# US 10,373,740 B2 · Communications cable with improved isolation between wire-pairs and metal foil tape

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- Number: US 10,373,740 B2
- Document ID: US10373740B2
- Status: Granted
- Kind: B2
- Application number: 16/057,307
- Filed: 2018-08-07
- Published: 2019-03-07
- Granted: 2019-08-06
- Earliest claimed: 2017-08-09
- Assignees: Panduit Corp.
- Applicants: Panduit Corp.
- Inventors: Royal O. Jenner; Masud Bolouri-Saransar; Ronald A. Nordin; Paul W. Wachtel; Stephen A. Thwaites; Roy B. Kusuma; James D. Malkemus; Scott M. Brown
- Web page: https://patentgrep.com/patent/US10373740B2

## CPC

- H01B 11/085: {composed of longitudinal tape conductors}
- H01B 11/002: {Pair constructions}
- H01B 11/1008: {Features relating to screening tape per se}
- H01B 13/22: Sheathing; Armouring; Screening; Applying other protective layers (H01B13/32 takes precedence)
- H05K 9/0086: {comprising a single discontinuous metallic layer on an electrically insulating supporting structure, e.g. metal grid, perforated metal foil, film, aggregated flakes, sintering}
- H01B 13/26: by winding, braiding or longitudinal lapping
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS

## Abstract

A communications cable having a plurality of twisted pairs of conductors and various embodiments of a metal foil tapes between the twisted pairs and a cable jacket is disclosed. In some embodiments, a metal foil tape includes a discontinuous metal layer and a polymer layer bonded to the metal layer. Portions of the metal layer and the polymer layer are deformed to form a plurality of dimples, the dimples forming air gaps between the polymer layer and the cable core or a barrier layer if used. The air gaps lower the overall dielectric constant between the metal layer and the cable core, thereby lowering the alien capacitance of the communications cable.

## Claims

### Claim 1

A method for manufacturing a communications cable, comprising:
forming a cable core comprising a plurality of twisted pairs of conductors; and
forming a barrier layer on the cable core;
at a point-of-application step of applying a metal foil tape on the barrier layer, creating dimples by deforming a metal layer and a polymer layer of the metal foil tape; and
after the dimples have been created, applying the metal foil tape onto the barrier layer.

### Claim 2 (depends on 1)

The method of claim 1, wherein the point-of-application step is a cable jacket application step.

### Claim 3 (depends on 2)

The method of claim 2, wherein creating the dimples in the metal foil tape at the cable jacket application step includes creating the dimples at a dimpling station between tape payoff of the metal foil tape prior to a jacket extrusion die.

### Claim 4 (depends on 1)

The method of claim 1, wherein the point-of-application step is a cable stranding step.

### Claim 5 (depends on 4)

The method of claim 4, wherein creating the dimples in the metal foil tape at the cable stranding step includes creating the dimples at a dimpling station between tape payoff of the metal foil tape prior to an application of the metal foil tape onto the barrier layer at a stranding machine.