Communication wire

Abstract

The present invention relates to an improved insulated conductor with allow dielectric constant and reduced materials costs. Apparatuses methods of manufacturing the improved insulated conductors are also disclosed.

What is claimed is:  
     
         1 . A wire comprising: 
 a conductor extending along a longitudinal axis, an insulation surrounding the conductor and at least one channel in the insulation extending generally along the longitudinal axis to form an insulated conductor.    
     
     
         2 . The wire of  claim 1 , wherein the insulated conductor has an overall dielectric constant of less than 2.0.  
     
     
         3 . The wire of  claim 1 , wherein the channel contains a material that has a dielectric constant that differs from a dielectric constant of the insulation.  
     
     
         4 . The wire of  claim 3 , wherein the channel contains air.  
     
     
         5 . The wire of  claim 1 , wherein the insulation includes a plurality of channels.  
     
     
         6 . The wire of  claim 5 , wherein no one of the plurality of channels has a cross-sectional area greater than about 30% of a cross-sectional areas of the insulation.  
     
     
         7 . The wire of  claim 1 , wherein an outer peripheral surface of the conductor forms one side of the at least one channel.  
     
     
         8 . The wire of  claim 1 , wherein the insulation fully surrounds the at least one channel.  
     
     
         9 . The wire of  claim 1 , wherein an outer peripheral surface of the conductor forms one side of at least a first channel and the insulation fully surrounds at least a second separate channel.  
     
     
         10 . The wire of  claim 1 , wherein the at least one channel has a cross-sectional area of at least 2.0×10 −5  in 2 .  
     
     
         11 . The wire of  claim 1 , further comprising an outer jacket surrounding the insulation.  
     
     
         12 . The wire of  claim 1 , wherein the insulated conductor has a diameter of less than about 0.042 in.  
     
     
         13 . The wire of  claim 12 , wherein the insulation has a thickness of less than about 0.010 in.  
     
     
         14 . The wire of  claim 1 , wherein two insulated conductors are twisted together to form a twisted pair.  
     
     
         15 . The wire of  claim 14 , wherein the delay skew is no greater than 15 ns between the insulated conductors.  
     
     
         16 . The wire of  claim 14 , further including a plurality of twisted pairs.  
     
     
         17 . The wire of  claim 16 , further comprising an outer jacket surrounding the twisted pairs.  
     
     
         18 . The wire of  claim 16 , wherein each twisted pair includes a shield.  
     
     
         19 . The wire of  claim 16 , wherein the delay skew is no greater than 15 ns between individual twisted pairs.  
     
     
         20 . The wire of  claim 1 , wherein the conductor is solid copper.  
     
     
         21 . The wire of  claim 1 , further comprising a secondary insulation surrounding the conductor.  
     
     
         22 . The wire of  claim 1 , wherein the insulated conductor passes a test selected from the group consisting of NFPA 255, NFPA 259, NFPA 262 or combinations thereof.  
     
     
         23 . The wire of  claim 22 , wherein the insulated conductor passes all of NFPA 255, NFPA 259 and NFPA 262.  
     
     
         24 . The wire of  claim 1 , wherein the insulated conductor generates at least 10% less smoke when burned according to a UL 910 Steiner Tunnel test when compared to an insulated conductor without channels in its insulation.  
     
     
         25 . The wire of  claim 1 , wherein the insulated conductor spreads flame at a rate at least 10% slower when burned according to a UL 910 Steiner Tunnel test when compared to an insulated conductor without channels in its insulation.  
     
     
         26 . An insulation for a wire comprising: 
 an elongated body of a polymeric material having a bore adapted to house a conductor, wherein at least one channel is located in the elongated body.    
     
     
         27 . The insulation of  claim 26 , wherein the channel has a cross-sectional area of at least 2.0×10 −5  in 2 .  
     
     
         28 . The insulation of  claim 26 , wherein the at least one channel is open to the bore.  
     
     
         29 . The insulation of  claim 26 , wherein the at least one channel is surrounded by the thermoplastic material.  
     
     
         30 . An insulated conductor comprising: 
 a conductor having a length; and    an insulation surrounding the conductor and having substantially the same length as the conductor,    wherein the insulation includes at least one channel that extends generally the length of the conductor.    
     
     
         31 . A wire with a minimized delay skew, comprising: 
 a first twisted pair having a first signal speed and having a channel in its insulation with a first predetermined cross-sectional area; and    a second twisted pair having a second signal speed and having a channel in its insulation with a second predetermined cross-sectional area,    wherein each cross-sectional area is selected to match the first signal speed to the second signal speed.    
     
     
         32 . The wire of  claim 30 , wherein the first signal speed differs from the second signal speed by less than about 15 ns.