PROCESS FOR MANUFACTURING A TWISTED PAIR OF WIRES

Abstract

A method of forming a twisted pair of wires for use with Ethernet-based networks. At least two wires are extruded with a cross-linked polyolefin insulating composition marketed under the registered trademark, EXRAD. The wires are twisted together with a consistent lay length to form a cable. The cable is irradiated to become thermoset. Electrical properties of the extruded wire are controlled during the extrusion step and concentricity of the wire and surrounding insulation is also monitored and controlled. The cable can be jacketed to provide greater mechanical protection.

Claims

1. A method of forming a twisted pair of wires for use with Ethernet-based networks, the steps comprising: a) extruding at least two wires with a cross-linked polyolefin insulating composition; b) twisting together said wires with a consistent lay length to form a cable; c) irradiating said cable; and d) thermosetting said cable.

2. The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein electrical properties of said extruded wire are controlled during said extrusion step (a) and twisting step (b).

3. The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, further comprising monitoring and controlling concentricity of said wire and surrounding insulation during said extrusion step (a).

4. The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein said irradiation step (c) is performed by an electron beam using a dosage range from 5 Mrad to 15 Mrad to cross-link the insulation.

5. The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, the steps further comprising jacketing said cable to provide greater mechanical protection.

6. The method of forming a twisted pair of wires for use with Ethernet-based networks in accordance with claim 1, wherein said insulating composition comprises a polyolefin based polymer compound.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:

[0013] FIG. 1 is a perspective view of two individual stranded or solid conductors insulated with an insulative composition accordance with the present invention; and

[0014] FIG. 2 is a schematic view of the two wires shown in FIG. 1 having a surrounding jacket.

[0015] Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0016] Although the following detailed description contains specific details for the purposes of illustration, those of ordinary skill in the art will appreciate that variations and alterations to the following details are within the scope of the invention. Accordingly, the exemplary embodiments of the invention described below are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.

[0017] Referring now to FIG. 1, the inventive process begins with individual stranded or solid conductors 10 insulated with a composition 12 created by the present assignee and marketed under the trademark, DATARAD. The wire 10 is extruded and insulated with the EXRAD composition. This insulation material 12 is an EXRAD compound that meets the ISO 6722-1 and SAE J1128 performance requirements.

[0018] Electrical properties of the insulated wire (e.g., capacitance and resistance) are controlled, as is well known in the art, during the extrusion step. Moreover, concentricity of the wire 10 and surrounding insulation 12 is also monitored and controlled, also as well known in the art.

[0019] Once the wire 10 and insulation 12 are extruded, the two insulated wires are twisted together with a consistent lay length to form a cable 14.

[0020] The twisted pair of wires 14 is then thermoset using electron beam accelerator also known as e-beam at room temperature. The twisted pair 14 is then irradiated by an electron beam using a range of dosage from 5 Mrad to 15 Mrad to cross-link the insulation.

[0021] After the wire and insulation 10 are cross-linked, the twisted pair 14 retains the twist form when the ends are cut. This twisted cable 14 can be used unjacketed. Alternatively, referring to FIG. 2, the cable 14 can be jacketed 16 to provide greater mechanical protection.

[0022] The final product is a cable that is useful for systems that allow multiple in-vehicle systems such as cameras and onboard diagnostics to simultaneously access information over a single, unshielded twisted pair cable. The cable meets the stringent electrical requirement of the automotive industry such as BroadR-Reach, IEEE 802.3, and SAE J3117 requirements.

[0023] Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. For example, parameters of conductor sizes and irradiation dosage can all be varied as required. Moreover, although two solid conductor have been shown in the aforementioned description, it should be understood that more than two conductors can be twisted together, and the conductors themselves can be individual strands.

[0024] Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.