Method for forming power over ethernet twisted pair communication cables

A method for forming a communications cable, the method comprising:

• providing four pairs of individually insulated conductors, the respective conductors of a first and third pair included in the four pairs each having a diameter of at least 0.0254 inches and the respective conductors of a second and fourth pair included in the four pairs each having a diameter of at least 0.0245 inches;
• determining respective twist lays for each of the four pairs to result in the communications cable satisfying Telecommunications Industry Association standard ANSI/TIA 568-C.2 for Category 6A cable, wherein determining respective twist lays comprises:
• determining a first twist lay for a first of the plurality of pairs between 0.292 inches and 0.357 inches;
• determining a second twist lay for a second of the plurality of pairs between 0.377 inches and 0.461 inches;
• determining a third twist lay for a third of the plurality of pairs between 0.311 inches and 0.380 inches;
• and
• determining a fourth twist lay for a fourth of the plurality of pairs between 0.412 inches and 0.504 inches;
• respectively twisting the conductors of each of four pairs to have the determined twist lays, wherein the four twisted pairs are capable of transmitting 100 Watts at 1.0 ampere per pair over a distance of 100 meters with at least 88% efficiency;
• and
• forming a jacket around the plurality of twisted pairs.

A method for forming a Category 6A communications cable, the method comprising:

• providing a plurality of individually insulated conductors, wherein a first portion of the plurality of conductors each have a diameter of at least 0.0254 inches and a second portion of the plurality of conductors each have a diameter of at least 0.0245 inches;
• forming four twisted pairs from the plurality of conductors including a first and third pair from the first portion of the plurality of conductors and a second and fourth pair from the second portion of the plurality of conductors, wherein each of the four pairs has a twist lay selected to result in the communications cable having a propagation delay skew of less than 45 nanoseconds per one hundred meters and a direct current resistance unbalance between every two of the plurality of twisted pairs of less than one hundred milliohms per one hundred meters;
• and
• forming a jacket around the four twisted pairs.