USPTO Wire & Cable Industry Patents for July/August 2022

United States Patent and Trademark Office (USPTO) as compile by the editors of Wire & Cable Technology International Cable Processing

Moisture Curable Composition for Wire and Cable Insulation and Jacket Layers
United States Patent 11,361,879
Issued June 14, 2022
Inventors: Yicki Zhang, Collegeville, PA, USA; Xindi Yu, Phoenixville, PA, USA; Bharat I. Chaudhary,
Princeton, NJ, USA; and Gerald Lawrence Witucki, Midland, MI, USA
Assignees: Dow Global Technologies LLC, Midland, MI, USA; Rohm and Haas Company, Collegeville, PA,
USA; and Dow Silicones Corporation, Midland, MI, USA
An insulation or jacket layer for a coated conductor is composed of (A) a crosslinked silane-functional polyolefi n, (B) a filler composed of greater than 50 wt% silica, based on the total weight of the filler, (C) a silicone-containing polymer selected from the group consisting of reactive linear silicone containing polymers, non-reactive linear silicone-containing polymers, and non-reactive branched silicone containing polymers, and (D) from 0.00 wt% to 20 wt% of a silanol condensation catalyst, based on the
total weight of the insulation or jacket layer.

Optical Fiber Cable, and Device and Method for Manufacturing Optical Fiber Cable
United States Patent
Issued June 14, 2022
Inventors: Masashi Kikuchi, Tsukuba, Japan; Yusuke Yamada, Tsukuba, Japan; Hisashi Izumita, Tsukuba,
Japan; Junichi Kawataka, Tsukuba, Japan; and Kazunori Katayama, Tsukuba, Japan
Assignee: Nippon Telegraph and Telephone Corporation, Tokyo, Japan
An intermittent tape core wire (140) of an optical fiber cable is assembled into a cable core so that in a k core wire, an l core wire, and an m core wire composed of a multi-core optical fibers continuously adjacent in the width direction of the intermittent tape core wire (140), a difference .theta. between a core wire twisting direction D2km of the k core wire at a bonding portion (142) connecting the k core wire and the l core wire and a core wire twisting direction D2kl of the k core wire at a bonding portion (142) connecting the k core wire and the m core wire is different from when manufactured.

Polymer Composition and Cable with Advantageous Electrical Properties
United States Patent 11,359,080
Issued June 14, 2022
Inventors: Villgot Englund, Gothenburg, Sweden; Per-Ola Hagstrand, Stenungsund, Sweden; Annika
Smedberg, Myggenas, Sweden; and Ulf Nilsson, Stenungsund, Sweden
Assignee: Borealis AG, Vienna, Austria
The invention relates to polymer composition comprising a polyolefin (a) and an inorganic filler (b) wherein the polyolefin (a) is obtainable by a high pressure process which process comprises the steps: (i) compressing one or more monomer(s) under pressure in a compressor, using a compressor lubricant for lubrication, (ii) polymerising a monomer optionally together with one or more comonomer(s) in a polymerisation zone, (iii) separating the obtained polyolefi n (a) from the unreacted products and recovering the separated polyolefi n (a) in a recovery zone, wherein in step (i) the compressor lubricant comprises a non-mineral oil, power cable, for example a direct current (DC) power cable, use of a polymer composition and a process for producing a DC power cable.

Rotatable Cable Reel
United States Patent 11,358,831
Issued June 14, 2022
Inventors: Juan Alberto Gonzalez, Powder Springs, GA, USA; and Franklin Clarence Calhoun, Carrollton,
Assignee: Southwire Company, LLC, Carrollton, GA, USA
A cable reel of the present disclosure can include two flanges and a central drum being independently rotatable from one another. The drum, which can be configured to receive a cable, can be mounted on an axle. The two flanges can be rotationally mounted on the axle at opposing distal ends of the axle.
Bearings in the flanges can allow for a full rotation of the flanges about the axle.

Communication Wire
United States Patent 11,355,262
Issued June 7, 2022
Inventors: David Wiekhorst, Potter, NE, USA; Spring Stutzman, Sidney, NE, USA; Jeff Stutzman, Sidney, NE,
USA; Scott Avery Juengst, Sidney, NE, USA; Frederick W. Johnston, Dalton, NE, USA; Jim L. Dickman, Sidney,
NE, USA; and Robert Kenny, Cincinnati, OH, USA
Assignee: CommScope Technologies LLC, Hickory, NC, USA
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 on 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.

Aluminum Alloy Wire Rod and Producing Method Therefor
United States Patent 11,355,258
Issued June 7, 2022
Inventors: Toru Sumi, Tokyo, Japan; Kazuya Nishi, Tokyo, Japan; Shohei Hata, Tokyo, Japan; Takashi
Hayasaka, Tokyo, Japan; and Takeshi Usami, Tokyo, Japan
Assignee: Hitachi Metals, Ltd., Tokyo, Japan
A wire rod made of an aluminum alloy. The aluminum alloy includes Al crystal grains, an Al–Zr
compound, and an Al– Co–Fe or Al–Ni–Fe compound. The aluminum alloy includes high-angle tilt crystal grain boundaries, each of which has a difference between crystal orientations in both its sides of 15 degrees or more, and low-angle tilt crystal grain boundaries, each of which has a difference between crystal orientations in both its sides of 2 degrees or more and less than 15 degrees. An average grain diameter of ones of the Al crystal grains surrounded by the high-angle boundaries is 12μm or more. An average grain diameter of the ones of the Al crystal grains surrounded by the high-angle boundaries, ones of the Al crystal grains surrounded by the high-angle boundaries and the low-angle boundaries, and ones of the Al crystal grains surrounded by the low-angle boundaries, is 10μm or less.

United States Patent 11,355,265
Issued June 7, 2022
Inventors: Masashi Moriyama, Tokyo, Japan; Detlan Huang, Tokyo, Japan; and Yoshinori Tsukamoto,
Tokyo, Japan
Assignee: Hitachi Metals, Ltd., Tokyo, Japan
A cable is composed of a cable core including one or more electric wires, a braided shield covering a periphery of the cable core and including braided metal wires, a sheath covering a periphery of the braided shield, and a cushion layer provided between the cable core and the braided shield. The cushion layer is composed of a braid including braided linear shape fiber yarns.

Magnet Wire with Corona Resistant Polyamideimide Insulation
United States Patent 11,352,521
Issued June 7, 2022
Inventors: Allan R. Knerr, Fort Wayne, IN, USA; Gregory S. Caudill, Fort Wayne, IN, USA; Vanessa Jean Scott,
Ossian, IN, USA; and David Mykel Geng, Avilla, IN, USA
Assignee: Essex Furukawa Magnet Wire USA LLC, Atlanta, GA, USA
Magnet wire with corona resistant enamel insulation may include a conductor, and at least one layer of polymeric enamel insulation may be formed around the conductor. The polymeric enamel insulation may include a filler dispersed in a base polyamideimide material. The filler may include between 20 percent and 80 percent by weight of silica dioxide and between 20 and 80 percent by weight of titanium dioxide. Additionally, the polymeric enamel insulation may have a thermal index of at least 230°C and a thermal index that is at least twice that of the base polymeric material.

Multifunctional Conductive Wire and Method of Making
United States Patent 11,352,258
Issued June 7, 2022
Inventor: Avetik Harutyunyan, Columbus, OH, USA
Assignee: Honda Motor Co., Ltd., Tokyo, Japan
The present disclosure is directed to multifunctional conductive wire and methods of making multifunctional conductive wire. According to some aspects, the multifunctional conductive wire disclosed herein can function as a current carrier and as a battery, either for providing or storing power. The multifunctional conductive wires disclosed herein can eliminate the need for heavy metal conductors in various devices while improving power efficiency.

Optical Fiber Cable with Reinforcement
United States Patent 11,353,669
Issued June 7, 2022
Inventors: Bradley Jerome Blazer, Granite Falls, NC, USA; Michael John Gimblet, Conover, NC, USA; Julian
Latelle Greenwood, III, Hickory, NC, USA; Jason Clay Lail, Conover, NC, USA; Warren Welborn McAlpine,
Hickory, NC, USA; and Eric John Mozdy, Horseheads, NY, USA
Assignee: Corning Optical Communications LLC, Charlotte, NC, USA
An optical communication cable includes a cable jacket formed from a first material, a plurality of core elements located within the cable jacket, and an armor layer surrounding the plurality of core elements within the cable jacket, wherein the armor layer is a multi-piece layer having a first armor segment extending a portion of the distance around the plurality of core elements and a second armor segment extending a portion of the distance around the plurality of core elements, wherein a first lateral edge of the first armor segment is adjacent a first lateral edge of the second armor segment and a second lateral edge of the first armor segment is adjacent a second lateral edge of the second armor segment such that the combination of the first armor segment and the second armor segment completely surround the plurality of core elements.

Wire Tension Control Device and Braiding Machine Using the Same Z
United States Patent 11,352,725
Issued June 7, 2022
Inventors: Yi-Ping Huang, Taoyuan, Taiwan; Chih-Wei Wu, Xinfeng Township, Taiwan; and Yi-Tseng Li, New
Taipei, Taiwan
Assignee: Industrial Technology Research Institute, Hsinchu, Taiwan
A wire tension control device including a bobbin and a magnetic moment generator is provided. The bobbin is confi gured to provide a wire. The magnetic moment generator includes a stator and a rotor relatively rotatable with respect to the stator. The rotor is connected to the bobbin. When the bobbin drives the rotor to rotate, the magnetic moment generator generates a tension on the wire.

Insulated Submarine Cable
United States Patent 11,355,263
Issued June 7, 2022
Inventors: Philip Shroll, Cambridge, Great Britain; Mark Stanley, Cambridge, Great Britain; James Young,
Cambridge, Great Britain; and Jeremy Featherstone, Cambridge, Great Britian
Assignee: JDR Cable Systems Ltd., Cambridgeshire, Great Britain
The invention relates to insulated submarine cables including conductive cores (3a, 3b) and insulating material (5a, 5b) surrounding the conductive cores (3a, 3b). Such an insulated cable includes a first length and a second length. The cable has a roughly constant core (3a) cross-sectional area A1 and a roughly constant insulating material (5a) thickness T1 along the first length, and a different roughly constant core (3b) cross-sectional area A3 and/or a different roughly constant insulating material (5b) thickness T2 along the second length. The cable may include one or more other lengths which join the first length and the second length to one another.

Charging Cable for Transmitting Electric Energy, Charging Plug and Charging Station for Discharging
Electric Energy to a Recipient of Electric Energy
United States Patent 11,349,230
Issued May 31, 2022
Inventor: Thomas Fuhrer, Blomberg, Germany
Assignee: Phoenix Contact E-Mobility GmbH, Schieder-Schwalenberg, Germany
A charging cable for transmitting electric energy has a nonmetallic sheathed cable and includes at least four electric conductor cables (a1, a2, b1, b2, pe) provided in the nonmetallic sheathed cable. A first electric conductor cable and a second electric conductor cable are both assigned to a first voltage potential. A third electric conductor cable and a fourth electric conductor cable are both assigned to a second voltage potential.

Poly(Phenylene Ether) Composition and Jacketed Cable Comprising Same
United States Patent 11,345,814
Issued May 31, 2022
Inventors: Hui Peng; Hui, Shanghai, China; Wei Shan, Shanghai, China; and Shen Zhang, Shanghai, China
Assignee: SHPP Global Technologies B.V., Bergen op Zoom, Netherlands
A composition includes specific amounts of a poly (phenylene ether), a hydrogenated block copolymer of an alkenyl aromatic monomer and a conjugated diene, a polypropylene, a polybutene, a flame retardant, and an ultraviolet absorbing agent comprising a bis(benzotriazole) compound. The composition is particularly useful for forming the jacket layer of electrical and optical cables.

Aluminum Alloy Wire, Aluminum Alloy Strand Wire, Covered Electrical Wire, and Terminal-Equipped
Electrical Wire
United States Patent 11,342,094
Issued May 24, 2022
Inventors: Misato Kusakari, Osaka, Japan; Tetsuya Kuwabara, Osaka, Japan; Yoshihiro Nakai, Osaka, Japan;
Taichiro Nishikawa, Osaka, Japan; Yasuyuki Otsuka, Yokkaichi, Japan; and Hayato Ooi, Yokkaichi, Japan
Assignees: Sumitomo Electric Industries, Ltd., Osaka, Japan; AutoNetworks Technologies, Ltd., Yokkaichi,
Japan; and Sumitomo Wiring Systems, Ltd., Yokkaichi, Japan
An aluminum alloy contains equal to or more than 0.005 mass- % and equal to or less than 2.2 mass% of Fe, and a remainder of Al and an inevitable impurity. In a transverse section of the aluminum alloy wire, a surface-layer void measurement region in a shape of a rectangle having a short side length of 30 μm and a long side length of 50 μm is defined within a surface layer region extending from a surface of the aluminum alloy wire by 30 .mu.m in a depth direction, and a total crosssectional area of voids in the surface-layer void measurement region is equal to or less than 2 μm2.

Spiral Shielding on a High Speed Cable
United States Patent 11,342,097
Issued May 24, 2022
Inventors: Sandor Farkas, Round Rock, TX, USA; and Bhyrav M. Mutnury, Austin, TX, USA
Assignee: Dell Products L.P., Round Rock, TX, USA
A dual axial cable includes first and second signal conductors and a shield. The first and second signal conductors transmit a differential signal. The shield includes a foil wrap spirally wrapped around the first and second conductors to form a plurality of foil wrap sections. Each of the foil wrap sections overlaps an adjacent foil wrap section. The periodicity of a pitch of each of the overlaps varies along a length of the dual axial cable.

High Voltage Power Cable with Fatigue-Resistant Water Barrier
United States Patent 11,335,477
Issued May 17, 2022
Inventors: Fabrizio Cristofani, Milan, Italy; Paolo Liboi, Milan, Italy; Silvio Frigerio, Milan, Italy; and Giovanni
Pozzati, Milan, Italy
Assignee: Prysmian S.p.A., Milan, Italy
A power cable has an insulated conductor; a copper water barrier, in form of a tube with a welding line, surrounding each insulated conductor; and a polymeric sheath surrounding each copper water barrier. The copper water barrier has a thickness and the polymeric sheath has a thickness such that a ratio between the thickness of the copper water barrier and the thickness of the polymeric sheath is 0.15 at most.

Shielded Cable Assembly
United States Patent 11,336,058
Issued May 17, 2022
Inventors: Nicole L. Liptak, Cortland, OH, USA; Bruce D. Taylor, Cortland, OH, USA; and Richard J. Boyer,
Mantua, OH, USA
Assignee: Aptiv Technologies Limited, St. Michael, Barbados
A shielded cable assembly capable of transmitting signals at speeds of 3.5 Gigabits per second (Gb/s) or higher without modulation or encoding over a single pair of conductors. The cable has a characteristic impedance of 95 Ohms and can support transmission data according to either USB 3.0 or HDMI 1.4 performance specifications. The wire cable includes a pair of conductors, a shield surrounding the conductors, and a dielectric structure configured to maintain a first predetermined spacing between the conductors and a second predetermined spacing between said conductors and said shield. The shield includes an inner shield conductor enclosing the dielectric structure and an outer shield conductor enclosing the inner shield conductor.

Method of Manufacture of Electrical Wire and Cable Having a Reduced Coefficient of Friction and
Required Pulling Force
United States Patent 11,328,843
Issued May 10, 2022
Inventor: Willaim T. Bigbee, Jr., Melissa, TX, USA
Assignee: Encore Wire Corporation, McKinney, TX, USA
A process for manufacturing finished wire and cable having reduced coefficient of friction and pulling force during installation, includes providing a payoff reel containing at least one internal conductor wire; supplying the at least one internal conductor wire from the reel to at least one extruder; providing the least one extruder, wherein the least one extruder applies an insulating material and a polymerized jacket composition over the at least one internal conductor wire, wherein the polymerized jacket composition comprises a predetermined amount by weight of nylon; a predetermined amount by weight f mineral oil in the range of 0.1% to 5% by weight; and a predetermined amount of silica in the range of 2% to 9% by weight; providing a cooling device for lowering the temperature of the extruded insulating material and the polymerized jacket composition and cooling the insulating material and the polymerized jacket composition in the cooling device; and, reeling onto a storage reel the finished, cooled, wire and cable for storage and distribution.

Method for Trimming Cable Shield
United States Patent 11,329,460
Issued May 10, 2022
Inventors: Grace L. Duncan, Seattle, WA, USA; Bradley J. Mitchell, Snohomish, WA, USA; Nick S. Evans,
Lynnwood, WA, USA; and Damine O. Martin, Everett, WA, USA
Assignee: The Boeing Company, Chicago, IL, USA
A shield trim is performed by tearing bunched shield strands circumferentially along a circular edge. The apparatus includes a pair of aligned metal plates that have been drilled through multiple times such that holes of varying diameters pass through both plates. A cable gripper on the entry side of the device clamps the cable in place. A shield gripper on the rear side of the device closes over the exposed shielding of the cable, and the two plates are pushed together. The shield gripper travels with the rear plate, pushing the shield over the wires and causing the shield to bunch between the two plates. With the two plates pushed together, both grippers open and the cable is pulled free from the device. This pull forces a stress concentration which tears the shield strands across the sharp edge of the hole, producing a uniformly trimmed shield.

Electric Vehicle Charging Cable
United States Patent 11,315,704
Issued April 26, 2022
Inventors: Jae Bok Lee, Seoul, South Korea; Do Hyun Park, Anyang-Si, South Korea; Chui Min Kim, SuwonSi, South Korea; and Hyun Woong Kim, Suwon-Si, South Korea
Assignee: LS Cable & System Ltd., Anyang-si, South Korea
The present disclosure relates to an electric vehicle charging cable capable of effectively cooling heat, which is generated therein during charging of an electric vehicle, using a cooling fluid, preventing damage to internal components thereof due to heat, and minimizing a diameter of the cable.

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