A CABLE CHANNEL FILLER AND CABLE CONTAINING THE SAME
FIELD of the INVENTION
The present invention relates to a cable channel filler and a cable having the
channel filler. More particularly the present invention relates to a channel filler
having a plurality of cable holding pockets with each pocket having an channel
opening having a channel width that is less than the diameter of the envelope area
of a cable or a twisted pair cable that to be placed in each pocket. The cable that
has our channel filler has a core that includes our channel filler which has a
plurality of cables in its pockets and which are separated a predetermined distance
from each other in the channel filler.
BA CKGROUND of the INVENTION
The most popular fillers are generally based on a circular cross-section wherein
each pocket generally has a cross-sectional area that is greater than the cross-
sectional envelope area of the twisted pair cable that is to be placed in the pocket,
and a pocket channel opening width that is equal to or greater than the diameter of
the envelope area of the cable(s) in the pocket.
SUMMARY of the INVENTION
Our channel filler has a plurality of longitudinally extending segmented tubular
pockets each with a longitudinally extending channel opening. The width of the
channel opening for each of the pockets is less than a cable envelope diameter of
the cable to be held in the pocket. The channel filler pockets allow holding the
cables in the pockets in a fixed relationship to each other. This provides good
dimension stability for each cable(s) within the channel filler.
For instance, with the preferred construction of our channel filler, each
segmented tubular pocket is sized to the cable it is to carry. Thus, the diameter
of the pocket is substantially equal to the diameter of the cable envelope that is
in the pocket and the width of the channel opening is equal to the cable
envelope diameter minus the maximum allowable cable compression distance.
This construction holds the cable in the pocket in place and generally provides
dimensional stability between the various cables in the pockets. Also, the
pockets can be spaced in such a way to provide appropriate spacing between
signal carrying cables to provide good signal characteristics such as
impedance, crosstalk, capacitance, etc.
A communication cable manufactured using the channel filler of our invention
generally has a cable such as a twisted pair cable in each pocket. Then the
cable containing channel filler is shielded and jacketed, just jacketed or any
other desired cable construction that would benefit from the use of our
elongated channel filler.
Therefore, it is an object of the present invention to provide a cable channel
filler having a longitudinally extending channel filler body having a plurality
of spaced longitudinally extending open pockets, with the pockets being sized
to hold a cable therein having a cable envelope diameter, and each of the
pockets having a channel opening extending from the pocket and the channel
opening having an opening width less than the envelope diameter.
It is still another object of the present invention to provide a cable channel
filler having a longitudinally extending channel filler having a four spaced,
parallel longitudinally extending open pockets for separating four twisted pair
cables, a cross-section of the channel filler having a first axis and a second
axis, the first axis being substantially perpendicular to the second axis,
a first pair of pockets being diametrically spaced from each other and being on
the first axis, a second pair of pockets being diametrically spaced from each
other and being on the second axis, each of the first pair of pockets having
substantially the same cross-sectional area, each of the second pair of pockets
having substantially the same cross-sectional area, the first pockets having a
depth greater than a depth equal to or greater than a first cable envelope
diameter of a first twisted pair cable to be place in the first pockets, and a
pocket diameter about equal to the first cable envelope diameter,
the width of the first pocket opening being substantially equal to the first cable
envelope diameter minus a maximum allowable compression distance of the
first twisted pair cable, the second pockets having a depth greater than a depth
equal to or greater than a second cable envelope diameter of a second twisted
pair cable to be place in second pockets, and a pocket diameter equal to about
the second cable envelope diameter, and the width of the second pocket
opening being substantially equal to the second cable envelope diameter minus
a maximum allowable compression distance of the second twisted pair cable.
It is still a further object of the present invention to provide a communication
cable having a cable core surrounded by a jacket, the cable core having a
longitudinally extending channel filler having four parallel spaced,
longitudinally extending open pockets for separating four twisted pair cables,
a cross-section of the channel filler having a first axis and a second axis,
the first axis being substantially perpendicular to the second axis, a first pair of
pockets being diametrically spaced from each other and being on the first axis,
a first twisted pair cable being in each of the first pair of pockets,
a second pair of pockets being diametrically spaced from each other and being
on the second axis, a second twisted pair cable being in each of the second pair
of pockets, each of the first pair of pockets having substantially the same
cross-sectional area, each of the second pair of pockets having substantially
the same cross-sectional area, each of the first pair of pockets having a depth
greater than a depth equal to or greater than a first cable envelope diameter and
a pocket diameter about equal to said first cable envelope diameter,
the width of said first pocket opening being substantially equal to the first
cable envelope diameter minus a maximum allowable compression distance of
said first twisted pair cable, each of the first pair of pockets having a depth
greater than a depth equal to or greater than a first cable envelope diameter of
the first twisted pair cable and a pocket diameter about equal to the first cable
envelope diameter, and the width of the first pocket opening being
substantially equal to the first cable envelope diameter minus a maximum
allowable compression distance of the first twisted pair cable.
The present invention and the advantages thereof will become more apparent
upon consideration of the following detailed description when taken in
conjunction with the accompanying drawings
BRIEF DESCRIPTION OF THE DRA WINGS
FIG. 1 is an enlarged perspective view of the elongated channel filler of our
invention.
FIG. 2 is a cross-sectional view taken along lines 2-2 of FIG. 1.
FIG. 3 is an enlarged partial cross-sectional plan view of FIG. 1.
FIG. 4 is an enlarged cross-sectional view of a twisted pair cable to be used
with the channel filler of FIG. 1.
FIG. 5 is perspective view of a cable utilizing our elongated channel filler.
FIG. 6 is an enlarged cross-sectional view taken along lines 6-6 of FIG. 5.
FIG. 7 is a perspective view of another cable utilizing our elongated channel
filler.
FIG. 8 is a perspective view of still another cable utilizing our elongated
channel filler.
FIG. 9 is an enlarged cross-sectional view of a further cable utilizing our
elongated channel filler.
FIG 10 is an enlarged cross-sectional view of an alternative channel filler in
accordance with our invention.
FIG. 11 and 12 are illustrative views of the axis of a pocket twisted about the
axis of our channel filler.
DETAILED DESCRIPTION
The following description taken in conjunction with the drawings will further
explain the inventive features of our elongated channel filler and cables
utilizing our elongated channel filler.
Referring to FIGS. 1-3, our elongated channel filler 20 has along its cross-
sectional plane a first axis 21 and a second axis 22. In the embodiment shown,
the channel filler has four pockets 23. 24, 26, and 27. The first axis 21 is
perpendicular to the second axis 22. The pockets 23 and 24 are centered on
the first axis 21 and pockets 26 and 27 are centered on the second axis 22.
The pockets 23 and 24 have the same cross-sectional area as each other and
pockets 26 and 27 have the same cross-sectional area as each other. If desired,
they can all have the same or different cross-sectional area depending on the
cables that are to be placed in the pockets. This is also of the case concerning
the pockets. There can be two or more pockets and more than four pockets.
The spacing between the pockets will depend on what cables are to be placed
in the pockets.
Referring to Fig. 3, there is shown an enlarged portion of the channel filler 20
to illustrate the similar characteristic's of all of the pockets. Each of the
pockets is a segmented tube having a diameter 28. The circular wall portion
29 of each pocket extends for greater than 180° . A spaced pair of
longitudinally extending walls 30, extend from the segmented portion of the
tube to provide a longitudinally extending rectangular channel opening 31. The
width 32, of the channel opening 31, of each pocket is less than the diameter
of the cable envelope in the pocket and equal to or greater than the envelope
diameter (i.e., 44, Fig. 4) minus the maximum allowable compression
distance of the cable to be placed in the pocket.
Each of the pockets has a depth 33, which extends from the filler envelope 34,
to the base of the pocket. The depth 33 is equal to or greater than the diameter
of the cable envelope to be placed in the pocket.
The cross-sectional area of each of the pockets 23, 24, 26 and 27 is shown as
being greater than the cross-sectional area of the twisted pair cable envelope
43 (Fig. 4). The cross-section area of the pocket shown in Fig. 3 is defined
by walls 29, 30 and the envelope 34. The cross-section area of each pocket
can be as small as the cross-sectional area of the envelope of the cable to be
placed therein.
The preferred material for the elongated channel filler is any suitable polymer
or copolymer depending on the needs of the user for crush resistance, breaking
strength, gel fillings, safety, and the need for flame and smoke resistance. In
many applications the material will be a polyethylene.
FIG. 4 illustrates a cross-section of a twisted pair cable 40 having a pair of
conductors 41, with appropriate insulation 42. The cable 40 has a circular
envelope 43. The diameter 44 of the circular envelope 43 is approximately
equal to the diameter of its respective pocket.
The conductors 41 , for the twisted pair cables are generally copper, tinned
copper, or any other appropriate conductor. The conductor insulation is
a foamed on non-foamed insulation of polyethylene, polypropylene,
fluorinated ethylene propylene, tetrafluoroethylene, polyvinyl chloride, etc.
The twisted pairs can be individually shielded if desired and in some cases,
some or all of the pockets can be used to hold bundles of fiber-optic cables
along with other types of cables.
Referring to FIGS. 5 and 6, there is shown a cable 50, having as its core our
elongated channel filler 20 with first pair of diametrically opposed pockets 23
and 24 each containing a twisted pair cable 52, having a long lay of about 0.5
in. to about 1.5 in. and with second pair of pockets 26 and 27, each containing
a twisted pair cable 53, having a short lay of about 0.25 in. to about 0.75 in.
The twisted pair cables 52 and 53 are the same construction as the twisted pair
cable 40. The core which contains the elongated channel filler 20, and the cables 52 and 53, in the pockets as shown in FIGS. 5 and 6, is surrounded by a
jacket 54 which was extruded thereover. The jacket 54 can be any suitable
jacket material normally utilized such as foamed on non-foamed polyvinyl
chloride, fluorinated polymers, polyethylene, the flame retardant compositions,
etc.
Generally for a communication cable having four twisted pair cables, all of the
same size with or without different lays, it can use our channel filler having a
diameter of about 0.150 inches to about 0.350 inches and channel pockets
having a diameter of about 0.050 inches to about 0.120 inches. The size of the
twisted pair cables are generally about 24 AWG. to about 22 AWG. For other
applications, the channel filler will have as many pockets as needed. For
instance, in a four pair cable, the channel filler will have four pockets, in a 10
pair cable, the channel filler would have 10 pockets.
Referring to FIG. 7 there is shown a cable 60 having the same construction as
the cable 50 except it has shield 61 wrapped around the core. The shield 61
may be any suitable shield such as an aluminum tape, BELDFOIL, DUOFOIL,
or any suitable metal tape. The shield 61 is wrapped around the core and then
the jacket 54 is extruded around the shield. In a known manner, a drain wire
(not shown ) can be inserted into the cable 60 if desired.
Referring to FIG. 8, there is shown a cable 65 using a drain wire 66. The cable
65 has the same construction as the cable 60 except in this embodiment, the drain wire 66 is helically wrapped around the lateral shield 61 for the dual
purpose of being a drain wire and to hold the lateral shield 61 in place. The
jacket 54 is then extruded over the shield 61 and drain wire 66.
Referring to FIG. 9, there is shown still another cable 70 having the same
construction as the cable 60 except in this embodiment, there is a channel filler
71 constructed the same a channel filler 20 except channel filler 71 has a
central longitudinally extending filler or strength member 72. This member 72
can be of any desired material and is generally a polyethylene rod.
The drain wire 66, is generally made with tinned copper, tinned aluminum, etc.
Referring to FIG. 10, there is shown a cable filler 75 with an alternative
structure. The cable filler shown has four longitudinally extending open
pockets 76. Each of the pockets 76 have a pair of spaced side walls 77 and 78
extending outwardly from the ends of an arcuate or convex bottom wall 79
towards the outer circumference 80 of the filler 75. The filler 75 has a central
axis 81, a rod central section 82 and an outer circumference 80. The outer
walls of the rod 82 being the pocket bottom wall 79. The pocket openings are
formed by the channel filler outer circumference wall 80 and have an opening
width 83. The opening width 83 is less than the diameter of the cable
envelope that is to be placed in the pocket i.e. 43 (FIG. 4 ). As noted above,
the smallest width of the opening 83 is the cable envelope diameter minus a
maximum allowable compression distance of said cable. Each pocket has a
depth 84 which extends perpendicular through the center 85 of the pocket
opening width 83 to the filler circumference 80. The depth 84 is equal to or
greater than the diameter of the cable envelope i.e. 43 (FIG. 4). The width
must be sufficiently wide so as not to crush the cable therein therefore, the
cross-sectional area of the pocket 76 when measured to the circumference 81
is greater than the cross-sectional area of the cable envelope i.e. 43 (FIG. 4).
As noted above, with regard to our channel filler 20, the channel filler 75 will
also have as many pockets as needed i.e. a 10 pair cable channel filler would
have 10 pockets.
The longitudinally extending pockets of our channel fillers 20 and 75 may
have their longitudinal axis 35 or the longitudinally extending center 85
extending parallel to their respective longitudinal axis 25, 81 of their
respective fillers 20 and 75 or twisted there around as illustratively shown by
FIGS 1 1 and 12.
Although I have described our preferred elongated channel filler as having
four pockets, the channel filler may have more or less pockets and the pockets,
as noted above, are preferably sized to the cables they are to hold. The pockets
can hold different types of cables as mentioned above and it may have other
alternative structures as referenced by but not limited to FIG 10.
It will, of course, be appreciated that the embodiments which have just been
described have been given by way of illustration, and the invention is not
limited to the precise embodiments described herein. Various changes and
modifications may be effected by one skilled in the art at without departing
from the scope or spirit of the invention as defined in the appended claims.