# US 2025/0157700 A1 · Layered profile insulation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2025/0157700 A1 - Document ID: US20250157700A1 - Status: Published application - Kind: A1 - Application number: 18/508,365 - Filed: 2023-11-14 - Published: 2025-05-15 - Earliest claimed: 2023-11-14 - Assignees: Leviton Manufacturing Co., Inc. - Applicants: Leviton Manufacturing Co., Inc. - Inventors: Paul Michael Good; Bradley G. Hess; Antoine Cotard - Web page: https://patentgrep.com/patent/US20250157700A1 ## CPC - H01B 17/56: Insulating bodies - H01B 7/0216: {Two layers} - H01B 7/0233: {Cables with a predominant gas dielectric} - H01B 11/002: {Pair constructions} - H01B 11/02: Cables with twisted pairs or quads - H01B 13/141: {of two or more insulating layers} - 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 conductor of a twisted-pair data cable comprises a primary profiled insulation layer formed over a conductive wire, and a second insulation layer formed over the primary profiled insulation layer. This design prevents nesting of the profiled insulation layers of adjacent conductors without the need to back-twist or forward-twist the conductors, thereby maintaining consistent center-to-center distance between the conductors of a twisted pair. Since the second insulation layer prevents nesting between the primary layers regardless of the widths of the troughs of the cross-sectional profile, this configuration also allows for a greater range of width ratios between the peaks and troughs of the cross-sectional profile, which can allow greater freedom in tuning the electrical characteristics of the twisted pair. ## Claims ### Claim 1 A data conductor, comprising: a first insulation layer applied to a conductive wire, wherein the first insulation layer has a profiled cross-sectional shape; and a second insulation layer applied over the first insulation layer. ### Claim 2 (depends on 1) The data conductor of claim 1, further comprising a foam insulation layer between the first insulation layer and the second insulation layer. ### Claim 3 (depends on 1) The data conductor of claim 1, wherein the profiled cross-sectional shape comprises peaks having respective longitudinal axes that are substantially parallel to a longitudinal axis of the conductive wire, and troughs between the peaks. ### Claim 4 (depends on 3) The data conductor of claim 3, wherein the peaks or the troughs are at least one of trapezoidal, rectangular, square, triangular, rounded, arched, or elliptical. ### Claim 5 (depends on 3) The data conductor of claim 3, wherein the second insulation layer is applied to the peaks of the first insulation layer. ### Claim 6 (depends on 1) The data conductor of claim 1, wherein at least one of the first insulation layer or the second insulation layer comprises a foamed insulation material. ### Claim 7 (depends on 1) The data conductor of claim 1, wherein the first insulation layer comprises a first insulation material, and the second insulation layer comprises a second insulation material. ### Claim 8 (depends on 1) The data conductor of claim 1, wherein the second insulation layer has a profiled cross-sectional shape. ### Claim 9 (depends on 1) The data conductor of claim 1, further comprising a third insulation layer layered between the conductive wire and the first insulation layer. ### Claim 10 (depends on 1) The data conductor of claim 1, wherein the data conductor is a component of a twisted pair of data conductors of a data cable. ### Claim 11 A method, comprising: applying a first layer of insulation to a conductive wire, wherein the first layer of insulation comprises a profiled cross-sectional shape; and applying a second layer of insulation over the first layer of insulation to yield an insulated data conductor. ### Claim 12 (depends on 11) The method of claim 11, wherein the profiled cross-sectional shape comprises peaks residing on an outer surface of the first layer of insulation, and troughs formed between the peaks. ### Claim 13 (depends on 12) The method of claim 12, wherein the applying of the second layer of insulation comprises applying the second layer of insulation to the peaks of the first layer of insulation. ### Claim 14 (depends on 11) The method of claim 11, wherein at least one of the first layer of insulation or the second layer of insulation comprises a foamed insulation material. ### Claim 15 (depends on 11) The method of claim 11, further comprising applying a third layer of insulation between the first layer of insulation and the second layer of insulation, wherein the third layer of insulation comprises a foamed insulation material. ### Claim 16 (depends on 11) The method of claim 11, wherein the second layer of insulation comprises a profiled cross-sectional shape. ### Claim 17 (depends on 11) The method of claim 11, further comprising applying a third layer of insulation between the conductive wire and the first layer of insulation. ### Claim 18 (depends on 11) The method of claim 11, wherein the applying of the first layer of insulation and the applying of the second layer of insulation are performed by a same extruder crosshead during a same pass of the conductive wire through the extruder crosshead. ### Claim 19 A conductor of a data cable, comprising: a conductive wire; a first insulation layer having a profiled cross-sectional shape surrounding the conductive wire; and a second insulation layer surrounding the first insulation layer. ### Claim 20 (depends on 19) The conductor of claim 19, wherein the profiled cross-sectional shape comprises peaks having respective longitudinal axes that are substantially parallel to a longitudinal axis of the conductive wire, and troughs formed between the peaks.