WO2018067590A1 - Compositions pour mélange, traitement par fusion et extrusion de mousse polymère et polymères cellulaires - Google Patents

Compositions pour mélange, traitement par fusion et extrusion de mousse polymère et polymères cellulaires Download PDF

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Publication number
WO2018067590A1
WO2018067590A1 PCT/US2017/054970 US2017054970W WO2018067590A1 WO 2018067590 A1 WO2018067590 A1 WO 2018067590A1 US 2017054970 W US2017054970 W US 2017054970W WO 2018067590 A1 WO2018067590 A1 WO 2018067590A1
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WIPO (PCT)
Prior art keywords
communications cable
inches
channels
cable
jacket
Prior art date
Application number
PCT/US2017/054970
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English (en)
Inventor
Charles A. Glew
Richard W. Speer
Original Assignee
Cable Components Group, Llc
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
Priority claimed from US15/284,177 external-priority patent/US10031301B2/en
Application filed by Cable Components Group, Llc filed Critical Cable Components Group, Llc
Publication of WO2018067590A1 publication Critical patent/WO2018067590A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/002—Inhomogeneous material in general
    • H01B3/004—Inhomogeneous material in general with conductive additives or conductive layers
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401—Optical cables
    • G02B6/4429—Means specially adapted for strengthening or protecting the cables
    • G02B6/443—Protective covering
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02—Details
    • H02G3/04—Protective tubing or conduits, e.g. cable ladders or cable troughs
    • H02G3/0406—Details thereof

Definitions

  • the present application relates generally to communication cables, and particularly to communication cables that allow transmission of both data and electrical power.
  • a broad range of electrical cables and buffered optical fibers are installed in modern buildings for a wide variety of uses. These cables are used, for example, to provide data transmission between computers, voice communications, as well as control signal transmission for building security, fire alarms, and temperature control systems. Cable networks extend throughout modern office and industrial buildings, and frequently extend through the space between the dropped ceiling and the floor above.
  • Ventilation system components are also frequently extended through this space for directing heated and chilled air to the space below the ceiling and also to direct return air exchange.
  • the space between the dropped ceiling and the floor above is commonly referred to as the plenum area.
  • Electrical cables and fiber optic cables extending through plenum areas are governed by special provisions of the National Electric Code (“NEC").
  • NFPA National Fire Protection Association
  • the National Fire Protection Association developed a standard to reduce the amount of flammable material incorporated into insulated electrical conductors, fiber optic buffers and jacketing of cables. Reducing the amount of flammable material, according to the NFPA, would reduce the potential of insulation, fiber optic buffering, and jacket materials to spread flames and smoke to adjacent plenum areas and potentially to more distant and widespread areas in a building.
  • the NFPA recognized the potential flame and smoke hazards created by burning cables in plenum areas and adopted in the NEC a standard for flame retardant and smoke suppressant cables.
  • the Steiner Tunnel Test has been adapted for the burning of cables according to the following test protocols: NFPA 262, Underwriters Laboratories (“U.L.”) 910, or Canadian Standards Association (“CSA”) FT-6.
  • the test conditions for each of the U.L. 910 Steiner Tunnel Test, CSA FT-6, and NFPA 262 are: a 300,000 BTU/hour flame is applied for 20 minutes to 24-foot lengths of test cables mounted on a horizontal tray within a tunnel.
  • the criteria for passing the Steiner Tunnel Test are as follows:
  • Underwriters Laboratory is a test method for determining whether components or materials of a cable can be designated as a non-halogen cable.
  • Underwriters Laboratory titled Acid Gas, Acidity and Conductivity of Combusted Materials and Assessment, uses IEC 60754-1, IEC 6074-2 and IEC 62821-1 to benchmark "all materials" within the cable design, i.e., insulation, spline or crosswebs, tapes or other cable fillers, fiber optic buffer and the overall jacket.
  • halogens e.g., chlorine, bromine and fluorine.
  • Test protocol 62821-1 Annex B determines the presence of a halogen using the Sodium Fusion Procedure as described in Part 5.3 IEC 62821-2, i.e., Chemical Test: Determination of Halogens - Elemental Test.
  • test protocol consists of the following stages:
  • Stage 0 Determination of Halogens - elemental test for chlorine, bromine and fluorine using the sodium fusion procedure as described in part 5.3 of IEC 62821-2 (Chemical Test: Determination of Halogens - Elemental Test). If the results for chlorine or bromine or fluorine are positive, proceed to Stage 1.
  • Stage 1 Test according to 6.2.1 of 60754-2 for pH and Conductivity. If the pH is >4.3, the conductivity is >2.5 ⁇ 8/ ⁇ and ⁇ 10 ⁇ / ⁇ , proceed to Stage 2.
  • Stage 2 Test according to 6.1.1 of 60754-1 for chlorine and bromine content expressed as HCI. If the result if ⁇ 0.5%, proceed to Stage 3.
  • Stage 3 Test for the determination of low levels of fluorine as described in part 45.2 of IEC 60684-2 (Determination of low levels of fluorine) Methods A (Ion selective electrode method fluoride) or B (Alizarin fluorine blue method).
  • the European standards have similar goals of fire retardant and low smoke generation cables. Polyvinylchloride, a halogenated material, remains a dominant jacketing grade throughout the European cable community.
  • the standards which have evolved are the so-called International Classification and Flame Test Methodology for Communications Cable. Based on these evolving standards, a new list of acronyms has evolved, albeit with much similarity to the North American standards.
  • Table 2 below, provides a listing and comparison of the North American standards and the European standards from most stringent flame retardancy and low smoke requirements to least stringent.
  • a balance of properties or attributes is needed for each component (e.g., insulation, buffer, cable fillers, fiber optic strength member, fiber optic blown tubing and jacketing) within copper and fiber communications cable so that it can meet the electrical performance of copper cabling or the transmission characteristics of fiber optic high speed data cable and pass the NFPA 262 Flame and Smoke Requirements, the NFPA 259 flame requirements and similarly the European standards for Class B and Class C.
  • component e.g., insulation, buffer, cable fillers, fiber optic strength member, fiber optic blown tubing and jacketing
  • Optical fiber cables exhibit a set of needs that include unique mechanical properties to prevent damage to the fragile glass fibers. These needs are evolving for hybrid copper and fiber designs, Passive Optical Networks (PON) or Power over Ethernet (PoE). For instance, PoE will generate more heat as it provides data transmission as well as power to LED lighting, wireless interface points, cameras and is employed in a wide range of other applications, whereby temperature control and office automation can be accomplished remotely from interactive phones and computer devices.
  • PON Passive Optical Networks
  • PoE Power over Ethernet
  • PoE relates to a system in which electrical power can pass safely along with data on cables (e.g., Ethernet cables).
  • IEEE 802.3af - 2003 standard provides for up to 15.4 watts of DC power and can operate with Category 3 cables at this low power requirement.
  • IEEE 802.3 at - 2009 standard also known as PoE+ or PoE plus provides for 25.5 watts of power over Category 5 or higher.
  • the present invention relates to a communications cable, which comprises a support separator providing a plurality of channels for receiving transmission media, said support separator comprising a first polymeric material, at least one optical fiber disposed in one of said channels, at least an electrical conductor (e.g., a twisted pair of conductors) capable of carrying at least about 10 watts of electrical power disposed in another one of said channels, an insulation at least partially covering said electrical conductor, a jacket surrounding said support separator and said transmission media, said jacket comprising a second polymeric material.
  • the first and second polymeric materials can be the same material, and in other embodiments, they can be different materials.
  • the support separator of the communications cable can comprise a foamed or a solid polymeric material.
  • the insulation of the twisted pairs can comprise a foamed or solid polymeric material.
  • the foamed polymer can exhibit a foaming level in a range of about 20% to about 60%, about 20% to about 70%, or about 30% to about 60%.
  • the foamed polymeric material can include a plurality of cellular structures characterized by a size in a range of about 0.0005 inches to about 0.003 inches or about 0.001 inches to about 0.002 inches. In some embodiments, at least about 60%, at least about 70%, or at least about 80% of the cellular structures are closed cells.
  • the foamed or solid polymeric material can comprise a fluoropolymer, e.g., a perfluoropolymer.
  • fluoropolymers include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), and PVDF (polyvinylidene fluoride).
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene tetrafluoroethylene or (poly(ethylene-co-tetraflu
  • the foamed or solid polymeric material can comprise a non- halogenated polymer, such as an engineered resin.
  • engineered resins or non- halogenated polymers include, but are not limited to, polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins such as polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer (LCP), and/or combinations thereof.
  • PPS polyphenylenesulfide
  • PEI polyetherimide
  • PSU polysulfone
  • PPSU polypheylsulfone
  • the present invention relates to a communications cable, having a one or more electrical conductors that are capable of carrying at least about 10 watts of power (e.g., 10 watts, 20 watts, 30 watts, 40 watts, 50 watts, 60 watts, or more than 60 watts).
  • the electrical conductor is capable of carrying power in a range of about 10 watts to about 200 watts.
  • each of the one or more electrical conductors can transmit data, electrical power, or both.
  • the communications cable can have a jacket with an internal diameter equal to or less than about 0.4 inches (about 10 mm).
  • the internal diameter of the jacket can be in a range of about 0.24 inches (6 mm) to about 0.32 inches (8 mm) or in a range of about 0.24 inches (6 mm) to about 0.27 inches (7 mm).
  • the thickness of the jacket can be from about 0.005 inches (0.172 mm) to about 0.015 inches (0.381 mm), or about 0.007 inches (0.18 mm) to about 0.010 inches (0.25 mm).
  • the electrical conductor is a twisted pair conductor.
  • Each wire of the twisted pair can have an American Wire Gauge (AWG) in a range of about 22 to about 26.
  • AVG American Wire Gauge
  • the optical fiber is a multi-mode optical fiber. In other aspects, the optical fiber is a single-mode optical fiber.
  • the separator of the communications cable described herein can have a flap-top configuration. In other embodiments, the separator can have arms that do not terminate in flap-top portions.
  • a communications cable which comprises a support separator including a central region and a plurality of outwardly extending portions extending from the central region, said outwardly extending portions providing a plurality of channels for receiving transmission media, said support separator comprising a foamed polymeric material, at least one electrical conductor disposed in one of said channels, said electrical conductor being capable of carrying an electrical power in a range of about 10 watts to about 200 watts, at least one optical fiber disposed in another one of said channels, a jacket surrounding said support separator and said transmission media, said jacket having an inner diameter equal to or less than about 0.4 inches.
  • at least one of outwardly extending portions comprises a flap-top.
  • At least two of the outwardly extending portions comprises a flap-top such that said flap-tops are configured to facilitate closure of one of said channels.
  • an optical fiber can be disposed in the closed channel.
  • a communications cable which comprises a support separator providing a plurality of channels for receiving transmission media, said support separator comprising a first polymeric material, at least one optical fiber disposed in one of said channels, at least an electrical conductor capable of carrying at least about 10 watts of electrical power disposed in another one of said channels, a tape surrounding at least one of the transmission media, said tape comprising a solid or a foamed second polymeric material.
  • the first and second polymeric materials can be the same or different.
  • FIG. 1 illustrates an embodiment of a jacketed Power over Ethernet 4-pair copper cable having five channels in one of which two fiber optic cables are disposed.
  • FIG. 2 illustrates an embodiment of a POE 4-pair copper cable having five channels with one closed channel in which two fiber optic cables are disposed.
  • FIG. 3 illustrates an embodiment of an POE cable according to the present teachings.
  • FIG. 4 illustrates another embodiment of a POE cable in which electrical conductors have foamed insulation.
  • FIG. 5 illustrates another embodiment of a POE cable according to the present teachings.
  • FIG. 6 schematically depicts the distribution of a plurality of thermocouples employed to measure the temperature at a plurality of locations within a bundle of cables
  • FIG. 7 shows temperatures recorded by a plurality of thermocouples as a function of time at a plurality of different locations for a bundle of 192 cables each including 4 twisted pairs of copper wires disposed in an LSPVC jacket, where the copper wires were insulated with a layer of polyolefin
  • FIG. 8 shows equilibrium temperatures recorded by the thermocouples used to obtain the temperature data presented in FIG. 7,
  • FIG. 9 shows temperatures recorded by a plurality of thermocouples as a function of time at a plurality of locations for another bundle of 192 cables each including 4 twisted pairs of copper wires disposed in an LSPVC jacket, where the copper wires were insulated with a two- layer insulation formed via coextrusion of polyolefin and FEP, [0049]
  • FIG. 10 shows equilibrium temperatures recorded by the thermocouples used to obtain the temperature data presented in FIG. 9,
  • FIG. 11 shows temperatures recorded by a plurality of thermocouples as a function of time at a plurality of locations for a bundle of 192 cables each including 4 twisted pairs of copper wires disposed in an FEP jacket, where the copper wires were insulated with an insulation layer formed of FEP,
  • FIG. 12 shows equilibrium temperatures recorded by the thermocouples used to obtain the temperature data presented in FIG. 11,
  • FIG. 13 shows temperatures recorded by a plurality of thermocouples as a function of time at a plurality of locations for a bundle of 192 cables each including 4 twisted pairs of copper wires disposed in an foamed FEP jacket, where the copper wires were insulated with a layer of foamed FEP,
  • FIG. 14 shows equilibrium temperatures recorded by the thermocouples used to obtain the temperature data presented in FIG. 13,
  • FIG. 15 shows temperatures recorded by a plurality of thermocouples as a function of time at a plurality of locations for a bundle of 192 cables each including 4 twisted pairs of copper wires disposed in a foamed MF A jacket,
  • FIG. 16 shows equilibrium temperatures recorded by the thermocouples used to obtain the temperature data presented in FIG. 15, and
  • FIG. 17 shows measured and theoretically extrapolated temperature data for cable bundles formed of copper wires of different gauges.
  • the present invention generally relates to communications cables that include different transmission media and can be used for transmission of data as well as electrical power.
  • the materials forming various components of the cable are selected to facilitate the dissipation of heat generated in the cable via passage of current therethrough.
  • a separator used to provide multiple channels in which transmission media are disposed the insulation of the transmission media and the cable's jacket are formed of foamed fluoropolymers so as to facilitate the dissipation of heat generated in the cable.
  • foamed components also reduces the amount of flammable material in the cable.
  • the efficient dissipation of heat in a POE cable allows forming such a cable in a compact manner, e.g., using a jacket with an inner diameter less than about 0.4 inches.
  • the terms "about” or “approximately” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the composition, part, or collection of elements to function for its intended purpose as described herein. These terms indicate at most a ⁇ 5% variation about a central value.
  • cross-talk is used herein consistent with its common usage in the art to refer to electromagnetic interference between conductors, cables, or other electronic circuit elements.
  • engineered resin or “engineering polymer” as used herein refers to any of the following polymers: polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins such as polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer (LCP), and/or combinations thereof.
  • PPS polyphenylenesulfide
  • PEI polyetherimide
  • PSU polysulfone
  • PPSU polypheylsulfone
  • PES/PESU polyetheretherketone
  • PEEK polyaryletherketone
  • fluoropolymer is used herein consistent with its common usage in the art to refer a polymer having at least one monomer that includes at least one fluorine atom.
  • per(halo)polymer is used herein consistent with its common usage in the art to refer to a polymer that includes monomers in which substantially all hydrogen atoms have been replaced with halogen atoms (e.g., fluorine, chlorine or bromine atoms).
  • perfluoropolymer is used herein consistent with its common usage in the art to refer to a fluoropolymer in which substantially all hydrogen atoms have been replaced with fluorine atoms.
  • “foaming level” is the ratio of the volume of cells in a cellular structure, e.g. a cellular separator, relative to the total volume of the structure.
  • melt-processable is meant that the polymer can be processed (i.e. fabricated into shaped articles, insulation(s), jacket coatings, films, fibers, tubes, wire coatings and the like) by conventional melt extruding, injecting or casting means.
  • thermoplastic refers to polymers that are pliable or moldable above a specific temperature and return to a solid state upon cooling. These polymers have the property of becoming soft when they are heated and of becoming rigid again when they are cooled, without undergoing an appreciable chemical change. Such a definition may be found, for example, in the encyclopedia called "Polymer Science Dictionary", Mark S. M. Alger, London School of Polymer Technology, Polytechnic of North London, UK, published by Elsevier Applied Science, 1989.
  • elastomer is intended to designate a true elastomer or a polymer resin serving as a base constituent for obtaining a true elastomer.
  • True elastomers are defined by the ASTM, Special Technical Bulletin, No. 184 standard as materials capable of being stretched, at room temperature, to twice their intrinsic length and which, once they have been released after holding them under tension for 5 minutes, return to within 10% of their initial length in the same time.
  • active nucleating agent is intended to denote a compound which acts both as a nucleating agent and, at the same time, participates in blowing, by at least partially decomposing to yield gaseous components.
  • FIGS. 1 schematically depicts a communication cable 100 according to an embodiment of the present teachings, which includes a support separator 101 providing five channels 110, 120, 130, 140, 150 for receiving transmission media.
  • the support separator 101 includes a central portion 102 and a plurality of arms 103 extending radially from the central portion 102 such that the channels 110, 120, 130, 140, 150 are provided between the plurality of arms 103.
  • each arm 103 extends from the central portion 102 to a flap top portion 104A.
  • two adjacent flap top portions 104A partially enclose one of the channels 110, 120, 130, 140, 150.
  • At least two adjacent flap top portions can circumferentially extend so as to cooperatively substantially or completely enclose a channel (e.g., channel 150 in FIG. 2).
  • the arms of the separator may not extend to a flap top portion.
  • the separator 101 is configured to provide five channels for receiving transmission media, in other embodiments, the number of channels can be less or more.
  • the support separator 101 of the communications cable 100 is formed of a foamed polymeric material, in other embodiments, it can be formed of a solid polymeric material.
  • the foamed polymeric support separator can exhibit a foaming level in a range of about 20% to about 60%, about 20% to about 70%, or about 30% to about 60%.
  • the foamed separator can comprise a plurality of cellular structures characterized by a size in a range of about 0.0005 inches to about 0.003 inches or about 0.001 inches to about 0.002 inches. In some embodiments, at least about 60%, at least about 70%, or at least about 80% of the cellular structures can be in in the form of closed cells.
  • the separator 101 can be formed of any suitable polymer.
  • the separator 101 can be formed of a fluoropolymer, such as a perfluoropolymer.
  • suitable polymeric materials include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), PVDF (polyvinylidene fluoride), and combinations thereof.
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene tetrafluoroethylene or (poly
  • the separator 101 can be formed of a non-halogenated polymer, i.e., engineered resin.
  • engineered resins include, but are not limited to, polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins such as polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer (LCP), and/or combinations thereof.
  • PPS polyphenylenesulfide
  • PEI polyetherimide
  • PSU polysulfone
  • PPSU polypheylsulfone
  • PES/PESU polyetherether
  • a twisted pair of electrical conductors (e.g., copper wires) 111, 121, 131 and 141 is disposed in each of channels 110, 120, 130, and 140.
  • Each twisted pair of electrical conductors 111, 121, 131 and 141 can be configured to carry electrical data, power, or combinations thereof.
  • the electrical conductors are configured to carry both power and communications data.
  • each twisted pair of electrical conductors 111, 121, 131 and 141 is capable of carrying at least about 10 watts of electrical power.
  • each twisted pair of electrical conductors can be capable of carrying electrical power in a range of about 10 watts to about 200 watts, e.g., in a range of about 20 watts to about 100 watts.
  • each electrical conductor can be configured to carry at least about 10 watts of power (e.g., 10 watts, 20 watts, 30 watts, 40 watts, 50 watts, 60 watts, or more than 60 watts).
  • the electrical conductors of the twisted pairs can have a gauge (AWG) in a range of about 22 to about 26.
  • AMG gauge
  • each twisted pair 111, 121, 131 and 141 can have an electrical insulation 113, 123, 133 and 143 wrapped around it.
  • the electrical insulation 113, 123, 133 and 143 of the communications cable 100 can be formed of a foamed or a solid polymeric material.
  • the insulation of the electrical conductors is formed of a solid polymeric material, such as a fluoropolymer (e.g., a perfluoropolymer).
  • suitable polymers include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), PVDF (polyvinylidene fluoride), and combinations thereof.
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)
  • ECTFE ethylene chlorotrifluoroethlyene
  • PVDF polyvinylidene fluoride
  • electrical insulation 113, 123, 133 and 143 can be formed of a foamed polymer.
  • the foamed polymer can exhibit a foaming level in a range of about 20% to about 60%, about 20% to about 70%, or about 30% to about 60%.
  • the foamed polymer can comprise a plurality of cellular structures (schematically depicted as circles) characterized by a size in a range of about 0.0005 inches to about 0.003 inches or about 0.001 inches to about 0.002 inches.
  • at least about 60%, at least about 70%, or at least about 80% of the cellular structures are closed cells.
  • two optical fibers 151 and 152 are disposed within the channel 150.
  • the optical fibers 151, 152 can be a single- mode or a multi-mode optical fiber for transmission of optical radiation (e.g., radiation at telecommunications wavelengths, e.g., at 1550 nm) from a proximal end of the cable to its distal end.
  • the optical fibers 151, 152 are enclosed within a buffer tubes 153a and 153b.
  • the buffer tubes 153a and 153b can be formed of any suitable polymer.
  • the buffer tube can be formed of a fluoropolymer, such as a perfluoropolymer.
  • suitable materials for foaming the buffer tubes include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), PVDF (polyvinylidene fluoride), and combinations thereof.
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene te
  • a tape 1 can enclose the electrical conductors and/or the optical fibers.
  • the tape 1 can be formed of a solid or foamed polymeric material, such as the polymers discussed above.
  • a jacket 105 surrounds the separator 101 and the transmission media disposed in the channels provided by the separator 101.
  • the jacket 105 can be formed using any suitable polymer.
  • suitable polymeric materials include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), PVDF (polyvinylidene fluoride), and combinations thereof.
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene tetrafluoroethylene or (poly(ethylene
  • the jacket 105 can have an internal diameter equal to or less than about 0.4 inches (about 10 mm).
  • the internal diameter of the jacket 105 can be in a range of about 0.24 inches (6 mm) to about 0.32 inches (8 mm) or in a range of about 0.24 inches (6 mm) to about 0.27 inches (7 mm).
  • the thickness of the jacket 105 can be from about 0.005 inches (0.127 mm) to about 0.015 inches (0.381 mm), or about 0.007 inches (0.18 mm) to about 0.010 inches (0.25 mm).
  • a jacket surrounding the separator and the transmission media can be formed of a foamed polymeric material.
  • FIG. 3 schematically depicts a communications cable 100' that is similar to the communications cable 100 discussed in connection with FIGS. 1 and 2 except that the communications cable 100' includes a foamed jacket 105'. More specifically, similar to the communications cable 100, the communications cable 100' includes the foamed separator 101, which provides five channels 110, 120, 130, 140, and 150. The twisted pairs of electrical conductors 111, 121, 131, and 141 are disposed, respectively, in the channels 110, 120, 130, and 140. Each twisted pair can carry electrical data, power, or combinations thereof.
  • the electrical conductors of the twisted pairs can have a gauge (AWG) in a range of about 18 to about 28.
  • the electrical insulations 112, 122, 132, and 142 surround the twisted pairs 111, 121, 131, and 141.
  • the optical fibers 151 and 152 are disposed within the channel 150.
  • the jacket 105' is formed of a foamed polymeric material.
  • the jacket 105' can be formed of a foamed fluoropolymer, e.g., a foamed perfluoropolymer.
  • fluoropolymers can include, without limitation, MFA (polytetrafluoroethylene-perfluoromethylvinylether), FEP (fluorinated ethylene propylene), PFA (perfluoroalkoxy), PVF (polyvinyl fluoride), ETFE (ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)), ECTFE (ethylene chlorotrifluoroethlyene), PVDF (polyvinylidene fluoride), and combinations thereof.
  • MFA polytetrafluoroethylene-perfluoromethylvinylether
  • FEP fluorinated ethylene propylene
  • PFA perfluoroalkoxy
  • PVF polyvinyl fluoride
  • ETFE ethylene tetrafluoroethylene or (poly(ethylene-co-tetrafluoroethylene)
  • ECTFE ethylene chlorotrifluoroethlyene
  • PVDF polyvinylidene fluor
  • the foamed jacket 105' can exhibit a foaming level in a range of about 20% to about 60%, about 20% to about 70%, or about 30% to about 60%.
  • the foamed jacket can comprise a plurality of cellular structures (herein depicted schematically by a plurality of small circles distributed through the jacket) characterized by a size in a range of about 0.0005 inches to about 0.003 inches or about 0.001 inches to about 0.002 inches.
  • at least about 60%, at least about 70%, or at least about 80% of the cellular structures are closed.
  • the foamed jacket 105' can provide certain advantages. For example, by forming the jacket of a foamed polymeric material, the amount of flammable material in the communications cable can be reduced. Further, the foamed jacket helps dissipate the heat generated inside the cable to the external environment.
  • the thickness of the jacket can be, for example, in a range of about 0.005 inches to about 0.015 inches, though other thicknesses may also be utilized.
  • FIG. 4 schematically depicts another embodiment 100" of a communications cable according to an embodiment of the present teachings, which is similar in all respects to the communications cable 100' discussed above in connection with FIG. 3, except that in this embodiment, each of the electrical conductors of the twisted pairs has a foamed insulation. More specifically, twisted pairs of electrical conductors 111 ', 12 , 13 , and 141 ' are disposed, respectively, in the channels 110, 120, 130, and 140.
  • Each electrical conductor of each twisted pair includes a foamed insulation.
  • the twisted pair 111 ' includes two electrical conductors 111 'a and l l l 'b, where the electrical conductor 111 'a includes a foamed insulation 113a and the electrical conductor l l l 'b includes a foamed insulation 113b.
  • the twisted pair 121 ' includes electrical conductors 121 'a and 121 'b having, respectively, foamed insulations 122'a and 122'b.
  • the twisted pairs 131 ' includes electrical conductors 131 'a and 131 'b having, respectively, foamed insulations 132'a and 132'b
  • the twisted pair 141 ' includes electrical conductors 141 'a and 141 'b having, respectively, foamed insulations 142 'a and 142'b.
  • the foamed insulation can have a foaming level in a range of about 20% to about 60%, about 20% to about 70%, or about 30% to about 60%.
  • the foamed polymeric material can comprise a plurality of cellular structures (depicted schematically herein by a plurality of circles distributed within the insulation) characterized by a size in a range of about 0.0005 inches to about 0.003 inches or about 0.001 inches to about 0.002 inches.
  • at least about 60%, at least about 70%, or at least about 80%, of the cellular structures are closed.
  • foamed insulation for the electrical conductors in the communications cable 100" can provide certain advantages. For example, it reduces the amount of potentially flammable material inside the cable, and it can in some cases help with heat management by facilitating the dissipation of heat generated in the electrical conductor.
  • the jacket 105' has an inner diameter less than about 0.4 inches, e.g., in a range of about 0.24 inches to about 0.4 inches.
  • the bufferings of the fiber optics disposed in the communications cable can also be formed of a foamed polymeric material, such as fluoropolymer materials.
  • a foamed polymeric material such as fluoropolymer materials.
  • fluoropolymer materials are those discussed above.
  • FIG. 5 schematically depicts such an embodiment 1000, which is similar to the communications cable 100" discussed in connection with FIG. 4, except that in this embodiment the fiber optic bufferings are formed of a foamed polymer.
  • the communications cable 1000 includes two fiber optics 151 and 152 disposed in one of the channels provided by the separator 101.
  • the fiber optic 151 includes a foamed buffering 152' and the fiber optic 152 includes a foamed buffering 153'.
  • the foaming level of the foamed bufferings can be, for example, in a range of about 20% to about 70%, though other foaming levels can also be employed.
  • a variety of known techniques can be employed to fabricate a communications cable according to the present teachings, such as the embodiments discussed above.
  • the foaming of various components of the communications cable can be made using chemical foaming and/or gas-injection foaming techniques.
  • the compositions and methods disclosed in U.S. Patent Nos. 7,968,613, 8,278,366, 8,318,819, 8,877,823, and 8,912,243, each of which is herein incorporated by reference in its entirety can be employed to foam various components of a communication cable according to the present teachings, such as the separator, the jacket, the wire insulation, etc.
  • a communications cable according to the invention provides a number of advantages. For example, it allows the use of different transmission media within the same cable. In addition, it allows transmission of not only data but also electrical power. In addition, a communication cable according to the teachings of the invention allows efficient management of heat generated within the cable.
  • one or more components of the cable e.g., a separator used for providing channels in which transmission media are disposed and/or a jacket of the cable, are formed of foamed polymers (e.g., foamed fluoropolymers), which allow the heat generated within the cable to be efficiently dissipated.
  • foamed polymers e.g., foamed fluoropolymers
  • the efficient management of the heat generated within the cable in turn allows a compact construction of the cable.
  • the inner diameter of the cable jacket can be less than about 0.4 inches.
  • FIG. 7 shows temperatures recorded by the thermocouples as a function of time for different currents flowing through each cable.
  • FIG. 8 shows the equilibrium temperatures recorded by the thermocouples for this cable bundle. This cable bundle showed a temperature rise of greater than 60 °C for an ambient temperature of 45 °C and a current of 0.5 amperes flowing through each cable, thus not meeting the temperature rating for the U.L. requirement.
  • a bundle of 192 cables each including 4-twisted pairs of copper wires disposed in an LSPVC jacket was tested.
  • the cables were manufactured using well known extrusion techniques.
  • Each copper wire was selected to have a 23 AWG and was insulated with a two- layer insulation formed via coextrusion of polyolefin and FEP.
  • the cables did not include a separator for separating different twisted pairs from one another.
  • FIG. 9 shows temperatures recorded by the thermocouples as a function of time for different currents flowing through each cable.
  • FIG. 10 shows the equilibrium temperatures recorded by the thermocouples for this cable bundle.
  • This cable bundle also showed a temperature rise of greater than 60 °C for an ambient temperature of 45 °C and a current of 0.5 amperes flowing through each cable, thus not meeting the temperature rating for the U.L. requirement.
  • a bundle of 192 cables each including 4-twisted pairs of copper wires disposed in a jacket formed of FEP was tested.
  • the cables were manufactured using well known extrusion techniques.
  • Each copper wire was selected to have a 23 AWG and was insulated with an insulation layer formed of FEP.
  • Each cable further included a crossweb formed of FEP providing separate channels in each of which one of the twisted pairs was disposed.
  • FIG. 11 shows the temperatures recorded by the thermocouples as a function of time for different currents flowing through each cable.
  • FIG 12 shows the equilibrium temperatures recorded by the thermocouples. The data shows that this cable bundle exhibited much enhanced thermal properties relative to the previous two cables. IV. All foamed FEP insulation, crossweb and jacket
  • a bundle of 192 cables each including 4-twisted pairs of copper wires disposed in a jacket formed of foamed FEP was tested.
  • the cables were manufactured using well known extrusion techniques.
  • Each copper wire was selected to have a 23 AWG and was insulated with an insulation layer formed of foamed FEP.
  • Each cable further included a crossweb formed of foamed FEP providing separate channels in each of which one of the twisted pairs was disposed.
  • the foaming of the insulation, crossweb and the jacket was achieved via chemical foaming using talc.
  • FIG. 13 shows the temperatures recorded by the thermocouples as a function of time for different currents flowing through each cable.
  • FIG 14 shows the equilibrium temperatures recorded by the thermocouples. This cable exhibited acceptable temperature rise up to 0.9 amperes.
  • a bundle of 192 cables each including 4-twisted pairs of copper wires disposed in a jacket formed of foamed MFA was tested.
  • the cables were manufactured using well known extrusion techniques.
  • Each copper wire was selected to have a 23 AWG and was insulated with an insulation layer formed of foamed MFA.
  • the cable further included a crossweb formed of foamed MFA providing separate channels in each of which one of the twisted pairs was disposed.
  • the foaming of the insulation, crossweb and the jacket was achieved via chemical foaming using talc.
  • FIG. 15 shows the temperatures recorded by the thermocouples as a function of time for different currents flowing through each cable.
  • FIG 16 shows the equilibrium temperatures recorded by the thermocouples. This cable bundle exhibited acceptable temperature rise up to 1 ampere of current through each cable, the maximum current that was applied to the cables.
  • the data presented in FIG. 17 shows that the gauge of the copper wires can have a significant impact on the temperature rise within a cable bundle as a function of current flowing through the cables.
  • the data for a cable bundle with copper wires having a gauge of 23 AWG corresponds to the data for the cable bundles discussed above in Example 1.
  • the data for the other gauges were obtained via extrapolation of the 23 AWG data based on the Ohmic resistance of the copper conductors using the following relation:
  • T AWG indicates theoretically extrapolated change in temperature (relative to ambient temperatru)
  • R AWG represents the Ohmic resistance of the wire used in the cable for which temperature extrapolation is desired
  • T 23AWG represents measured temperature change for a cable bundle in which the copper wires have a gauge of 23 AWG
  • R23AWG represents the Ohmic resistance of a copper wire having a gauge of 23 AWG.

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Abstract

Selon un aspect, la présente invention concerne un câble de communication, qui comprend un séparateur de support fournissant une pluralité de canaux pour recevoir des supports de transmission, ledit séparateur de support comprenant un premier matériau polymère, au moins une fibre optique disposée dans l'un desdits canaux, au moins un conducteur électrique apte à porter au moins environ 10 watts d'énergie électrique disposée dans un autre desdits canaux, une isolation recouvrant au moins partiellement ledit conducteur électrique, une gaine entourant ledit séparateur de support et ledit support de transmission, ladite gaine comprenant un second matériau polymère. Dans certains modes de réalisation, les premier et second matériaux polymères peuvent être le même matériau, et dans d'autres modes de réalisation, ils peuvent être différents matériaux.
PCT/US2017/054970 2016-10-03 2017-10-03 Compositions pour mélange, traitement par fusion et extrusion de mousse polymère et polymères cellulaires WO2018067590A1 (fr)

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