Vapor proof high speed communications cable and method of manufacturing the same

A quad cable construction and a method of manufacturing the same are provided for use in communications for a local area network, while offering significant vapor migration and petroleum immersion resistance characteristics. A cable is provided with inner and outer jackets encompassing a helix configuration of insulated signal conductors. A core filler is provided to substantially fill the core and interstices between the insulated signal conductors. The core filler and inner jacket are formed of vapor proof material and bound with the insulated signal conductors in a manner that substantially fills all grooves and crevices around the insulated signal conductors to substantially prevent vapor migration along the cable length. An outer jacket may be provided that is impervious to gas, thereby permitting the cable to be submerged in petroleum for extended periods of time without affecting operation.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the preferred embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, the drawings show embodiments which are presently preferred. It should be understood, however, that the present invention is not limited to the precise arrangements, materials and instrumentality shown in the attached drawings.

FIG. 1 illustrates an enlarged cross-sectional view of a conventional multiple differential pair category 5 cable.

FIG. 2 illustrates an enlarged cross-sectional view of a quad cable formed in accordance with a preferred embodiment of the present invention.

FIG. 3 illustrates an enlarged cross-sectional view of a quad cable formed in accordance with an alternative embodiment of the present invention.

FIG. 4 illustrates an enlarged cross-sectional view of a multiple differential pair category 5 cable formed in accordance with an alternative embodiment of the present invention.

1. A vapor proof cable for carrying high speed data transmissions, the cable comprising:

2. The cable of claim 1, further comprising:

3. The cable of claim 1, further comprising:

4. The cable of claim 1, further comprising:

5. The cable of claim 1, further comprising:

6. The cable of claim 1, further comprising:

7. A vapor proof cable comprising:

8. The vapor proof cable of claim 7 wherein said pulled core filler sealably engages said at least four insulated signal conductors and fills said hollow core along a length of said at least four insulated signal conductors to prevent vapors inside said peripheral material from migrating along said peripheral interstices.

9. The vapor proof cable of claim 7 wherein said pulled core filler forms a seal with inner interstices of said at least four insulated signal conductors preventing vapor migration along a length of said inner interstices of said at least four insulated signal conductors.

10. The vapor proof cable of claim 7 wherein said peripheral material includes inner and outer jackets, said inner jacket having a dielectric constant higher than a dielectric constant of insulation on said at least four insulated signal conductors.

11. The vapor proof cable of claim 7 further including a pressure extruded layer substantially filling interstices between said at least four insulated signal conductors, said pressure extruded layer sealably engaging said at least four insulated signal conductors.

12. The vapor proof cable of claim 7 further including a jacket, wherein said jacket constitutes a pressure extruded PVC inner jacket substantially filling interstices between said at least four insulated signal conductors.

13. The vapor proof cable of claim 7 further including a jacket, wherein said jacket includes an outer nylon layer substantially impervious to gas.

14. The vapor proof cable of claim 7 wherein said pulled core filler is compressed by said at least four insulated signal conductors and substantially filling interstices of said hollow core between said at least four insulated signal conductors.

15. The vapor proof cable of claim 7 wherein said pulled core filler constitutes a cotton core compressed by said at least four insulated signal conductors and filling interstices of said hollow core between said at least four insulated signal conductors.

16. The vapor proof cable of claim 7 wherein said pulled core filler constitutes an aramid yarn core compressed by said at least four insulated signal conductors and filling interstices of said hollow core between said at least four insulated signal conductors.

17. A method of manufacturing a cable, said method comprising:

18. The method of claim 17 further comprising hermetically encasing the at least four insulated signal conductors in a jacket, said filling step preventing vapors, which have entered an interior of the jacket, from migrating in the interior of the jacket along the length of the at least four insulated signal conductors.

19. The method of claim 17 further comprising pressure extruding a compound over the at least four insulated signal conductors to form an inner jacket, the inner jacket having a dielectric constant higher than a dielectric constant of insulation on the at least four insulated signal conductors.

20. The method of claim 17 further comprising pressure extruding an inner layer surrounding the at least four insulated signal conductors to fill the grooves between and about the at least four insulated signal conductors.

21. The method of claim 17 further comprising pressure extruding a PVC compound around the at least four insulated signal conductors to form an inner jacket to fill the grooves between and about the at least four insulated signal conductors.

22. The method of claim 17 further comprising adding an outer nylon jacket that is substantially impervious to gas.

23. The method of claim 17 wherein said pulling step includes pulling and compressing the at least four insulated signal conductors until the vapor proof filler fills the internal grooves between the at least four insulated signal conductors.

24. The method of claim 17 wherein said pulling step includes compressing the at least four insulated signal conductors until the vapor proof filler fills interstices between the at least four insulated signal conductors.

25. A method of manufacturing a cable, comprising:

26. The method of claim 25 wherein said twisting step includes twisting at least four insulated signal conductors into said helix configuration with a hollow core, and further comprising pulling a compressible filament to fill said hollow core.

27. The method of claim 25 further comprising pulling a compressible filament into and filling inner interstices between said at least two insulated signal conductors to block vapor once entering the vapor proof peripheral material from migrating along a length of said inner interstices.

28. A vapor proof cable for carrying high speed date transmissions, the cable comprising:

29. The vapor proof cable of claim 28 wherein said at least two insulated signal conductors include at least four insulated signal conductors twisted in a helix configuration and defining a hollow core, and wherein a compressible filament core fills said hollow core.

30. The vapor proof cable of claim 28 wherein said at least two insulated signal conductors includes at least four insulated signal conductors twisted in a helix configuration, wherein said at least four insulated signal conductors have inner segments defining inner interstices, and wherein a compressible filament core fills said inner interstices to block vapor migration along a length of said inner segments.