USPTO Wire & Cable Industry Patents for September/October 2022

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

Quad-Shield Coaxial Cable
United States Patent 11,417,443
Issued August 16, 2022
Inventor: Michael Lawrence, Syracuse, NY, USA
Assignee: PPC Broadband, Inc., East Syracuse, NY, USA
A quad-shield coaxial cable includes an insulator portion configured to encircle an inner conductor portion, an inner conductive foil portion configured to encircle the insulator portion, an inner braided shield portion configured to encircle the inner conductive foil layer portion, an outer braided shield portion configured to encircle the inner braided shield portion, an outer conductive foil portion configured to encircle the outer braided shield portion and a jacket portion configured to encircle the outer conductive foil portion.

Fabrication of Reinforced Superconducting Wires
United States Patent 11,417,445
Issued August 16, 2022
Inventors: Paul Aimone, Bridgewater, MA, USA; Francois-Charles Dary, Boston, MA, USA; and David B. Smathers, Columbus, OH, USA
Assignee: H.C. Starck Solutions Coldwater, LLC, Coldwater, MI, USA
In various embodiments, superconducting wires feature assemblies of clad composite filaments and/or stabilized composite filaments embedded within a wire matrix. The wires may include one or more stabilizing elements for improved mechanical properties.

Armoured Cable for Transporting Alternate Current with Permanently Magnetized Armour Wires
United States Patent 11,410,794
Issued August 9, 2022
Inventors: Paolo Maioli, Milan, Italy; Marco Ruzzier, Milan, Italy; and Monica Lucarelli, Milan, Italy
Assignee: Prysmian S.p.A., Milan, Italy
The present disclosure relates to an armoured AC cable comprising at least one core comprising an electric conductor, and an armour surrounding the at least one core and comprising ferromagnetic wires, wherein the ferromagnetic wires are permanently magnetized with a remanent magnetic field which is uniform or variable along the cable length L. The present disclosure also relates to a process for producing an armoured AC cable, a method for improving the performances of an armoured AC cable and a method for reducing losses in an armoured AC cable.

Bending-Resistant Communication Cable and Wire Harness
United States Patent 11,410,793
Issued August 9, 2022
Inventors: Toshiharu Shimizu, Susono, Japan; and Hiroki Kondo, Susono, Japan
Assignee: Yazaki Corporation, Tokyo, Japan
A bending-resistant communication cable includes a parallel two-core shielded wire that includes a drain wire in a gap between two-core communication wires and is formed by collectively covering the two-core communication wires and the drain wire by an external conductor. Each of the drain wires in a plurality of parallel two-core shielded wire is arranged to face inside of the bending-resistant communication cable. Further, a twist pitch of the plurality of two-core shielded wires is 20 mm or more and less than 100 mm.

Cold Rolled Steel Wire, Method and Reinforcement of Flexible Conduits
United States Patent 11,408,049
Issued August 9, 2022
Inventors: Sylvian Foissey, Meximieux, France; and Gaelle Bascourt, Viriat, France
Assignee: Arcelormittal Wire France, Bourg en Bresse, France
A cold rolled steel wire having the following chemical composition expressed in percent by weight, 0.2≤C%≤0.6, 0.5≤Mn%≤1.0, 0.1≤Si≤0.5%, 0.2≤Cr≤1.0%, P≤0.020%, S≤0.015%, N≤0.010%, and optionally not more than 0.07% Al, not more than 0.2% Ni, not more than 0.1% Mo and not more than 0.1% Cu, the balance being iron and the unavoidable impurities due to processing. This wire has a microstructure including bainite and, optionally, up to 35% acicular ferrite and up to 15% pearlite. A fabrication method and flexible conduits for hydrocarbon extraction are also provided.

Wire Spool Cover
United States Patent 11,407,609
Issued August 9, 2022
Inventor: Robert Haag, North Bend, OR, USA
Cover adapted for covering a spool of wire mounted on a shaft for preventing tangling of the wire during use, comprising a first cover portion comprising an outer wall and side walls, and a second cover portion comprising an outer wall and side walls adapted to attach to the shaft adjacent sides of the spool of wire without removing it from the shaft, the first and second cover portions being adapted for mating to cover the wire spool on the shaft, the second cover portion comprising an opening for allowing the wire on the spool to pass through the outer wall and allowing the spool of wire to rotate freely on the shaft to dispense the wire in a tangle-free manner from the spool as the wire is pulled through the opening.

Power Cable with Conductor Strand Fill Containing Recycled Crosslinked Compounds
United States Patent 11,410,795
Issued August 9, 2022
Inventors: David Horton, Lexington, SC, USA; Tyson Baker, Lexington, SC, USA; and Chris Dekonkoly, Lexington, SC, USA
Assignee: Prysmian S.p.A., Milan, Italy
A power cable and a process of manufacturing a power cable, where the power cable includes a core containing stranded electrically conductive wires that are impregnated with a water-blocking composition, wherein the water-blocking composition contains, based on a total weight of the water-blocking composition: (i) a thermoplastic polymer; and (ii) a positive amount of up to 30 wt % of a crosslinked polymer, where the crosslinked polymer is in the form of a powder having a particle diameter less than 900µm and the crosslinked polymer is dispersed in the thermoplastic polymer.

Copper Alloy Wire, Plated Wire, Electrical Wire and Cable
United States Patent 11,404,181
Issued August 2, 2022
Inventors: Hiromitsu Kuroda, Tokyo, Japan; Takashi Hayasaka, Tokyo, Japan; Detian Huang, Tokyo, Japan; Ryohei Okada, Tokyo, Japan; and Tamotsu Sakurai, Tokyo, Japan
Assignee: Hitachi Metals, Ltd., Tokyo, Japan
A copper alloy wire is made of a copper alloy, and the copper alloy contains indium, a content of which is equal to or more than 0.3 mass % and equal to or less than 0.45 mass %. A tensile strength of the copper alloy wire is equal to or higher than 800 MPa, and an electrical conductivity of the same is equal to or higher than 80% IACS.

Method for Converting Wire Rod of Nonferrous Metals and Alloys Thereof to Wire with High Elongation and in the Annealed State
United States Patent 11,400,500
Issued August 2, 2022
Inventor: Guilio Properzi, Milan, Italy
A method for converting wire rod of nonferrous metals and alloys thereof to wire with high elongation and in the annealed state, wherein the reduction in diameter in order to pass from wire rod to wire is carried out by way of a plastic deformation process. The temperature of the metal subjected to plastic deformation is controlled in order to have, at the end of the plastic deformation process, the wire at a temperature higher than or equal to the recrystallization temperature. This avoids the thermal treatment of annealing, necessary in conventional production techniques, achieving a considerable saving in production costs and a wire with characteristics similar to those of a wire subjected to annealing.

Cable Jacket
United States Patent 11,401,359
Issued August 2, 2022
Inventors: Asa Wannerskog, Stenungsund, Sweden; and Ola Fagrell, Stenungsund, Sweden
Assignee: Borealis AG, Vienna, Austria
The present invention relates to a cable jacket comprising a random heterophasic propylene copolymer, the random heterophasic polypropylene copolymer comprising a matrix (M) being a random propylene copolymer (R-PP) and dispersed therein an elastomeric propylene copolymer (E), wherein the random propylene copolymer (R-PP) comprises a first propylene copolymer fraction (R-PP1) having a comonomer content in the range of 0.8 to 6.0 mol % and a second propylene copolymer fraction (R-PP2) having a comonomer content in the range of 7.2 to 20.0 mol %, based on the overall amount of fractions (R-PP1) and (R-PP2), and wherein the random heterophasic propylene copolymer has MFR2 (230°C) measured according to ISO 1133 in the range of 0.5 to 15 g/10 min, and Charpy impact strength measured according to ISO 179-1/1eA at -20°C in the range of 5 to 20 kJ/m2 The present invention further relates to a power cable comprising the cable jacket.

Cable System Having Shielding Layers to Reduce and or Eliminate EMI Leakage
United States Patent 11,394,156
Issued July 19, 2022
Inventors: Hecham Elkhatib, Aurora, IL, USA; Darijus Baltrukonis, Naperville, IL, USA; and Abel Almazan, St. Charles, IL, USA
Assignee: Cinch Connectivity Solutions Inc., Lombard, IL, USA
The cable attaches a first component and a second component using a quick disconnect connector pair. The cable includes a twisted pair of wires with a separate shield. A portion of the shielding near the connector is removed to expose the wires and assemble the wires to the connector. To reduce the EMI leakage, the inner shell encloses the exposed portions of the wires. In order to maintain the ground path for the shielding of the shielded twisted wire pairs, the shielding for the twisted wire pairs is connected to the shell. The outer shells facilitate the quick disconnect feature. The outer shell includes one or more slots. The slot allows a portion of the outer shell to become a cantilever beam. The beam deflects during disengagement and engagement with the outer shell.

Ethernet Cable Cross-Filler with Notches
United States Patent 11,393,610
Issued July 19, 2022
Inventors: Bradley G. Hess, Sinking Spring, PA, USA
Assignee: Berk-Tek LLC, New Holland, PA, USA
A cross filler for arrangement within a LAN cable has a plurality of twisted pair conductors. The cross filler has a body and a plurality of radially extending arms from a center point. Each of the arms has a plurality of spaced apart notches cut into the arms, the notches spaced apart along the length of the arms. Each of the notches are dimensioned allowing bending of the LAN cable without physical breakdown of the cross filler.
Optical Fiber Core Wire
United States Patent 11,385,431
Issued July 12, 2022
Inventors: Masatoshi Tanaka, Amagasaki, Japan; Yoshiki Yamakawa, Amagasaki, Japan; Hideaki Itou, Amagasaki, Japan; and Daiki Tabei, Amagasaki, Japan
Assignee: Mitsubishi Cable Industries, Ltd., Tokyo, Japan
The coated optical fiber (10) includes: an optical fiber (11) including a core (111) and a cladding (112); a first buffer layer (121) covering the optical fiber (11), and having a refractive index lower than that of the cladding (112) and a Shore D hardness of D/20.0/1 or higher; a second buffer layer (122) covering the first buffer layer (121), and having a higher Shore D hardness than the first buffer layer (121); and a jacket (13) covering the second buffer layer (122).

Tracking Metallic Wires During a Winding Operation
United States Patent 11,383,283
Issued July 12, 2022
Inventor: Joseph Timothy Clark, Louisville, KY, USA
Assignee: Clark Innovative Technologies, Lebanon, KY, USA
Methods, apparatus, systems, and computer-readable media are provided for tracking amounts of wires provided to a winding head during a winding operation of a wire distribution system. The wires can be tracked using one or more wire tracking devices that can be disposed at one or more locations within the wire distribution system. The wire tracking devices can provide information related to the amounts of wires and the types of wires being used to wind about a winding head/form. The information can be used to check for errors during a winding operation and indicate the progress of the winding operation. The information can also be used to update wire-availability data to reflect the amount of wire that has been provided during the winding operation.

Combination Cable for Vehicle
United States Patent 11,377,050
Issued July 5, 2022
Inventor: Kenta Kobayashi, Mie, Japan
Assignee: Sumitomo Wiring Systems, Ltd., Mie, Japan
Provided is a combination cable for a vehicle that is capable of reducing noise interference and cross-talk between twisted pair wires. The combination cable for a vehicle includes a wire bundle and a sheath covering the wire bundle. The wire bundle includes a two-core first twisted pair wire, a two-core second twisted pair wire, a one-core first wire, and a one-core second wire. When viewed in cable cross-section, the wire bundle has the first twisted pair wire disposed on one side of a center line that runs from a center of the first wire to a center of the second wire, and has the second twisted pair wire disposed on the other side of the center line, and the first twisted pair wire and the second twisted pair wire are separated from each other.

Systems & Methods for Additive Manufacturing Using Aluminum Metal-Cored Wire
United States Patent 11,370,068
Issued June 28, 2022
Inventors: Patrick Berube, Traverse City, MI, USA; Gregory J. Bramer, Traverse City, MI, USA; and Shuang Liu, Appleton, WI, USA
Assignee: Hobart Brothers LLC, Troy, OH, USA
A method of forming an additively manufactured aluminum part includes establishing an arc between a metal-cored aluminum wire and the additively manufactured aluminum part, wherein the metal-cored aluminum wire includes a metallic sheath and a granular core disposed within the metallic sheath. The granular core comprises aluminum metal matrix nano-composites (Al-MMNCs) that comprise an aluminum metal matrix and ceramic nanoparticles. The method includes melting a portion of the metal-cored aluminum wire using the heat of the arc to form molten droplets. The method includes transferring the molten droplets to the additively manufactured aluminum part under an inert gas flow and solidifying the molten droplets under the inert gas flow to form deposits of the additively manufactured aluminum part.

Methods to Generate Elongated Wires Having a Metallic Substrate Thereon and Devices Comprising the Same
United States Patent 11,373,780
Issued June 28, 2022
Inventors: Ghassan Kassab, La Jolla, CA, USA; Zachary Berwick, San Diego, CA, USA; Matthew J. Phillips, Carlsbad, CA, USA; and Peter J. D’Aquanni, Murrieta, CA, USA
Assignee: 3DT Holdings, LLC (San Diego, CA)
Methods to generate elongated wires having a metallic substrate thereon and devices comprising the same. In a method of generating a device, the method comprises the steps of applying a first nonconductive coating upon an elongated core body of the device; applying a first conductive coating upon the first nonconductive coating; applying a photoresist coating upon the first conductive coating; directing a laser/light from a laser/light source upon portions of the photoresist coating to cause said portions of the photoresist coating to harden; applying a first chemical to the photoresist coating to remove the photoresist coating that was not hardened by the laser/light; and applying a second chemical to the hardened photoresist coating to expose portions of the first conductive coating previously positioned below the hardened photoresist coating.

Hybrid Cables for Use with Sensitive Detectors
United States Patent 11,373,783
Issued June 28, 2022
Inventors: Christopher W. McNutt, Woodstock, GA, USA; Amir Sekhavat, Marietta, GA, USA; and Nathan Spare, Ellinwood, KS, USA
Assignee: Superior Essex International LP, Atlanta, GA, USA
A hybrid cable for use with sensitive detectors may include a central power delivery component, a data delivery component positioned around the power delivery component, and a jacket formed around the power delivery component and the data delivery component. The power delivery component may include a plurality of shielded first individually insulated conductors. The data delivery component may include four twisted pairs of second individually insulated conductors and respective shield layers formed around each of the four pairs. An outer diameter of the cable may be less than 8.5 mm, and the cable may be capable of transmitting data within an operating frequency range of up to 2.5 GHz over a distance of at least 100 m.

Fire Resistant Data Communication Cable
United States Patent 11,367,541
Issued June 21, 2022
Inventors: Gregg Raymond Szylakowski, Loveland, OH, USA; and Scott M. Brown, Independence, KY, USA
Assignee: General Cable Technologies Corporation, Highland Heights, KY, USA
Data communication cables include twisted wire pairs, a fire retardant tape, a metallized tape shield, a braided metallic shield and a jacket layer. The fire retardant tape surrounds the twisted wire pairs has an overlap of about 15% to about 25%. The data communication cables are also halogen-free and may pass the fire retardant standards of National Fire Protection Agency (“NFPA”) 130.

Hybrid Electro-Optic Wireline Cable
United States Patent 11,366,275
Issued June 21, 2022
Inventors: John Laureto Maida, Houston, TX, USA; Sudhir Kumar Gupta, Kingwood, TX, USA; Michael Joseph LeBlanc, Houston, TX, USA; Arabinda Misra, Houston, TX, USA; and Ramon Hernandez Marti, Houston, TX, USA
Assignee: Halliburton Energy Services, Inc., Houston, TX, USA
A hybrid electro-optic (EO) wireline cable includes optical fibers strategically placed within to allow acoustic sensing methods as well as provide power and electrical telemetry. The hybrid EO wireline cable contains optical fibers in the interstices among symmetrically arranged electrical wire bundles to allow a hybrid EO cable to be concurrently used for electrical telemetry and optical fiber sensing without interference in a wellbore environment. This hybrid EO cable maintains electric and magnetic field symmetry which allows an optimal electrical signaling rate through orthogonal propagation modes. By placing optical fibers symmetrically inside the interstitial spaces between electrical wire bundles, the cable maintains its optimal signaling rate and avoids the mechanical and electrical limitations that would be introduced when combining electrical wires and optical fibers in a wireline cable.

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