as controlled cross-talk and impedance, and mechanical characteristics which enable the cable to be easily manufactured, handled and installed.
  • the present invention relates to a communications cable comprising at least two twisted pairs of insulated conductors housed in respective independent cavities longitudinally formed within an elongated integral body, said cavities being defined by a continuous peripheral wall having a substantially circular cross-section and a maximum diameter adapted to prevent any relative movement of the twisted pairs of insulated conductors with respect to one another.
  • said pairs of insulated conductors are slidingly housed in said cavities in such a way that each of said pairs of insulated conductors is substantially free to move within said cavities along the longitudinal direction of the cable.
  • each of said cavities is defined by a continuous peripheral wall, which physically separates said cavity from each of the other, cavities.
  • any movement of the twisted pairs in a direction different from the longitudinal one is substantially prevented.
  • substantially circular cross-section is used to indicate not only a perfectly circular cross-section, but also any cross-section which is comparable to a circular cross-section for its intended purpose, e.g. slightly oval.
  • maximum diameter is intended to indicate either the diameter of the cavity when the cross-section of the cavity is circular, or the maximum cross-sectional dimension of the cavity when the cross-section of the cavity is not perfectly circular.
  • the communications cable of the present invention enables to achieve an optimal control of the cross-talk phenomenon thanks to the fact that the twisted pairs are housed in the cavities in a substantially fixed position with respect to one another, i.e. thanks to the fact that any movement of the twisted pairs along the radial and circumferential direction of the cable is substantially prevented.
  • each pair is free to slide within the cavities along the longitudinal direction of the cable, so that the twisted pairs can move with respect to one another long the longitudinal direction when the cable is bent and can also be easily extracted from the cavities during the installation of the cable without risks of damaging the insulated conductors.
  • the cable construction of the invention does not require, as it is common in the prior art, any helical torsion of the cavities along the cable length to help the stabilization of the twisted pairs of insulated conductors, with an outstanding simplification of the manufacturing operation and with a reduction of costs.
  • the cable of the invention also has a good mechanical strength, while maintaining an adequate flexibility which facilitates the handling and the installation of the cable, thanks to the presence of a one-piece body for containing and separating the twisted pairs.
  • the elongated integral body is preferably made of a polymeric material suitable for manufacturing a cable, such as materials including polyolefins, for example polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polyvinylchloride alloys, ethylene vinylacetate copolymers (EVA), fluorinated copolymers such as fluorinated ethylene-propylene copolymers (FEP) and ethylene trifluoroethylene copolymers (ETFE), polyurethane and low smoke zero halogen (LSOH) compositions, such as PE, PP or EVA incorporating flame retardant additives, such as inorganic fillers, including magnesium hydroxide and calcium carbonate.
  • PE polyethylene
  • PP polypropylene
  • PVC polyvinylchloride
  • EVA ethylene vinylacetate copolymers
  • FEP fluorinated ethylene-propylene copolymers
  • ETFE ethylene trifluoroethylene copolymers
  • said insulated conductors are twisted in pairs at different lay lengths, the lay length being preferably comprised between about 10 mm and about 30 mm and, still more preferably, the lay length of each pair differing from the lay length of another pair of about 0.5 mm to about 5 mm.
  • the cavities have a maximum diameter comprised between about 1.5 mm and about 3.0 mm, depending on the diameter of the conductors forming the twisted pair.
  • the elongated body comprises two cavities - respectively housing a first and a second twisted pair - angularly offset at an angle of about 180° with respect to one another.
  • three or four cavities are formed within the elongated integral body, said three or four cavities being angularly offset at an angle of about 120° or of about 90°, respectively. In this way, the maximum reciprocal distance among the twisted pairs is advantageously achieved.
  • said communications cable may further comprise at least one cavity longitudinally formed within said elongated integral body for slidingly housing a respective optical transmitting element.
  • a cavity housing an optical transmitting element may have a cross-section of any suitable shape, provided that the latter is sufficient for the cavity to contain the transmitting element itself.
  • such a cavity has a substantially circular cross-section.
  • optical transmitting element refers to any transmitting element comprising an optical fiber, including a single optical fiber, a plurality of optical fibers, a bundle of optical fibers or a ribbon of optical fibers, which may be housed within said cavity either as such or enclosed in a protective structure.
  • the protective structure may comprise a polymeric sheath; optionally, it may further comprise additional polymeric sheaths and/or reinforcing elements, such as tensile resistant yarns (e.g. Kevlar ® ).
  • said communications cable may comprise at least one additional cavity longitudinally formed within said elongated integral body and adapted to house an electrically conductive element.
  • electrically conductive element refers to any elongated element, typically of metal, e.g. copper or aluminum, capable of transmitting electrical energy, including bare or insulated metal wire and insulated twisted metal wires, wherein the term wires comprises either plenum metal conductor or a plurality of stranded metal conductors.
  • a cavity housing an electrically conductive element may have a cross-section of any suitable shape, provided that the latter is sufficient for the cavity to contain the electrically conductive element itself.
  • such a cavity has a substantially circular cross-section.
  • the communications cable of the invention comprises four cavities angularly offset at an angle of about 90° the cavities housing: at least two twisted pairs of insulated conductors, an optical transmitting element and an electrically conductive element.
  • the twisted pairs are conveniently housed in those cavities which are angularly offset at an angle of about 180° achieving in this way the maximum reciprocal distance among the same.
  • the cable may comprise a longitudinal reinforcing member disposed within said elongated integral body. More preferably, said longitudinal reinforcing member is centrally disposed within said elongated body.
  • the presence of the reinforcing member advantageously confers to the cable an additional strength, which is desirable when cables are required to be installed with high pulling strength or when the cable includes optical elements.
  • the invention relates to an extrusion apparatus for continuously manufacturing a communications cable, as previously disclosed comprising :
  • the extrusion apparatus of the invention comprises a plurality of ducts substantially arranged according to the same spatial configuration which the twisted pairs of insulated conductors have in the final cable.
  • four ducts arranged according to a square array may be provided in a male die of an extrusion apparatus designed for manufacturing a final cable comprising four longitudinal cavities angularly offset at an angle of about 90°
  • three ducts arranged according to a triangular array may be provided in a male die of an extrusion apparatus designed for manufacturing a final cable comprising three longitudinal cavities angularly offset at an angle of about 120°.
  • a radially inner portion of the extrusion flowpath is defined within the male die between the ring-shaped splitting member and the support body, and a radially outer portion of the extrusion flowpath is defined between the male die and the female die.
  • the ring-shaped splitting member splits the overall flow of a suitable polymeric material being extruded into radially inner and radially outer subflows which will form the radially inner and, respectively, the radially outer portions of the elongated integral body of the cable.
  • the radially inner subflow of the polymeric material will form a central core portion and a number of spacer portions radially extending therefrom of the elongated integral body, while the radially outer subflow of the polymeric material will form an outer jacket portion integral with said spacer and core portions.
  • the distance between the front side of the ring-shaped splitting member and an inner opening of the second portion of the female die is comprised between about 1 mm and about 4 mm.
  • front and rear are used to indicate, respectively, those parts of the extrusion apparatus which are closest and, respectively, farthest from the outer opening of the female die.
  • the distance between the front side of the ring-shaped splitting member and the inner opening of the second portion of the female die it is advantageously possible to determine the thickness of all the portions (core, spacers and outer jacket) of the elongated integral body in order to meet the final geometrical requirements of the cable.
  • the free ends of the ducts are housed in said second portion of the female die at a predetermined distance from an outer opening of said second portion.
  • said distance is comprised between about 1 mm and about 3 mm.
  • the extrusion flowpath defined within the extrusion apparatus of the invention advantageously comprises, upstream of the outer opening of the female die, an end portion having a predetermined length which allows to stabilize the shape of the elongated integral body and, most importantly, the shape of the cavities defined therein.
  • the distance between the front side of the ring-shaped splitting member and the free end of the ducts is comprised between about 6 mm and about 10 mm.
  • the inner walls of said first portion of the female die form an angle with respect to the extrusion axis comprised between about 25° and about 30°.
  • Such inclination of the inner walls of the first portion of the female die with respect to the extrusion axis advantageously enables to optimize the flow of the extruding material.
  • the radially outer surface of the ring-shaped splitting member is tapered.
  • the radially outer surface of the ring-shaped splitting member form a taper angle with respect to the extrusion axis comprised between about 25° and about 30°.
  • the taper angle formed between the outer surface of the ring-shaped splitting member and the extrusion axis is equal to the angle formed between the inner walls of the first portion of the female die and the extrusion axis.
  • the flow of the polymeric material within the extruder may advantageously be optimized.
  • the above-mentioned ranges of the taper angle allow to determine the cross-section of the radially outer portion of the extrusion flowpath in such a way as to obtain an adequate extrusion rate of the material being extruded, while avoiding the risks of creating an undesired turbulence of the flowing material and/or dead points within the extrusion flowpath.
  • the distance between the radically outer surface of the ring-shaped splitting member and the inner walls of the first portion of the female die is substantially constant and is comprised between about 1 mm and about 3 mm.
  • the extrusion apparatus of the invention further comprises a channel centrally formed within the support body of the male die for housing a longitudinal reinforcing member.
  • a plant for continuously manufacturing a communications cable according to the invention comprises at least one extrusion apparatus as defined above.
  • the plant further comprises:
  • the plant further comprises at least one tensioning device downstream of said twisting device for imparting a predetermined tension to said plurality of twisted pairs.
  • the tensioning device allows to adjust the tension of the twisted pairs of insulated conductors.
  • the plant further comprises a lubricating device upstream of said extrusion apparatus for delivering a predetermined amount of a suitable lubricating material onto the surface of said twisted pairs of insulated conductors.
  • the plant further comprises a vacuum-cooling apparatus arranged downstream of said extrusion apparatus for vacuum-cooling the cable leaving said extrusion apparatus.
  • this vacuum-cooling apparatus enables to stabilize the shape of the elongated integral body and, most importantly, of the cavities provided therein in an optimal manner and as promptly as possible after the extrusion of the cable.
  • the plant further comprises at least one cable storing device downstream of said extrusion apparatus for storing the cable leaving said extrusion apparatus.
  • the extrusion of the elongated integral body directly around the twisted pairs enables to manufacture in just one shot an elongated integral body around the twisted pairs, with an ensuing productivity increase with respect to the methods of the prior art.
  • said method enables to manufacture in just one shot a cable having transmissive elements of different nature, such as at least two twisted pairs of insulated conductors, an optical transmitting element and/or an electrically conductive element, thus accomplishing both the transmission of data and the power supply to electrical devices.
  • the twisting step of the insulated conductors is carried out so as to impart to each twisted pair different lay lengths comprised between about 10 mm and about 30 mm.
  • the method further comprises the step of vacuum-cooling the cable leaving the extrusion apparatus, so as to promote a shape stabilization of the elongated integral body and of the cavities provided therein.
  • this vacuum-cooling step enables to stabilize the shape of the elongated integral body and substantially avoids the risk of a collapse of the cavities provided therein as promptly as possible after the extrusion of the cable.
  • the method for manufacturing a communications cable further comprises the steps of:
  • said longitudinal reinforcing member is located at a central location within said spatial configuration of the twisted pairs of insulated conductors.
  • the aforementioned method steps are carried out by means of the extrusion apparatus and plant described hereinabove.
  • a communications cable according to a first preferred embodiment of the invention is generally indicated at 1.
  • the cable 1 has an outer diameter D c and comprises four twisted pairs 49 of insulated conductors 50.
  • the outer diameter D c of the cable 1 is comprised between about 5.5 mm and about 7.5 mm, while outer diameter of the insulated conductors 50 is comprised between about 0.75 mm and about 1.5 mm.
  • Each insulated conductor 50 comprises a conductive core 51 surrounded by a polymeric insulation 52.
  • the conductive core 51 may be a metallic wire made of any of the well-known metallic conductors, such as copper, aluminum, copper-clad aluminum, copper-clad steel, etc.
  • the thickness of the insulating material is preferably comprised between about 0.10 mm and about 0.25 mm.
  • the insulating material may be foamed or expanded through the use of a blowing or foaming agent. Suitable insulating materials for the twisted pairs include polyvinylchloride (PVC), polyvinylchloride .alloys, polyethylene (PE), polypropylene (PP) and flame retardant materials such as fluorinated polymers.
  • Exemplary fluorinated polymers to be used in the invention include fluorinated ethylene propylene copolymers (FEP), ethylene trifluoroethylene copolymers (ETFE), ethylene chlorotrifluoroethylene copolymers (ECTFE), perfluoroalkoxypolymers (PFA's), and mixtures thereof.
  • Exemplary PFA's include copolymers of tetrafluoroethylene and perfluoropropylvinylether (e.g. Teflon® PFA 340) and copolymers of tetrafluoroethylene and perfluoromethylvinylether (MFA copolymers which are available from
  • the insulated conductors 50 are twisted in pairs, preferably at different lay lengths of about 10 mm to about 30 mm. For instance, when four twisted pairs are provided within the four longitudinal cavities, as illustrated in fig. 1 , the respective lay length may be of about 12 mm, about 15 mm, about 18 mm and about 21 mm.
  • the twisted pairs 49 are slidingly housed in respective cavities 53 longitudinally formed within an elongated integral body 2 made of any of the polymer materials conventionally used in cable construction described hereinabove, such as for example polyethylene (PE).
  • PE polyethylene
  • the cavities 53 have a substantially circular cross-section having a diameter D max adapted to prevent any relative movement of the twisted pairs 49 with respect to one another and allowing, at the same time, each twisted pair 49 to be substantially free to move within the cavities 53 along the longitudinal direction X-X of the cable 1.
  • Each cavity is defined by a respective substantially continuous peripheral wall, which allows to physically separate said cavity from the others, thus avoiding undesirable contacts between twisted pairs housed in different respective cavities.
  • the cavities 53 are preferably angularly offset with respect to one another, in the example illustrated in figure 1 at an angle of about 90°.
  • the diameter D max of each cavity 53 is of about 2.0 mm.
  • a central core portion 3 a plurality of spacer portions 4 radially extending from the central core portion 3 and an outer jacket portion 5 integral with the spacer portions 4.
  • the plant 6 comprises an extrusion apparatus 11 which will be described in greater detail in the following with reference to figure 3 .
  • a feeding device 7 adapted to supply the insulated conductors 50.
  • such feeding device 7 comprises eight feeding reels 14, each supplying one insulated conductor 50.
  • the feeding reels 14 are disposed in pairs within respective twisting cylinders 15 each forming a twisting device of the insulated conductors 50.
  • Each twisting cylinder 15 comprises two apertures 16 crossed by the insulated conductors 50 unwound from the feeding reels 14 housed in the cylinder 15. In this way, each twisting cylinder 15 is adapted to twist two insulated conductors 50 around each other.
  • such a feeding device 7, which incorporates the twisting devices 15, enables to reduce the space occupied by the plant 6.
  • the twisting devices 15 may be arranged immediately downstream of the feeding device 7, in which case a greater space would be occupied by the plant 6.
  • each feeding reel 14 rotates around a rotation axis S-S
  • each twisting cylinder 15 rotates around a rotation axis T-T
  • said axis S-S and said axis T-T being, respectively, substantially perpendicular and substantially parallel to the manufacturing direction M-M.
  • a tensioning device 9 for example constituted by a plurality of co-rotating cylinders 17 arranged in pairs, is provided so as to impart a predetermined tension to the twisted pairs 49.
  • the cylinders 17 rotate about a rotation axis U-U substantially perpendicular to the manufacturing direction M-M.
  • the tensioning device 9 may have the additional function of temporarily storing, if necessary, a predetermined length of twisted pairs 49.
  • the plant 6 comprises a lubricating device 10 supported downstream of the tensioning device 9 and upstream of the extrusion apparatus 11.
  • the lubricating device 10 is adapted to deliver, for example by spraying, a predetermined amount of lubricating material onto the surface of the twisted pairs 49 of insulated conductors 50.
  • Suitable lubricating materials include silicone compounds, hydrocarbon lubricating compounds, fluorinated liquids, talc, grease and the like.
  • the lubricating device 10 preferably comprises a chamber 18, in which a plurality of delivering nozzles, conventional per se and not shown, are supported.
  • the chamber 18 is provided with a plurality of inlet apertures 19' and outlet apertures 19" for respectively letting in and letting out the twisted pairs 49 into and from the lubricating device 10.
  • the nozzles are in fluid communication with respective reservoirs containing the lubricating material, conventional per se and not shown, by means of a number of conventional conduits not shown.
  • the plant 6 further comprises, downstream of the extrusion apparatus 11, a vacuum-cooling apparatus 12 for vacuum-cooling the cable 1 leaving the extrusion apparatus 11.
  • the vacuum-cooling apparatus 12 comprises a chamber 20 in which a suitable cooling medium, such as for example cooled water, circulates and which is in fluid communication with a vacuum-pump, not shown, so as to obtain a vacuum degree, preferably comprised between about 40 mmHg and about 250 mmHg, adapted to minimize the risk of any collapse of the cavities 53 formed in the elongated integral body 2 of the cable 1.
  • the chamber 20 is also in fluid communication with a heat exchanger, not illustrated and known per se, which is provided for cooling the cooling medium leaving the chamber 20.
  • a heat exchanger not illustrated and known per se, which is provided for cooling the cooling medium leaving the chamber 20.
  • the chamber 20 and the heat exchanger are arranged in a closed circuit in which a circulation pump (not shown) is provided for recirculating the cooling medium, thus limiting the consumption of the same.
  • the plant 6 further comprises, downstream of the vacuum-cooling apparatus 12, at least one cable storing device 13 for storing the cable 1 leaving the vacuum-cooling apparatus 12.
  • the cable storing device preferably comprises a storing reel 21 having a rotation axis V-V substantially perpendicular to the manufacturing direction M-M.
  • a cable tensioning device 22 is also provided, preferably comprising a tensioning cylinder 23 having a rotation axis Z-Z substantially perpendicular to the manufacturing direction M-M.
  • the extrusion apparatus 11 comprises an extrusion die 24 supported by a support frame 33 and arranged along the extrusion axis E-E.
  • the extrusion die 24 includes a female die 25 and a male die 26.
  • the male die 26 is partially housed within an opening 39 longitudinally formed in the support body 33 and protrudes along the extrusion axis E-E within an extrusion chamber 47 defined between the support body 33 and the female die 25.
  • the female die 25 has a first substantially funnel-shaped portion 27 and a second cylindrical portion 28 having a substantially constant diameter and provided with respective inner and outer opening 35, 29.
  • the inner walls of the first portion 27 form an angle ⁇ with respect to the extrusion axis E-E. In the example illustrated, such angle ⁇ is of about 25°.
  • the second portion 28 of the female die has a diameter D which is substantially equal to the outer diameter D c of the cable 1 to be manufactured.
  • the male die 26 comprises a support body 30 which advantageously includes an inner cavity 38 that allows to reduce the weight thereof.
  • the support body 30 supports a plurality of ducts 31 extending along a direction substantially parallel to the extrusion axis E-E and having a diameter D d which is substantially equal to the diameter D max of the cavities of the cable 1 to be manufactured.
  • the plurality of ducts 31 is arranged according to a predetermined spatial configuration corresponding to the arrangement of the cavities 53 in the final communications cable 1. In the example illustrated, four ducts 31 are arranged according to a square array.
  • the male die 26 further comprises a ring-shaped splitting member 32 which is supported by the ducts 31 at a predetermined distance L 2 from the first portion 27 of the female die 25.
  • the female die 25 and the male die 26 define between each other an extrusion flowpath, generally indicated at 8, for the polymeric material being extruded to form the elongated integral body 2 of the communications cable 1.
  • a radially inner portion 8a of the extrusion flowpath 8 is defined within the male die 26 between the ring-shaped member 32 and the support body 30, and a radially outer portion 8b of the extrusion flowpath 8 is defined between the male die 26 and the female die 25.
  • the ring-shaped splitting member 32 splits the overall flow of material being extruded (polyethylene) into a radially inner subflow and a radially outer subflow which will form the radially inner portions (i.e. the central core portion 3 and the spacer portions 4) and, respectively, the radially outer portions (i.e. the outer jacket portion 5) of the elongated integral body 2 of the communications cable 1.
  • the distance L 1 is suitably selected in order to obtain the desired thickness of all the portions (core 3, spacers 4 and outer jacket 5) of the cable 1. In the illustrated example, the distance L 1 is of about 1 mm.
  • the radially outer surface of the ring-shaped splitting member 32 is tapered.
  • the radially outer surface of the splitting member 32 preferably forms a taper angle ⁇ with respect to the extrusion axis E-E, which is preferably equal to the angle ⁇ .
  • ⁇ and ⁇ have a value of about 25°.
  • the above distance L 2 determined between the radially outer surface of the ring-shaped splitting member 32 and the inner walls of the first portion 27 of the female die 25, is of about 1 mm.
  • the ring-shaped splitting member 32 is preferably positioned along the male die 26 in such a way as to determine a suitable distance L 3 between its front side and the free ends of the ducts 31.
  • the distance L 3 is of about 8 mm.
  • the free ends of the ducts 31 are preferably housed in the second portion 28 of the female die 25 at a predetermined distance L 4 from the outer opening 29 of the second portion 28.
  • an end portion 8c of the extrusion flowpath 8 is defined which contributes to stabilize both the shape of the elongated integral body 2 and the shape of the cavities 53.
  • such a distance L 4 has a value of about 2 mm.
  • the position of the free ends of the ducts 31 in the second portion 28 of the female die 25 may be regulated so as to form spacer portions 4 integral with the outer jacket portion 5, to obtain the desired thickness of the same and to allow the formation of cavities 53 having the desired diameter D max .
  • this adjustment of the free ends of the ducts 31 in the second portion 28 of the female die 25 so as to determine a proper distance L 4 is carried out by displacing the female die 25 with respect to the male die 26.
  • the position of the female die 25 with respect to the male die 26 may be conveniently regulated as follows.
  • the female die 25 is slidingly mounted within a mating cavity 57 formed at a front end of the support frame 33 and, as such, it may be freely moved along the latter thanks to the action of a threaded locking ring 41 threadably engaged in a way known per se with the outer surface of the support frame 33 and abutting against the female die 25.
  • the relative position of the female die 25 with respect to the male die 26 can thus be easily adjusted by moving the locking ring 41 along the support frame 33, i.e. by screwing or unscrewing the same.
  • the contact between the female die 25 and an inner annular surface of the locking ring 41 is effectively maintained during the extrusion operations thanks to the pressure exerted by the material being extruded on the first portion 27 of the female die 25.
  • the locking ring 41 is centrally provided with an opening 42, coaxial with the outer opening 29 of the second portion 28 of the female die 25, for delivering the extruded cable 1 out of the extrusion apparatus 11.
  • the extrusion chamber 47 defined within the cavity 57 is in communication with a conveying chamber 34 defined within a feeding hopper 37 fixed to the support frame 33 downstream of a conventional extrusion screw, not illustrated and known per se.
  • the extrusion screw is disposed along a direction substantially perpendicular to the extrusion axis E-E.
  • the extrusion apparatus 11 is also provided with a threaded locking ring 40, adapted to close the rear end of the same.
  • a first embodiment of a method for manufacturing the communications cable 1 according to the invention comprises the following steps.
  • a plurality of Insulated conductors 50 is provided by unwinding the feeding reels 14. of the feeding device 7.
  • the insulated conductors 50 are supplied through the outlet apertures 16 of the twisting cylinders 15.
  • the insulated conductors 50 are reciprocally twisted in pairs, at a selected lay length. In this way, a plurality of twisted pairs 49 of insulated conductors 50 is formed.
  • a predetermined tension is imparted to the twisted pairs 49 by means of the tensioning device 9, around which the twisted pairs 49 are wound by rotating the cylinders 17 about the rotation axis U-U.
  • said method comprises the additional step of delivering a lubricating material onto the surface of the twisted pairs 49.
  • the twisted pairs 49 are transferred to the lubricating device 10 through the inlet apertures 19'.
  • the surface of the twisted pairs 49 is coated with lubricating material sprayed by the delivering nozzles.
  • the twisted pairs 49 leave the lubricating device 9 through the outlet apertures 19" and are transferred to the extrusion apparatus 11.
  • the twisted pairs 49 of insulated conductors 50 enter the ducts 31.
  • each of the twisted pairs 49 is kept at a predetermined distance from the other pairs 49 according to a predetermined spatial arrangement.
  • a constant flow of polymeric material is fed by the extrusion screw to the extrusion apparatus 11 wherein the material is extruded around the twisted pairs 49 while maintaining the same in said predetermined spatial configuration by means of the ducts 31. More particularly, the flow of the polymeric material being extruded is split into two subflows flowing in the radially inner and radially outer portions 8a, 8b of the extrusion flow path 8. In this way, the elongated integral body 2 of the cable 1, is continuously formed by extrusion preventing at the same time that the twisted pairs 49 of insulated conductors 50 become permanently linked to the inner surface of the cavities 53.
  • the cable 1 which has a temperature preferably comprised between about 150°C and about 220°C and, still more preferably, between about 150°C and about 180°C, is vacuum-cooled by means of the vacuum-cooling apparatus. 12 to a temperature comprised between about 20°C and about 50°C, at a pressure of about 80 mmHg, so as to promote an effective shape stabilization of the cavities 53.
  • the cable 1 is wound around the cable tensioning device 22. Once the desired tension has been imparted to the cable 1, the latter is transferred to the cable storing device 13 and wound therearound.
  • a longitudinal reinforcing member 43 for example a wire made of steel or of fiber-reinforced plastics (for example plastics incorporating fiberglass), is centrally disposed within the elongated integral body 2.
  • an additional embodiment of the extrusion apparatus of the invention comprises a male die 26 provided with a support body 30 in which a channel 48 of suitable shape is axially formed.
  • the channel 48 is centrally disposed along the extrusion axis E-E and is adapted to house the longitudinal reinforcing member 43 up to a tip portion of the support body 30.
  • an additional embodiment of said method for manufacturing the above-mentioned cable 101 according to the invention further comprises the following additional steps.
  • the longitudinal reinforcing member 43 is provided in a manner known per se. Subsequently, the longitudinal reinforcing member 43 is arranged at a central location within the spatial configuration of the twisted pairs 49 of insulated conductors 50 and, finally, the longitudinal reinforcing member 43 is fed to said extrusion apparatus 111 (more particularly, it enters the channel 48 centrally disposed along the extrusion axis E-E), together with the spatially arranged pairs 49 of insulated conductors 50.
  • the reinforcing member 43 travels along the channel 48 up to the tip portion of the support body 30 before being incorporated in the polymeric material flowing in a central portion 8d of the flowpath 8 defined between the ducts 31.
  • Figure 9 illustrates an alternative embodiment of the communications cable according to the invention, generally indicated at 201.
  • the cable 201 comprises an optical transmitting element 46 housed in one cavity 54 formed in the elongated integral body 2.
  • the cavity 54 has a substantially circular cross-section, such cavity 54 may have any suitable shape sufficient to contain the optical transmitting element 46.
  • the optical transmitting element 46 may be in the form of a plurality of optical fibers 44 (e.g. twelve) enclosed in a microsheath 45 of polymeric material.
  • This cable 201 advantageously allows to reach a plurality of end-users connected at different levels (i.e. connected by means of conventional copper wires or optical fibers) or to subsequently upgrade a conventional copper wire connection to an optical fiber connection.
  • a cable according to the invention may also comprise, further to the at least two cavities respectively housing two twisted pairs, also at least one empty cavity adapted to receive an optical transmitting medium.
  • Said cable may thus installed as such and an optical transmitting medium can subsequently be disposed within said empty cavity at the need, preferably by means of the so called "blown installation" technique.
  • either a single optical fiber or an assembly comprising a plurality of optical fibers, both specifically adapted for blown installation may be installed in said cavity according to conventional blown installation techniques.
  • Figure 10 illustrates another alternative embodiment of the communications cable according to the invention, generally indicated at 301.
  • an electrically conductive element e.g. an insulated copper wire, generally indicated at 56 in figure 10 , is housed in a longitudinal cavity 55, according to the illustrated embodiment of substantially circular cross-section.
  • the electrically conductive element 56 may replace one of the twisted pairs 49 in order to supply power to electrical devices, as in the case of opto-electric converters.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Communication Cables (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Claims (15)

  1. Câble de communication (1, 101, 201, 301) comprenant au moins deux paires torsadées (49) de conducteurs isolés (50), logées dans des cavités (53) respectives séparées qui sont formées dans le sens longitudinal dans un corps (2) monobloc allongé, lesdites cavités (53) étant délimitées par une paroi périphérique continue dudit corps (2) monobloc et ayant une section sensiblement circulaire et un diamètre maximal (Dmax) adapté pour empêcher tout mouvement relatif des paires torsadées (49) de conducteurs isolés (50), l'une par rapport à l'autre, câble dans lequel lesdites paires (49) de conducteurs isolés (50) sont logées de façon coulissante dans lesdites cavités (53), de manière à ce que chacune des paires (49) de conducteurs isolés (50) soit sensiblement libre pour se déplacer dans les cavités (53), dans le sens longitudinal (X-X) du câble (1, 101, 201, 301).
  2. Câble (1, 101, 201, 301) selon la revendication 1, dans lequel les conducteurs isolés (50) sont torsadés avec des pas différents, compris entre 10 mm et 30 mm.
  3. Câble (1, 101, 201, 301) selon la revendication 1, dans lequel les cavités (53) ont un diamètre maximal (Dmax) compris entre 1,5 mm et 3,0 mm.
  4. Câble (1, 101, 201, 301) selon la revendication 1, dans lequel le corps (2) monobloc allongé comporte au moins deux cavités qui présentent un décalage angulaire l'une par rapport à l'autre, avec un angle prédéterminé.
  5. Câble (1, 101, 201, 301) selon la revendication 1, comprenant en outre un élément de transmission optique (46) ou un élément électriquement conducteur (56) logé dans une cavité (54, 55) respective, formée dans le sens longitudinal dans le corps (2) monobloc allongé.
  6. Câble (1, 101, 201, 301) selon la revendication 1, comprenant en outre au moins une cavité (53) supplémentaire vide et séparée, qui est réalisée dans le sens longitudinal dans le corps (2) monobloc allongé.
  7. Câble (1, 101, 201, 301) selon la revendication 1, comprenant en outre un élément de renfort (43) longitudinal qui est disposé au centre du corps (2) monobloc allongé.
  8. Dispositif d'extrusion (11, 111) destiné à fabriquer en continu un câble de communication (1, 101, 201, 301) selon l'une quelconque des revendications 1 à 7, comprenant :
    a) une filière d'extrusion (24) dotée d'un axe d'extrusion (E-E) et comportant :
    i) une partie femelle de filière (25) avec une première portion (27), sensiblement en forme d'entonnoir (27), et une deuxième portion (28) sensiblement cylindrique avec un diamètre (D) sensiblement constant, et
    ii) une partie mâle de filière (26) comprenant un corps support (30) portant une pluralité de conduits (31), dans une direction qui est parallèle audit axe d'extrusion (E-E) et dans une configuration spatiale prédéterminée, et un élément de division (32) de forme annulaire, qui est porté par lesdits conduits (31), à une distance prédéterminée de la partie femelle de filière (25);
    dans lequel un chemin d'écoulement d'extrusion (8) est défini à l'intérieur de la partie mâle de filière (26), entre l'élément de division (32) annulaire et ledit corps support (30) et entre la partie mâle de filière (26) et la partie femelle de filière (25), et
    dans lequel les extrémités libres des conduits (31) sont disposées dans la deuxième portion (28) de la partie femelle de filière (25).
  9. Dispositif d'extrusion (11, 111) selon la revendication 8, dans lequel la distance (L1) entre la face frontale de l'élément de division (32) en forme d'anneau et une ouverture intérieure (35) de la deuxième portion (28) de la partie femelle de filière (25) est comprise entre 1 mm et 4mm.
  10. Dispositif d'extrusion (11, 111) selon la revendication 8, dans lequel la distance (L4) entre l'extrémité libre des conduits (31) et une ouverture extérieure (29) de la deuxième portion (28) de la partie femelle de filière (25) est comprise entre 1 mm et 3 mm.
  11. Dispositif d'extrusion (11, 111) selon la revendication 8, dans lequel les parois intérieures de la première portion (27) de la partie femelle de filière (25) forment un angle (α) avec l'axe d'extrusion (E-E), qui est compris entre 25° et 30°.
  12. Dispositif d'extrusion (11, 111) selon la revendication 8, dans lequel la surface radialement extérieure de l'élément de division (32) en forme d'anneau est conique.
  13. Dispositif d'extrusion (11, 111) selon la revendication 12, dans lequel la surface radialement extérieure de l'élément de division (32) forme un angle de cône (β) avec l'axe d'extrusion (E-E), qui est compris entre 25° et 30°.
  14. Dispositif d'extrusion (11, 111) selon la revendication 12, dans lequel la distance (L2) entre la surface radialement extérieure de l'élément de division (32) en forme d'anneau et les parois intérieures de la première portion (27) de la partie femelle de filière (25) est comprise entre 1 mm et 3 mm.
  15. Dispositif d'extrusion (11, 111) selon la revendication 8, comportant en outre un canal (48) qui est formé au centre du corps support (30) de la partie mâle de filière (26).
EP02708331A 2001-02-28 2002-02-26 Cable de communication, et installation de fabrication idoine Expired - Lifetime EP1364376B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP02708331A EP1364376B1 (fr) 2001-02-28 2002-02-26 Cable de communication, et installation de fabrication idoine

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
EP01200743 2001-02-28
EP01200743 2001-02-28
US27275801P 2001-03-05 2001-03-05
US272758P 2001-03-05
PCT/EP2002/002003 WO2002073634A2 (fr) 2001-02-28 2002-02-26 Cable de communication, et procede et installation de fabrication
EP02708331A EP1364376B1 (fr) 2001-02-28 2002-02-26 Cable de communication, et installation de fabrication idoine

Publications (2)

Publication Number Publication Date
EP1364376A2 EP1364376A2 (fr) 2003-11-26
EP1364376B1 true EP1364376B1 (fr) 2009-07-29

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EP (1) EP1364376B1 (fr)
AT (1) ATE438185T1 (fr)
WO (1) WO2002073634A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010034136A1 (de) * 2010-08-12 2012-02-16 Norbert Harthauß Verfahren zur Reparatur eines beschädigten Bereiches einer elektrischen Leitung

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1295910A1 (fr) * 2001-09-25 2003-03-26 Borealis GmbH Composition de mousse isolante
US7196271B2 (en) 2002-03-13 2007-03-27 Belden Cdt (Canada) Inc. Twisted pair cable with cable separator
CN111703985B (zh) * 2020-06-18 2021-09-07 郑州铁路职业技术学院 一种计算机网络布线装置
CN115148416B (zh) * 2022-07-04 2023-08-01 江西亨顺线缆有限公司 一种电力电缆的制造工艺

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4755629A (en) * 1985-09-27 1988-07-05 At&T Technologies Local area network cable
US5132488A (en) * 1991-02-21 1992-07-21 Northern Telecom Limited Electrical telecommunications cable
US5767441A (en) * 1996-01-04 1998-06-16 General Cable Industries Paired electrical cable having improved transmission properties and method for making same
US5821467A (en) * 1996-09-11 1998-10-13 Belden Wire & Cable Company Flat-type communication cable

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010034136A1 (de) * 2010-08-12 2012-02-16 Norbert Harthauß Verfahren zur Reparatur eines beschädigten Bereiches einer elektrischen Leitung

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EP1364376A2 (fr) 2003-11-26
WO2002073634A2 (fr) 2002-09-19
WO2002073634A3 (fr) 2002-11-14
ATE438185T1 (de) 2009-08-15

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