High performance support-separator for communications cable

An interior support-separator for a communications cable extending along a longitudinal length of said communications cable, comprising;

• an external radial and axial surface, said interior support having a central region, said central region also extending along a longitudinal length of said interior support;
• said interior support comprising at least one anvil shaped core support-separator section radially and axially defined by said central region;
• each of said anvil shaped core support-separator sections defining one or more clearance channels that also extend along said longitudinal length of said at least one anvil shaped core support-separator sections and;
• each of said anvil-shaped core support-separator sections comprise clearance walls of said one or more clearance channels defined by a circular geometry that includes a flap-top allowing for opening or closing said exterior radial and axial surfaces of said channel walls of said one or more clearance channels.

An interior support-separator for a communications cable assembly extending along a longitudinal length of

• said communications cable, comprising;
• an external radial and axial surface, said
• interior support-separator having a central region, said central region also extending along a longitudinal length of said interior support;
• said interior support comprising at least one anvil shaped core support-separator section radially and axially defined by said central region;
• each of said anvil shaped core support-separator sections defining one or more clearance channels that also extend along said longitudinal length of said anvil shaped core support-separator sections, and;
• each of said anvil-shaped core support-separator sections comprise clearance walls of said one or more clearance channels defined by a circular geometry that includes a flap-top allowing for opening or closing said exterior radial and axial surfaces of said channel walls of said one or more clearance channels wherein said anvil shaped core support-separator sections are themselves twisted to a specified lay length.

A method for producing a high performance communications cable by introducing an interior anvil-shaped core support-separator section or sections with an external radial and axial surface with a longitudinal length, said external radial and axial surfaces having a central region extending along a longitudinal length of an interior support with one or more clearance channels and;

• each of said anvil-shaped core support-separator sections comprise clearance walls of said one or more clearance channels defined by a circular geometry that includes a flap-top allowing for opening or closing said exterior radial and axial surfaces of said channel walls of said one or more clearance channels into a jacket of said cable by;
• passing a plurality of transmission conductors within said one or more clearance channels of said interior support-separator through a first die that aligns the plurality of transmission conductors with surface features of said internal support allowing for intentional twisting of said conductors,
• forcing each of said plurality of conductors into a proper clearance channel of said interior support-separator where said one or more clearance channels are optionally closed by single or double flap-tops, thereby maintaining a spatial relationship between each of said transmission conductors by use of a second die,
• heating said second die allowing for closing of said exterior surface of said one or more clearance channels,
• taping and twisting said interior support allowing for closing of said exterior surface of said one or more clearance channels, and;
• jacketing said interior support containing each of said conductors within said one or more clearance channels.