Abstract: A communications cable is provided comprising a conductor and polymer insulation encasing said conductor, the polymer insulation having a foamed interior and having an exterior surface formed from longitudinally running rounded peaks and valleys. A process is also provided for producing this polymer insulation or unfoamed polymer insulation having the same or similar peak/valley exterior surface by extruding molten thermoplastic polymer through an orifice to coat a conductor passing through the orifice, thereby forming polymer insulation on the conductor, said orifice defining the exterior surface of said polymer insulation comprising longitudinally running rounded peaks and valleys, said peaks covering at least about 30% of said exterior surface and having a height that is at least 50% of the width of said peaks.

Abstract: A process of twinning a pair of polymer-insulated conductors to form a twisted pair, where the polymer-insulated conductors are formed by extruding a uniformly thick coating of polymer onto the conductors. More than one twisted pair is encased in a polymer jacket forming a cable. The twisted pair obtains a desirable average impedance performance using a reduced amount by weight of polymer forming said polymer-insulated conductors by: (i) extruding to form longitudinally running peaks and valleys in the exterior surface of each of the polymer-insulated conductors of the pair of polymer-insulated conductors and (ii) twinning resultant polymer-insulated conductors to nest at least one of the peaks in the exterior surface of one of the polymer-insulated conductors in at least one of said valleys in the exterior surface of the other of the polymer-insulated conductors of the pair of polymer-insulated conductors.

Abstract: A process of twinning a pair of polymer-insulated conductors to form a twisted pair, where the polymer-insulated conductors are formed by extruding a uniformly thick coating of polymer onto the conductors. More than one twisted pair is encased in a polymer jacket forming a cable. The twisted pair obtains a desirable average impedance performance using a reduced amount by weight of polymer forming said polymer-insulated conductors by: (i) extruding to form longitudinally running peaks and valleys in the exterior surface of each of the polymer-insulated conductors of the pair of polymer-insulated conductors and (ii) twinning resultant polymer-insulated conductors to nest at least one of the peaks in the exterior surface of one of the polymer-insulated conductors in at least one of said valleys in the exterior surface of the other of the polymer-insulated conductors of the pair of polymer-insulated conductors.

Abstract: A process of twinning a pair of polymer-insulated conductors to form a twisted pair, where the polymer-insulated conductors are formed by extruding a uniformly thick coating of polymer onto the conductors. More than one twisted pair is encased in a polymer jacket forming a cable. The twisted pair obtains a desirable average impedance performance using a reduced amount by weight of polymer forming said polymer-insulated conductors by: (i) extruding to form longitudinally running peaks and valleys in the exterior surface of each of the polymer-insulated conductors of the pair of polymer-insulated conductors and (ii) twinning resultant polymer-insulated conductors to nest at least one of the peaks in the exterior surface of one of the polymer-insulated conductors in at least one of said valleys in the exterior surface of the other of the polymer-insulated conductors of the pair of polymer-insulated conductors.

Abstract: The present invention relates to the extrusion of a composition comprising tetrafluoroethylene/hexafluoropropylene copolymer, 10-60 wt % inorganic particulate filler, and hydrocarbon polymer for dispersing the filler in the copolymer, preferably 0.1 to 5 wt % hydrocarbon polymer, at low temperatures, e.g. up to 650° F. (343° C.).

Abstract: The present invention relates to jacketed cable especially useful for plenum enclosures of buildings, the jacket of the cable comprising perfluoropolymer, such as tetrafluoroethylene/hexafluoropropylene copolymer, and inorganic char-forming agent, and preferably an additional ingredient, hydrocarbon polymer, the cable passing the NFPA-255 burn test.

Abstract: FEP compositions are provided that provide foam insulation in coaxial cable that surpasses the return loss obtained when PFA is used to make the foamed insulation, one composition comprising a blend of tetrafluoroethylene/hexafluoropropylene copolymers, one of said copolymers exhibiting a strip force of at least about 3 lbf (13.3 N) and another of said copolymers exhibiting a strip force no greater than about 2.5 lbf (11.1 N), said blend exhibiting a strip force of at least about 3 lbf (13.3 N), each said strip force being the force necessary to break adhesion between conductor and said one of said copolymers, said another of said copolymers, and said blend, respectively, and another composition comprising tetrafluoroethylene/hexafluoropropylene copolymer having an MFR of no greater than about 16 g/10 min and containing —CF3 end groups and an effective amount of wire affinity end groups to exhibit a strip force of at least about 3 lbf (13.

Abstract: A process of twinning a pair of polymer-insulated conductors to form a twisted pair, where the polymer-insulated conductors are formed by extruding a uniformly thick coating of polymer onto the conductors. More than one twisted pair is encased in a polymer jacket forming a cable. The twisted pair obtains a desirable average impedance performance using a reduced amount by weight of polymer forming said polymer-insulated conductors by: (i) extruding to form longitudinally running peaks and valleys in the exterior surface of each of the polymer-insulated conductors of the pair of polymer-insulated conductors and (ii) twinning resultant polymer-insulated conductors to nest at least one of the peaks in the exterior surface of one of the polymer-insulated conductors in at least one of said valleys in the exterior surface of the other of the polymer-insulated conductors of the pair of polymer-insulated conductors.

Abstract: A communications cable is provided comprising a conductor and polymer insulation encasing said conductor, the polymer insulation having a foamed interior and having an exterior surface formed from longitudinally running rounded peaks and valleys. A process is also provided for producing this polymer insulation or unfoamed polymer insulation having the same or similar peak/valley exterior surface by extruding molten thermoplastic polymer through an orifice to coat a conductor passing through the orifice, thereby forming polymer insulation on the conductor, said orifice defining the exterior surface of said polymer insulation comprising longitudinally running rounded peaks and valleys, said peaks covering at least about 30% of said exterior surface and having a height that is at least 50% of the width of said peaks.

Abstract: A process of twinning a pair of polymer-insulated conductors to form a twisted pair, where the polymer-insulated conductors are formed by extruding a uniformly thick coating of polymer onto the conductors. More than one twisted pair is encased in a polymer jacket forming a cable. The twisted pair obtains a desirable average impedance performance using a reduced amount by weight of polymer forming said polymer-insulated conductors by: (i) extruding to form longitudinally running peaks and valleys in the exterior surface of each of the polymer-insulated conductors of the pair of polymer-insulated conductors and (ii) twinning resultant polymer-insulated conductors to nest at least one of the peaks in the exterior surface of one of the polymer-insulated conductors in at least one of said valleys in the exterior surface of the other of the polymer-insulated conductors of the pair of polymer-insulated conductors.

Abstract: Communication cable is provided comprising a twisted pair of polymer insulated conductors, the twisting to form the twisted pair forcing the surface of polymer insulation of each polymer-insulated conductor of said polymer-insulated conductors into contact with one another, the polymer insulation of each polymer-insulated conductor including (i) a foamed portion being crushable by the forcing together of the contacting surfaces of the polymer insulation of each of the polymer-insulated conductors and (ii) a crush-resistant portion extending radially within said insulation into the foamed portion and being present where the surface of the polymer-insulated conductors are into said contact with one another, thereby protecting the foamed portion from crushing by the forcing together of the contacting surfaces.

Abstract: The present invention relates to plenum cables jacketed with a composition comprising perfluoropolymer, inorganic char-forming agent, and hydrocarbon polymer, which passes the NFPA-255 burn test.

Abstract: FEP compositions are provided that provide foam insulation in coaxial cable that surpasses the return loss obtained when PFA is used to make the foamed insulation, one composition comprising a blend of tetrafluoroethylene/hexafluoropropylene copolymers, one of said copolymers exhibiting a strip force of at least about 3 lbf (13.3 N) and another of said copolymers exhibiting a strip force no greater than about 2.5 lbf (11.1 N), said blend exhibiting a strip force of at least about 3 lbf (13.3 N), each said strip force being the force necessary to break adhesion between conductor and said one of said copolymers, said another of said copolymers, and said blend, respectively, and another composition comprising tetrafluoroethylene/hexafluoropropylene copolymer having an MFR of no greater than about 16 g/10 min and containing —CF3 end groups and an effective amount of wire affinity end groups to exhibit a strip force of at least about 3 lbf (13.

Abstract: Communication cable is provided comprising a twisted pair of polymer insulated conductors, the twisting to form the twisted pair forcing the surface of polymer insulation of each polymer-insulated conductor of said polymer-insulated conductors into contact with one another, the polymer insulation of each polymer-insulated conductor including (i) a foamed portion being crushable by the forcing together of the contacting surfaces of the polymer insulation of each of the polymer-insulated conductors and (ii) a crush-resistant portion extending radially within said insulation into the foamed portion and being present where the surface of the polymer-insulated conductors are into said contact with one another, thereby protecting the foamed portion from crushing by the forcing together of the contacting surfaces.