High performance support-separators for communications cable supporting low voltage and wireless fidelity applications and providing conductive shielding for alien crosstalk

Abstract

The present invention includes a high performance communications cable that provides for reduction or elimination of cross-talk between transmission media in combination with power conductors for wireless fidelity applications and includes one or more core support-separators having various shaped profiles which define a clearance to maintain a spacing and/or channel between the transmission media or transmission media pairs as well as for the power conductors. The core may be formed of a conductive or insulative material to further reduce cross-talk that is comprised of principally polymer blends that include olefin and/or fluoropolymer and/or chlorofluoropolymer based resins with and without inorganic additives. These unique blends offer both flame and smoke suppression while maintaining the characteristics necessary to improve electrical performance and allow for severe cost reduction over conventional separators. These polymers blends can also be utilized for fabricating shielding materials. The specially shaped core support-separators can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extend along the longitudinal length of the communications cable. Alternatively, with no jacket for cable completion, a portion of the separator wherein a thin layer of material can act as a type of skin for future mechanical protection is provided. The specially shaped core support-separators have both a central region as well as a plurality of shaped sections that extend outward from the central region that are either solid or partially solid, foamed or foamed with a solid skin surface.

1 . A high performance communications cable comprising; 
 an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable;    said interior support also having a central region, said central region also extending along a longitudinal length of said interior support of said communications cable;    said interior support comprising one or more outwardly extended shaped portions extended from said central region wherein said central region or other location within said said communications cable provides spacing for extending at least one limited power circuit conductor along said longitudinal length of said communications cable.    
     
     
         2 . The high performance communications cable of  claim 1 , wherein said interior support, outwardly extended portions and said central region simultaneously support said at least one limited power circuit conductor for wireless communications and at least one conductor for wired communications networks.  
     
     
         3 . The high performance communications cable of  claim 1 , wherein said interior support, outwardly extended portions and said central region may be shielded or unshielded.  
     
     
         4 . The high performance communications cable of  claim 1 , wherein said interior support, outwardly extended portions and said central region provide proper spacing and support for meeting IEEE standards 802.3(a), (b), (g) and (h) as well as IEEE standard (a)(f).  
     
     
         5 . The high performance communications cable of  claim 1 , wherein said interior support, outwardly extended portions and said central region provide proper spacing and support for low voltage conductors capable of carrying either AC or DC voltage such that said voltage is in a range of from 5-60 volts with wattages in a range of 5-30 W.  
     
     
         6 . The high performance communications cable of  claim 5 , capable of carrying voltage preferably in a range of from 10-50 volts with wattages in a range of 5-20 W.  
     
     
         7 . The high performance communications cable of  claim 5 , capable of carrying voltage most preferably in a range of from 12-24 volts with wattages no greater than 14 W.  
     
     
         8 . The high performance communications cable of  claim 1 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a conductive inorganic fillers or additives or alternatively metallic additives and optionally including shielding around individual conductor pairs or around said interior support such that said cable and associated support, central region and extended portions are capable of lowering or eliminating crosstalk and more specifically lowering alien near end crosstalk (anext) and/or far end crosstalk (FEXT).  
     
     
         9 . The high performance communications cable of  claim 1 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a materials combination of inorganic fillers or additives and organic polymer blends.  
     
     
         10 . The high performance communications cable of  claim 1 , wherein said interior support, said central region, and said outwardly extended portions are comprised of organic blends including homo and copolymers of polyvinyl chloride with fluorinated ethylene propylene, fluorinated ethylene, chlorinated ethylene propylene, fluorochloronated ethylene, perfluoroalkoxy, fluorochloronated propylene, a copolymer of tetrafluoroethylene and perfluoromethylvinylether (MFA), a copolymer of ethylene chlorinated trifluoroethylene, as well as homo and copolymers of ethylene and/or propylene with fluorinated ethylene propylene, fluorinated ethylene, chlorinated ethylene propylene, fluorochloronated ethylene, perfluoroalkoxy, fluorochloronated propylene, MFA, ECTFE, as well as blends of polyvinyl chloride and the like.  
     
     
         11 . The high performance communications cable of  claim 10 , wherein said interior support, said central region, and said outwardly extended portions are comprised of said organic blends that also include inorganic additives or fillers comprising; metal oxides, metal hydrates, silica or silicon oxides, brominated compounds, phosphated compounds, metal salts, ammonium octyl molybdate or any combination thereof.  
     
     
         12 . The high performance communications cable of  claim 10 , wherein said interior support, said central region, and said outwardly extended portions are comprised of compounds such as acid gas scavengers to scavenge gasses such as hydrogen chloride and hydrogen fluoride.  
     
     
         13 . The high performance communications cable of  claim 10 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a polymer blend ratio of fluorinated polymers or copolymers to ethylene, acrylate or vinyl chloride based polymers or copolymers of from 0.1% to up to 99% of said fluorinated polymers to said ethylene, acrylate or vinyl chloride based polymers or copolymers.  
     
     
         14 . The high performance communications cable of  claim 10 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a foamed polymer blend ratio of fluorinated polymers or copolymers to vinyl chloride polymers or copolymers of from 0.1% to up to 99% of said fluorinated polymers to said ethylene, acrylate or vinyl chloride based polymers or copolymers and wherein said foam polymer blend includes use of a nucleating agent such as BN 3 . polytetrafluoroethylene, carbon black, calcium carbonate or the like.  
     
     
         15 . The high performance communications cable of  claim 10 , wherein said interior support, said central region, and said outwardly extended sections comprises solid, partially solid, or foamed organic or inorganic dielectric materials either solid or partially solid, foamed or foamed with a solid skin surface and wherein said foamed materials are produced with any chemical blowing agent such as magnesium carbonate, gas injection, Celogen® or any nucleating agent.  
     
     
         16 . An interior support-separator for a communications cable extending along a longitudinal length of said communications cable, comprising; 
 an interior support with an external radial and axial surface, extending along a longitudinal length of said communications cable;    said interior support also having a central region, said central region also extending along a longitudinal length of said interior support of said communications cable;    said interior support comprising one or more outwardly extended shaped portions extended from said central region wherein said central region or other location within said said communications cable provides spacing for extending at least one limited power circuit conductor along said longitudinal length of said communications cable.    
     
     
         17 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, outwardly extended portions and said central region simultaneously support said at least one limited power circuit conductor for wireless communications and at least one conductor for wired communications networks.  
     
     
         18 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, outwardly extended portions and said central region may be shielded or unshielded.  
     
     
         19 . An interior support-separator for a communications cable of  claim 16 ,wherein said interior support, outwardly extended portions and said central region provide proper spacing and support for meeting IEEE standards 802.3(a), (b), (g) and (h) as well as IEEE standard (a)(f).  
     
     
         20 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, outwardly extended portions and said central region provide proper spacing and support for low voltage conductors capable of carrying either AC or DC voltage such that said voltage is in a range of from 5-60 volts with wattages in a range of 5-30W.  
     
     
         21 . An interior support-separator for a communications cable of  claim 20 , capable of carrying voltage preferably in a range of from  10 - 50  volts with wattages in a range of 5-20 W.  
     
     
         22 . An interior support-separator for a communications cable of  claim 20 , capable of carrying voltage most preferably in a range of from  12 - 24  volts with wattages no greater than  14  W.  
     
     
         23 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a conductive inorganic fillers or additives or alternatively metallic additives and optionally including shielding around individual conductor pairs or around said interior support such that said cable and associated support, central region and extended portions are capable of lowering or eliminating crosstalk and more specifically lowering alien near end crosstalk (anext) and/or far end crosstalk (FEXT).  
     
     
         24 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a materials combination of inorganic fillers or additives and organic polymer blends.  
     
     
         25 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of organic blends including homo and copolymers of ethylene, methacrylate or polyvinyl chloride with fluorinated ethylene propylene, fluorinated ethylene, chlorinated ethylene propylene, fluorochloronated ethylene, perfluoroalkoxy, fluorochloronated propylene, a copolymer of tetrafluoroethylene and perfluoromethylvinylether (MFA), a copolymer of ethylene chlorinated trifluoroethylene, as well as homo and copolymers of ethylene and/or propylene with fluorinated ethylene propylene, fluorinated ethylene, chlorinated ethylene propylene, fluorochloronated ethylene, perfluoroalkoxy, fluorochloronated propylene, MFA, ECTFE, as well as blends of polyvinyl chloride and the like.  
     
     
         26 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of said organic blends that also include inorganic additives or fillers comprising; metal oxides, metal hydrates, silica or silicon oxides, brominated compounds, phosphated compounds, metal salts, ammonium octyl molybdate or any combination thereof.  
     
     
         27 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of compounds such as acid gas scavengers to scavenge gasses such as hydrogen chloride and hydrogen fluoride.  
     
     
         28 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a polymer blend ratio of fluorinated polymers or copolymers to ethylene, acrylate or vinyl chloride based polymers or copolymers of from 0.1% to up to 99% of said fluorinated polymers to said ethylene, acrylate or vinyl chloride based polymers or copolymers.  
     
     
         29 . An interior support-separator for a communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended portions are comprised of a foamed polymer blend ratio of fluorinated polymers or copolymers to vinyl chloride polymers or copolymers of 0.1% to up to 99% of said fluorinated polymers to said ethylene, acrylate or vinyl chloride based polymers or copolymers and wherein said foam polymer blend includes use of a nucleating agent such as BN 3 , polytetrafluoroethylene, carbon black, calcium carbonate or the like.  
     
     
         30 . The high performance communications cable of  claim 16 , wherein said interior support, said central region, and said outwardly extended sections comprises solid, partially solid, or foamed organic or inorganic dielectric materials either solid or partially solid, foamed or foamed with a solid skin surface and wherein said foamed materials are, produced with any chemical blowing agent such as magnesium carbonate, gas injection, Celogen ® or any nucleating agent.  
     
     
         31 . A high performance communications cable comprising an interior support 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 section and wherein each region or section can support a low voltage conductor capable of providing the necessary voltage an wattage to satisfy IEEE standards 802.11 (a), (b), (g) and (h) as well as IEEE standard 802.3 (a)(f) and any superseding standards supporting wireless fidelity network systems and wherein said interior support is comprised of conductive and/or metal filled or surface treated metallic materials for reduction or elimination of any form of crosstalk.    
     
     
         32 . The high performance communications cable of  claim 31 , wherein said interior support, said central region, and said anvil shaped core support-separator sections comprises solid, partially solid, or foamed thermoplastic or thermosetting dielectric materials and wherein said foamed materials are produced with any chemical blowing agent such as BN 3 , gas injection, or any nucleating agent.  
     
     
         33 . The high performance communications cable of  claim 31 , communications cable of  claim 31 , wherein said interior support comprises a center portion, wherein said center portion of said interior support may be hollow along said longitudinal length of said communications cable.  
     
     
         34 . The high performance communications cable of  claim 31 , wherein each of said anvil-shaped core support-separator sections comprises channel walls defining said one or more clearance channels and where said clearance channels are defined by a semi-circular geometry such that there remains a 180 degree opening along said external radial and axial surface of said interior support.  
     
     
         35 . The high performance communications cable of  claim 31 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a semi-closed semi-circular geometry such that there remains less than a 160 degree opening along said exterior radial and axial surface, but more than a 10 degree opening along said external surface of said interior support of said clearance channels.  
     
     
         36 . The high performance communications cable of  claim 31 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remains closed but optionally includes a flap-top allowing for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         37 . The high performance communications cable of  claim 31 , wherein said flap-top is comprised of a press-fit arrangement that is hinged allowing for opening and closing said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         38 . The high performance communications cable of  claim 31 , wherein said flap-top is sealed by use of heat, tape, interlocking, or by skin extrusion of said hinged press-fit arrangement.  
     
     
         39 . The high performance communications cable of  claim 31 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remain closed but optionally includes an interlocking double flap-top, where said double flap-top is adhered to or adjoined with a surface on each side of said clearance walls for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         40 . The high performance communications cable of  claim 31 , wherein said double flap-top is comprised of a press-fit arrangement on each end that may remain in an opened or closed position for said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         41 . The high performance communications cable of  claim 31 , wherein said channel walls comprise interior surfaces that are corrugated including internal axial grooves separated by a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity and such that said conductor or conductor pairs are optionally forced against an edge of said grooves or sections of said channel walls.  
     
     
         42 . The high performance communications cable of  claim 31 , wherein said channel walls comprise interior surfaces that are corrugated including internal axial grooves separated by a sufficient distance such that individual conductors or conductor pairs forced into said grooves maintain required electrical integrity as well as reduction or elimination of any form of crosstalk.  
     
     
         43 . The high performance communications cable of  claim 31 , wherein said interior support comprises a corrugated or convoluted external radial and axial surface extending along a longitudinal length of said communications cable, such that external surfaces of said anvil shaped core-support sections include external radial grooves also extending along said longitudinal length of said support such that said interior support can itself function as a cable jacket for said communications cable.  
     
     
         44 . The high performance communications cable of  claim 31 , wherein each of said anvil shaped core-support sections are optionally singularly filled with individual or paired metal or optionally coaxial electrical transmitting conductors or optical fiber light transmitting conductors, or filled with a combination of said individually or paired metal or optical conductors along said longitudinal length of said support and said cable.  
     
     
         45 . The high performance communications cable of  claim 31 , wherein said interior support is defined by a circumference of between 0.100 and 0.800 inches and wherein said clearance channel diameters are preferably defined by a diameter of 0.060 to 0.100 inches and are more preferably defined by a diameter of between 0.076 and 0.087 inches to specifically accommodate in the range between 22 and 26 AWG metal conductor pair with insulation or in the range of between 12 and 20 AWG metal conductor in a coaxial arrangement.  
     
     
         46 . The high performance communications cable of  claim 31 , wherein said metal conductors are copper with or without metallic shielding.  
     
     
         47 . The high performance communications cable of  claim 31 , wherein said metal conductors are aluminum with or without metallic shielding.  
     
     
         48 . The high performance communications cable of  claim 31 , wherein said cable comprises an axial strength member wherein said axial strength member optionally lies parallel to said interior support inside said communications cable jacket or within said hollow portion of said interior support along said longitudinal direction of said support and said cable.  
     
     
         49 . The high performance communications cable of  claim 31 , wherein said at least one anvil shaped support-separator section comprises an optional slotted section distinct from said support-separator sections that is sufficient to contain a grounding wire with an optional shielding tape.  
     
     
         50 . 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 section and wherein each region or section can support a low voltage conductor capable of providing the necessary voltage and wattage to satisfy. IEEE standards 802.11 (a), (b), (g) and (h) as well as IEEE standard 802.3 (a)(f) and any superseding standards supporting wireless fidelity network systems and wherein said interior support is comprised of conductive and/or metal filled or surface treated metallic materials for reduction or elimination of any form of crosstalk.    
     
     
         51 . The interior support of  claim 50 , wherein said interior support, said central region, and said anvil shaped core support-separator sections comprises solid, partially solid, or foamed thermoplastic dielectric materials and wherein said foamed materials are produced with any chemical blowing agent such as magnesium carbonate, gas injection, Celogen R  or any nucleating agent.  
     
     
         52 . The interior support of  claim 50 , wherein said interior support comprises a center portion, wherein said center portion of said interior support may be hollow along said longitudinal length of said communications cable.  
     
     
         53 . The interior support of  claim 50 , wherein each of said anvil-shaped core support-separator sections comprises channel walls defining said one or more clearance channels and where said clearance walls are defined by a semi-circular geometry such that there remains a 180 degree opening along said external radial and axial surface of said interior support.  
     
     
         54 . The interior support of  claim 50 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a semi-closed semi-circular geometry such that there remains less than a 160 degree opening along said exterior radial and axial surface, but more than a 10 degree opening along said external surface of said interior support, typically said opening of said channel is between 0.005and 0.011 inches.  
     
     
         55 . The interior support of  claim 50 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remain closed but optionally includes an optionally interlocking flap-top for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         56 . The interior support of  claim 55 , wherein said flap-top is comprised of a press-fit arrangement that may remain in an opened or closed position for said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         57 . The interior support of  claim 55 , wherein said flap-top is sealed by use of heat, tape, or interlocking of said hinged press-fit arrangement.  
     
     
         58 . The interior support of  claim 55 , wherein each of said anvil-shaped core support-separator sections comprises clearance walls defined by a fully closed circular geometry that remains closed but optionally includes an interlocking double flap-top, where said double flap-top is adhered to or adjoined with a surface on each side of said clearance walls for opening or closing said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         59 . The interior support of  claim 55 , wherein said double flap-top is comprised of a press-fit arrangement on each end that may remain in an opened or closed position for said exterior radial and axial surfaces of said channel walls of said clearance channels.  
     
     
         60 . The interior support of  claim 55 , wherein said double flap-top is sealed by use of heat, tape, or interlocking of said hinged press-fit arrangement.  
     
     
         61 . The interior support of  claim 50 , wherein said channel walls comprise interior surfaces that are corrugated including internal axial grooves separated by a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity and such that said conductor or conductor pairs are optionally forced against an edge of said grooves or sections of said channel walls.  
     
     
         62 . The interior support of  claim 50 , wherein said channel walls comprise interior surfaces that are ribbed including internal radial grooves separated by a sufficient distance such that individual conductors or conductor pairs maintain required electrical integrity as well as reduction or elimination of any form of crosstalk.  
     
     
         63 . The interior support of  claim 50 , wherein said interior support comprises a corrugated or convoluted external radial and axial surface extending along a longitudinal length such that external surfaces of said anvil shaped core-support sections include external radial grooves also extending along said longitudinal length of said support such that said interior support itself functions as a cable jacket.  
     
     
         64 . The interior support of  claim 50 , wherein each of said anvil-shaped core-support sections are optionally singularly filled with individual or paired metal or optionally coaxial electrical transmitting conductors or optical fiber light transmitting conductors, or filled with a combination of said individually or paired metal or optical conductors along said longitudinal length of said support.  
     
     
         65 . The interior support of  claim 50 , wherein said interior support is defined by a circumference of between 0.100 and 0.800 inches and wherein said clearance channels are preferably defined by a diameter of between 0.060 and 0.100 inches and more preferably defined 0.076 and 0.092 inches to specifically accommodate in the range between 22 and 26 AWG metal conductor pair with insulation or in the range of between 12 and 20 AWG metal conductor in a coaxial arrangement.  
     
     
         66 . The interior support of  claim 50 , wherein said metal conductors are copper with or without metallic shielding.  
     
     
         67 . The interior support of  claim 50 , wherein said metal conductors are aluminum with or without metallic shielding.  
     
     
         68 . The interior support of  claim 50 , wherein said cable comprises an axial strength member wherein said axial strength member lies within said hollow portion of said interior support along said longitudinal direction of said support.  
     
     
         69 . The interior support of  claim 50 , wherein said at least one anvil shaped support-separator section comprises an optional slotted section distinct from said support-separator sections that is sufficient to contain a grounding wire.  
     
     
         70 . The interior support of  claim 50 , wherein said at least one anvil shaped support-separator sections comprise rounded edges of said anvil shaped supports at an outer radial end of said anvil shaped sections sufficient to reduce overall weight and size of said support-separator and subsequently said cable.  
     
     
         71 . The interior support of  claim 50 , wherein said at least one anvil shaped support-separator sections comprise minimized dual lobes at an outer radial end of said multi-anvil shaped sections sufficient to minimize and reduce overall weight and size of said support-separator and subsequently said cable as well as providing assymetric spacing between conductors or conductor pairs.  
     
     
         72 . 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 radically 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, said anvil shaped core support-separator sections themselves twisted to a specified lay length.    
     
     
         73 . An interior support of  claim 72 , providing a specified lay length by implementing a twisting of said clearance channels thereby providing said lay length twist into said support-separator prior to manufacturing said final communications cable assembly.  
     
     
         74 . An interior support of  claim 72 , providing a specified lay length by implementing a twisting of said clearance channels thereby providing said lay length twist into said support-separator during manufacturing of said final communications cable assembly.  
     
     
         75 . A method for producing a high performance communications cable by introducing an interior support-separator section or sections with a longitudinal length, said external radial and axial surfaces having a central region extending along said longitudinal length of said interior support with said one or more clearance channels into a jacket of said cable by; 
 passing a plurality of transmission conductors within said 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 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 channels,    taping and twisting said interior support allowing for closing of said exterior surface of said channels, and;    jacketing said interior support containing each of said conductors within said clearance channels.    
     
     
         76 . The method of producing a cable as in  claim 75 , by omitting the step of heating.  
     
     
         77 . The method of producing a cable as in  claim 75 , by omitting the use of a second die.  
     
     
         78 . The method of producing a cable as in  claim 75 , by including the use of a metal ring for forcing said conductors into a proper clearance channel and forcing closure of said flap-tops.  
     
     
         79 . The method of producing a cable as in  claim 75 , by omitting the step of taping and twisting.  
     
     
         80 . The method of producing a cable as in  claim 75 , by omitting the step of jacketing said cable.  
     
     
         81 . An interior support-separator for a communications cable of  claim 50 , comprising, along said cross-section a Maltese-cross shaped configuration with two arm members such that said Maltese-cross shape is optionally skewed along one arm member with at least one axis along said arm member providing a length along said one axis of said arm member that is longer than along any other axis and providing larger blunt tipped ends at both ends of said arm member than blunt tipped ends at both ends of an arm member with a length shorter than said other longer arm member and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         82 . An interior support-separator for a communications cable of  claim 50 , wherein said Maltese-cross shaped cross-sectional configuration along said cross-section includes step-like sections along a perimeter of said support-separator providing small interstitial sectional grooves along an inner circumferential portion of clearance channels provided by said support-separator and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         83 . An interior support-separator for a communications cable of  claim 50 , extending along a longitudinal length of a communications cable, comprising a central region of said separator and along said separator a cross-section of a solid diamond shaped configuration with an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         84 . The interior support-separator of  claim 50 , comprising within said cross-section, two hollow triangular orifices in said central region of said interior support-separator, said hollow triangular orifices shaped as equilateral triangles, one said triangular orifice facing upright and said other triangular orifice facing downward such that that a peak of each triangular orifice is facing in opposite directions.  
     
     
         85 . The interior support-separator of  claim 84 , comprising within said cross-section, a diamond shaped orifice in said central region of said interior support-separator.  
     
     
         86 . The interior support-separator of  claim 84 , comprising within said cross-section, a center slit orifice in said central region of said interior support-separator.  
     
     
         87 . An interior support-separator for a communications cable of  claim 50 , extending along a longitudinal length of a communications cable comprising along said support-separator's cross-section a pendulum shaped configuration with two ends and with two semi-circular disc pendants that comprise a circular central region of said pendulum shaped separator and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         88 . The interior support-separator of  claim 87 , where said semi-circular disc pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.  
     
     
         89 . An interior support-separator for a high performance communications cable as in  claim 87 , extending along a longitudinal length of a communications cable comprising along said support-separator's cross-section a pendulum shaped configuration with two ends with a pendant shaped sections being semi-elliptical disc shaped pendants that comprise a central region of said pendulum shaped separator and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         90 . The interior support-separator of  claim 89 , where said semi-elliptical disc pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.  
     
     
         91 . An interior support-separator for a high performance communications cable extending along a longitudinal length of a communications cable comprising along said support-separator's cross-section a pendulum shaped configuration with two ends with a pendant shaped section comprising triangular shaped pendants with apexes that face in opposite directions along a horizontal plane in a central region of said pendulum shaped separator comprising a diamond-like shape and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         92 . The interior support-separator of  claim 91 , wherein said triangular shaped pendants may be nearer either end of said central region of said pendulum shaped separator than near said central region.  
     
     
         93 . The interior support-separator for a high performance communications cable of  claim 92 , extending along a longitudinal length of a communications cable, comprising, along its cross-section, a dual-lobed shaped pendulum-like configuration with curved elongated lobed end portions along a top portion and a bottom portion of said pendulum-like separator creating at least two clearance channels for conductors or conductor pairs and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         94 . The interior support-separator of  claim 93 , wherein said dual-lobed shaped pendulum-like structures with curved elongated lobed end portions may be nearer either end of said central region of said pendulum shaped separator than near said central region.  
     
     
         95 . An interior support-separator for a communications cable of  claim 91 , extending along a longitudinal length of a communications cable, comprising at least two symmetrical or asymmetrical intersecting arms that intersect in a cross-like manner along an essentially horizontal and vertical axis; 
 said intersecting arms provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like pattern along said horizontal and vertical axes said intersecting arms providing four or more separate clearance channels and wherein said arms are comprised of solid or foamed materials and wherein said foamed materials are produced with any chemical blowing agent or any nucleating agent and wherein said support-separator may include foamed or solid flame retraded polyolefins with an FEP skin or foamed or solid conductive plastics with an FEP skin.    
     
     
         96 . An interior support-separator for a communications cable of  claim 91 , extending along a longitudinal length of a communications cable, comprising at least two intersecting arms that intersect in a cross-like manner along an essentially horizontal and vertical axis; 
 said intersecting arms optionally provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like saw-tooth pattern along said horizontal and vertical axes and;    a central portion of said intersection of said arms, said central portion comprising a solid predetermined shaped member that includes step-like portions cut away from said central solid member and an optional hollow orifice in a center region of said central portion of said interior support-separator and where said central region is void of a saw-tooth member along at least one or more of said horizontal and vertical axes.    
     
     
         97 . An interior support-separator for a communications cable of  claim 91 , extending along a longitudinal length of a communications cable comprising at least two spatial quadrants defined by a horizontal arm member of said support including a two sided drill-bit-like shaped central member with geometrically symmetric sections in opposite quadrants and; each said drill-bit-like shape a mirror image of said other drill-bit-like shape in said other quadrant and said support in sum appears to be shaped as a mirrored battleship and an optional hollow orifice in a center region of said central portion of said interior support-separator.  
     
     
         98 . An interior support-separator for a communications cable of  claim 91 , extending along a longitudinal length of a communications cable, comprising at least two intersecting arms that intersect in a cross-like manner comprising a cross-like support separator along an essentially horizontal and vertical axis; 
 said intersecting arms optionally provided with ladder-like steps evenly spaced along each arm and along a complete length of said arm whereby each arm with said ladder-like steps forms a rifle-like saw-tooth pattern along said horizontal and vertical axes and;    a central portion of said intersection of said arms, said central portion comprising an optional hollow center wherein said vertical and horizontal intersecting arms are initially wide or narrow along a horizontal or vertical axis and become finally narrow or wide along same said horizontal or vertical axis such that said cross-like support separator comprises an asymmetric pattern.    
     
     
         99 . An interior support-separator for a communications cable of  claim 91 , extending along a longitudinal length of a communications cable comprising at least two spatial quadrants defined by a horizontal member of said support optionally comprising rifle-like saw-blade tooth sections along either a top or bottom portion of said horizontal member.  
     
     
         100 . The-interior support-separator for a communications cable of  claim 99 , wherein said horizontal member is optionally comprised of a semi-flexible material, a semi-flexible thermoplastic material, or a semi-rigid thermoset material.  
     
     
         101 . An interior support-separator for a high performance communications cable as in  claim 91 , extending along a longitudinal length of a communications cable comprising at least two spatial quadrants defined by two horizontal members with two sides of said support connected by a vertical member with two sides such that said complete support appears as a symmetric or skewed angle iron with a z-like shape and where each of said members may be longer, shorter or the same length as each of the other two members.  
     
     
         102 . The interior support-separator of  claim 101 , wherein said complete support-separator optionally includes rifle-like saw-blade tooth sections along any or all members of said support and along either side of each member of said support.  
     
     
         103 . A high performance communications cable comprising; 
 an interior support-separator with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;    said support comprised of a polyolefin based material capable of meeting specific flammability and smoke generation requirements as defined by UL 910, NAPA 262, and EN 50266-2-x, class B test specifications and any superseding specification(s).    
     
     
         104 . A high performance communications cable comprising; 
 an interior support-separator with an external radial and axial surface, extending along a longitudinal length of said communications cable, said interior support also having a central region, said central region also extending along a longitudinal length of said interior support and said communications cable;    said cable comprising 24 pair of electrical conductors and a twenty fifth pair of electrical conductors wherein said twenty fifth pair is placed within an orifice within said central region of said interior support-separator.    
     
     
         105 . The high performance communications cable of  claim 84  wherein said cable meets IEEE 812, IEEE 803, EIA/TIA CAT 5e and CAT 6 electrical performance requirements for communications cables and passes flammability and smoke generation requirements as defined by UL 910, NFPA 255, 259 or 262, and EN 50266-2-x, class B test specifications as well as NFPA 72 test criteria for circuit integrity, and any superseding specification(s).