Abstract: An insulated conductor (20) for use in a communication cable which includes a filling material (30) includes a copper conductor (25) and a composite insulation system (27) comprising two concentric layers of insulation. An inner foam layer (28) of the insulation comprises a cellular plastic material (28) which includes a stabilizer system. An outer layer (29) of the insulation is referred to as a skin and comprises a stabilized solid plastic material. The stabilizer system in each of the cellular and solid layers includes a bifunctional portion that functions as an antioxidant and as a metal deactivator and that has a relatively high resistance to extraction. The level of the bifunctional portion of the stabilizer in the cellular material is substantially greater than that in the skin inasmuch as it has been found that the level of the stabilizer cellular layer contiguous to the copper wire determines the oxidation performance level of the composite insulation.

Abstract: Cordage (17) which may be used for any of the commonly marketed lengths of etractile cords comprises an array of a plurality of conductors (11--11) each insulated with a suitable plastic material. The array of conductors is enclosed in inner and outer jackets (52, 54). The inner jacket comprises a polyvinyl chloride (PVC) plastic material, for example, and has a thickness of about 0.015 inch. Covering the inner jacket is an outer jacket comprising a polyvinyl chloride plastic material having a thickness of about 0.005 inch and having a colorant constituent. The PVC composition of the inner jacket is such that it is a less expensive composition than that of the outer jacket. Enclosing the outer jacket is a layer (56) which comprises a top coating material. The top coating material provides the cordage with enhanced retractibility and prevents discoloration as well as plasticizer migration from the outer jacket.

Abstract: Extruder tooling for directing plastic materials to enclose a conductor (26) being advanced along a path of travel through a core tube (97) and aligned dies includes disc-like flow passages (107, 129) which are disposed concentrically about and perpendicularly to the conductor. This arrangement minimizes conductor tension in a pressure extrusion arrangement by significantly reducing the length of the plastic-to-conductor contact within the extruder. The length and width of each flow passage normal to and along a path of travel are sufficient to provide a uniform distribution of plastic material circumferentially about the conductor and to dissipate stresses which have been induced in the plastic materials. In a tubing arrangement, the length of a cantilevered portion of the core tube is reduced significantly which results in improved concentricity of the plastic material about the conductor.

Abstract: A cable which is suitable for use as a riser cable in buildings comprises a plurality of conductors each of which is covered with a composite insulation. The composite insulation comprises an inner layer of an expanded polyethylene material and an outer layer of a polyvinyl chloride material with the percent expansion of the inner layer and the thickness of the outer layer being such as to optimize several cable parameters. The resultant cable is one which has excellent fire-retardant properties such as, for example, an unusually low fuel content. Advantageously, this same cable lends itself to color coding for inside wiring and is capable of having a relatively high pair count density. All these parameters are optimized within the framework of specific transmission requirements.

Abstract: Capacitance unbalance-to-ground between conductors of a twisted pair, each of which may be insulated with at least a layer of cellular plastic insulation, is maintained within acceptable limits by controlling the extrusion of the insulation to maintain the measured coaxial capacitance and associated outside diameter of the insulated conductors within a range of values which correspond to acceptable capacitance unbalance-to-ground values.