Abstract: The present invention relates to an improved insulated conductor with a low dielectric constant and reduced materials costs. The conductor (12) extends along a longitudinal axis and an insulation (14, 14<1>) surrounds the conductor (12). At least one channel (16, 16<1>) in the insulation (14, 14<1>) extends generally along the longitudinal axis to form an insulated conductor. Apparatuses and methods of manufacturing the improved insulated conductors are also disclosed.

Abstract: A modular jack, comprising a jack frame and terminal housing, for accepting one or more twisted pairs of conductors. Running through a base of the terminal housing are one or more wire management tunnels. Each of the tunnels has a first opening located within a first end of the terminal housing, a second opening located within a second end of the terminal housing, and a third opening located within a surface of the terminal housing from which extends a plurality of turrets. A twisted pair of conductors enters the wire management tunnel through either the first or second opening, and then travels through the wire management tunnel before exiting through said third opening. The twisted pair of conductors exiting the third opening then terminate within one or more slots defined by neighboring turrets.

Abstract: The present invention relates to an improved insulated conductor with a low dielectric constant and reduced materials costs. The conductor extends along a longitudinal axis and an insulation surrounds the conductor. At least one channel in the insulation extends generally along the longitudinal axis to form an insulated conductor. Apparatuses methods of manufacturing the improved insulated conductors are also disclosed.

Abstract: A telecommunications cable includes multiple binder units. Each binder unit includes a predetermined number of twisted pairs enclosed by a binder unit wrap. A foil free edge tape is applied over the top of the unit wrap with the foil facing inwardly. A drain wire is pulled between the foil and the unit wrap. A preselected number of binder units are enclosed by an overall core wrap, and a shield is applied over the top of the overall core wrap such that the shield surface faces inwardly for improved termination methods. An overall drain wire is placed between the overall core and overall shield. The entire cable may be enclosed by a jacket or sheath.

Abstract: A method of forming flexible communications wire for use in Local Area Networks is disclosed. A plurality of individual metal strands are formed into a central conductor. The central conductor is then compressed and/or heated to bond adjacent strands together and to reduce the diameter of the wire.

Abstract: A cable includes a pre-selected number of binder units. Each binder unit includes an even number of paired couples of conductors, evenly divided into quads, and an additional twisted pair of conductors, coupled with and encircled around a length of a filler material, extended in parallel so the quads of conductor pairs surround the additional pair of conductors and the filler material. A binder unit wrap encloses each binder unit and a foil free edge tape is applied with the foil facing inwardly and a drain wire pulled between the foil and the unit wrap. An overall core wrap encloses each binder unit, and a shield is applied over the top of the overall core wrap such that the shield surface faces inwardly for improved termination methods. An overall drain wire is placed between the overall core wrap and overall shield. The entire cable may be enclosed by a jacket or sheath. A method for forming the cable is also disclosed.

Abstract: A method for manufacturing a conductor that includes extruding insulation around a conductive wire. The insulation should be extruded directly onto and around the conductive wire. The insulating material includes a first medium impact grade polypropylene copolymer, a second medium impact grade polypropylene copolymer, and another polyolefin, where the first medium impact grade polypropylene copolymer has a melt flow index that is greater than the second medium impact grade polypropylene copolymer melt flow index. The insulation material can also include at least one flame retardant.

Abstract: The invention is comprised of a cable assembly having a cable, a modular plug, and a molded stress relief body. The cable includes at least one twisted wire pair of a given length and at least one outer jacket that surrounds a portion of the length of the twisted wire pair, wherein each individual wire of the twisted wire pair is comprised of a conductor wire and an outer insulator. The modular plug includes an uppermost surface and a receiving cavity to establish an electrical connection with the cable. A molded stress relief body is used to cover at least a portion of the cable and the modular plug. To reduce the amount of stress and strain encountered by and between the modular plug and the cable, the molded stress relief body is molded about, or bonded to, at least a portion of the twisted wire pair that is not surrounded by the outer jacket of the cable.

Abstract: A method of forming flexible communications wire for use in Local Area Networks is disclosed. A plurality of individual metal strands are formed into a central conductor. The central conductor is then compressed and/or heated to bond adjacent strands together and to reduce the diameter of the wire.

Abstract: The invention is directed to a multi-pair cable having an outer jacket and at least two pairs of twisted wire cables having different lay lengths and being disposed within the jacket. The wires of each twisted wire pair have a conductor surrounded by an insulating material, wherein the conductors of the respective twisted wire pairs have different strand twist lengths. The lay lengths of the twisted wire pairs are correlated with the strand twist length of the conductors of the individual twisted wire pairs so that the phase delay of the twisted wire pairs of the cable is matched to within an acceptable range for data transmission. Conversely, where the lay lengths of the twisted wire pairs is specified, the strand twist lengths of the respective conductors of the individual twisted wire pairs can be correlated with the lay lengths of the twisted wire pairs so that the phase delay of the twisted wire pairs of the cable is brought to within an acceptable range for the intended application.