# US 2018/0025816 A1 · Process for manufacturing a twisted pair of wires

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- Number: US 2018/0025816 A1
- Document ID: US20180025816A1
- Status: Published application
- Kind: A1
- Application number: 15/214,724
- Filed: 2016-07-20
- Published: 2018-01-25
- Earliest claimed: 2016-07-20
- Assignees: Champlain Cable Corporation
- Applicants: Champlain Cable Corporation
- Inventors: Futsum G. Woldesus; Richard Scott Antic; Solomon Mulugeta; Gary Paul Newton
- Web page: https://patentgrep.com/patent/US20180025816A1

## CPC

- H01B 13/145: {Pretreatment or after-treatment}
- H01B 11/002: {Pair constructions}
- H01B 13/24: by extrusion {(extrusion of cables with plastic material in general B29C48/15)}
- 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})

## Abstract

A method of forming a twisted pair of wires for use with Ethernet-based networks. At least two wires are extruded with a cross-linked polyolefin insulating composition marketed under the registered trademark, EXRAD®. The wires are twisted together with a consistent lay length to form a cable. The cable is irradiated to become thermoset. Electrical properties of the extruded wire are controlled during the extrusion step and concentricity of the wire and surrounding insulation is also monitored and controlled. The cable can be jacketed to provide greater mechanical protection.

## Claims

### Claim 1

A method of forming a twisted pair of wires for use with Ethernet-based networks, the steps comprising:
a) extruding at least two wires with a cross-linked polyolefin insulating composition;
b) twisting together said wires with a consistent lay length to form a cable;
c) irradiating said cable; and
d) thermosetting said cable.

### Claim 2 (depends on 1)

The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein electrical properties of said extruded wire are controlled during said extrusion step (a) and twisting step (b).

### Claim 3 (depends on 1)

The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, further comprising monitoring and controlling concentricity of said wire and surrounding insulation during said extrusion step (a).

### Claim 4 (depends on 1)

The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein said irradiation step (c) is performed by an electron beam using a dosage range from 5 Mrad to 15 Mrad to cross-link the insulation.

### Claim 5 (depends on 1)

The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, the steps further comprising jacketing said cable to provide greater mechanical protection.

### Claim 6 (depends on 1)

The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein said insulating composition comprises a polyolefin based polymer compound.