Patents for March/April 2023

USPTO Wire & Cable Industry Patents as compiled by our editors

Aluminum Alloy Wire, Aluminum Alloy Strand Wire, Covered Electrical Wire, and Terminal-Equipped Electrical Wire
US Patent 11594346
Published February 28, 2023
Inventors: Misato Kusakari, Osaka, Japan; Tetsuaya 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 μm in a depth direction, and a total cross-sectional area of voids in the surface-layer void measurement region is equal to or less than 2 μm2.

Cable Jacket Composition
US Patent 11591455
Published February 28, 2023
Inventors: Anna Hjärtfors, Kungälv, Sweden; Yi Liu, Engerwitzdorf, Austria; Victor Sumerin, Helsinki, Finland; and Joseph Thorman, Helsinki, Finland
Assignee: Borealis AG, Vienna, Austria
The present invention relates to a cable jacket composition comprising a multimodal olefin copolymer, wherein said olefin copolymer has a density of 0.935-0.960 g/cm3 and MFR2 of 1.5-10.0 g/10 min and comprises a bimodal polymer mixture of a low molecular weight homo- or copolymer and a high molecular weight copolymer wherein the composition has ESCR of at least 2000 hours and wherein the numerical values of cable wear index and composition MFR2 (g/10 min) follow the correlation: Wear index<15.500+0.900*composition MFR2. The invention further relates to the process for preparing said composition and its use as outer jacket layer for a cable, preferably a communication cable, most preferably a fiber optic cable.

Optical Fiber Cable
US Patent 11592634
Published February 28, 2023
Inventors: Shinnosuke Sato, Sakura, Japan; Mizuki Isaji, Sakura, Japan; Koji Tomikawa, Sakura, Japan; and Ken Osato, Sakura, Japan
Assignee: Fujikura Ltd., Tokyo, Japan
An optical fiber cable includes: optical fiber units each having optical fibers; a wrapping tube that wraps around the optical fiber units; a filling disposed inside the wrapping tube; and a sheath that covers the wrapping tube. The optical fiber units includes outer units that are disposed at an outermost layer of the optical fiber units. The outer units are twisted in an SZ shape around a cable central axis of the optical fiber cable. The filling is sandwiched between one of the outer units and the wrapping tube in a cross-sectional view.

Round and Small Diameter Optical Cables with a Ribbon-like Optical Fiber Structure
US Patent 11592632
Published February 28, 2023
Inventors: Joseph Cignarale, Greer, SC, USA; Doug Baker, Spartanburg, SC, USA; Yoshio Hashimoto, Greer, SC, USA; and Ken Osato, Chiba, Japan
Assignees: AFL Telecommunications LLC and Fujikura Ltd.
An optical fiber cable including an optical fiber ribbon in a pipe, wherein the ribbon includes at least two optical fibers arranged side by side, and wherein at least two of the optical fibers are bonded intermittently along a length of the fibers.

Alumina Hydrate Particles, Flame Retardant, Resin Composition and Electric Wire/Cable
US Patent 11591520
Published February 28, 2023
Inventor: Seiji Matsui, Kagawa, Japan
Assignee: Konoshima Chemical Co., Ltd., Osaka, Japan
The present invention provides alumina hydrate particles, a flame retardant and a resin composition that are each for an electric wire/cable covering material improvable in flame retardancy and mechanical properties while the covering material keeps acid resistance; such an electric wire/cable; and producing methods thereof. The alumina hydrate particles of the present invention for electric wire/cable covering material have an average particle size of 0.5 to 2.5 μm, and having a primary particle variation R of 24% or less, the variation R being represented by the following expression: primary particle variation R (%)=“standard deviationσ(μm) of major axis diameters of the primary particles”/“average value(μm) of the major axis diameters of the primary particles”×100.

Cable For Distributing Network Power and Data
US Patent 11594348
Published February 28, 2023
Inventors: Thomas F Craft, Jr., Murphy, TX, USA; Willis F. James, Wylie, TX, USA; David A. Winkler, Arlington, VA, USA; Gary L. Guilliams, Hayes, VA, USA; Randall D. Stevens, Lincolnton, NC, USA; and Thomas G. Leblanc, Westminster, MA, USA
Assignee: CommScope Technologies LLC, Hickory, NC, USA
A power cable or a hybrid power-data cable includes power conductors and a plurality of continuity wires positioned radially outside of the power conductors. The continuity wires are positioned relative to the power conductors such that a cut in the cable will sever one of the plurality of continuity wires before a cut into the power conductors can occur.

Low-Profile Cable Armor
US Patent 11587699
Published February 21, 2023
Inventors: Peter Lafreniere, Matapoisett, MA, USA; Stephen Lundgren, Marion, MA, USA; Paulo Damoura, Dorchester, MA, USA; Ronald Pegg, New Bedford, MA, USA; Antonio Araujo, New Bedford, MA, USA; and David Campbell, Bristol, RI, USA
Assignee: AFC Cable Systems, Inc., New Bedford, MA, USA
Disclosed is a cable assembly including at least one conductor and a metal sheath disposed over the at least one conductor, the metal sheath including a continuous strip of metal having a plurality of revolutions. A first revolution of the plurality of revolutions may include a first section having a curved profile extending into an interior cavity of the metal sheath, and a second section extending from the first section, the second section extending along a lengthwise axis, wherein a length of the second section, along the lengthwise axis, is at least two times as large as a diameter of the first section when the metal sheath is in a linear configuration. The first revolution may further include a third section extending from the second section, the third section including a free end terminating within a recess defined by a curved profile of a first section of an adjacent revolution.

High Strength Dielectric Member for a Communications Cable
US Patent 11587700
Published February 21, 2023
Inventors: Ted Q. Cobb, Jr., Hickory, NC, USA; and Trent M. Hayes, Hickory, NC, USA
Assignee: CommScope Technologies LLC, Hickory, NC, USA
A new dielectric material for a communication cable has a dielectric base with strength members embedded therein. By a new process, vacuum voids are formed in the dielectric base and at least partially contain or about the strength members. The material is particularly well suited for a first dielectric tape, where the cable includes a first insulated conductor, the first dielectric tape and a second insulated conductor, with the first insulated conductor being twisted with the second insulated conductor with the first dielectric tape residing between the first insulated conductor and the second insulated conductor. The material is also suitable for a separator of the cable serving to separate twisted pairs from each other within the cable as well as other components of the cable such as an insulation layer of one or more of the insulated conductors of the twisted pairs.

Optical Cable Having a Buffer Tube with Flexible Ribbon
US Patent 11585999
Published February 21, 2023
Inventors: Ray Lance Marvin, Hickory, NC, USA; James David Holder, Hickory, NC, USA; and Michael Gray Doub, Claremont, NC, USA
Assignee: Prysmian S.p.A., Milan, Italy
An optical cable includes a plurality of buffer tubes, each of the buffer tubes includes a flexible ribbon, the flexible ribbon including a plurality of optical fibers, the flexible ribbon being wrapped with a finished tape.

Waterproof Cable and Waterproof Cable Manufacturing Method
US Patent 11581108
Published February 14, 2023
Inventor: Takao Asano, Gumma, Japan
Assignee: Hosiden Corporation, Osaka, Japan
To provide a waterproof cable that is easily manufactured and improves waterproofness. The waterproof cable includes: a first cable; a second cable, an end of which is connected with an end of the first cable; a first resin member that coats a connecting part and is formed by insert-molding; a second resin member that coats the first resin member and is formed by insert-molding; and a third resin member that coats the second resin member and is formed by insert-molding.

Magneto-Sensitive Wire for Magnetic Sensor and Production Method Therefor
US Patent 11579212
Published February 14, 2023
Inventors: Norihiko Hamada, Aichi-ken, Japan; and Akihiro Shimode, Aichi-ken, Japan
Assignee: Aichi Steel Corporation, Tokai, Japan
A magneto-sensitive wire (magneto-sensitive body) made of a Co-based alloy having a composite structure in which crystal grains are dispersed in an amorphous phase. The Co-based alloy is, for example, a Co—Fe—Si—B-based alloy, and the total amount of Si and B is preferably 20 to 25 at % with respect to the Co-based alloy as a whole. Preferably, the average diameter of the crystal grains is 70 nm or less and the area ratio of the crystal grains is 10% or less to the composite structure as a whole. The magneto-sensitive wire has a circular cross section and the wire diameter is about 1 to 100 μm. Such a magneto-sensitive wire can be obtained, for example, through a heat treatment step of heating an amorphous wire composed of a Co-based alloy at a temperature equal to or higher than a crystallization start temperature and lower than a crystallization end temperature.

Optical Fiber Cable with Improved Fire Protection Performance
US Patent 11579388
Published February 14, 2023
Inventors: Emanuela Gallo, Berlin, Germany; Michael Alexander Heinz, Berlin, Germany; Tomasz Kazmierczak, Lodz, Poland; and Kirsten Langfeld, Berlin, Germany;
Assignee: Corning Research & Development Corporation, Corning, NY, USA
An optical fiber cable comprises a cable core including at least one optical transmission element to transfer light, and a cable jacket surrounding the cable core. The cable jacket is embodied as a multilayered structure having a first sheath layer and at least a second sheath layer being surrounded by the first sheath layer. The material of the first and the second sheath layer is halogen free. The material of the first sheath layer and the material of the second sheath layer have a different flame retardant additive providing different flame retardant mechanisms.

Diffusion Barriers for Metallic Superconducting Wires
Us Patent 11574749
Published February 7, 2023
Inventors: David B. Smathers, Columbus, OH, USA; and Paul R. Aimone, Bridgewater, MA, USA
Assignee: Materion Newton Inc., Newton, MA, USA
In various embodiments, superconducting wires incorporate diffusion barriers composed of Ta alloys that resist internal diffusion and provide superior mechanical strength to the wires.

Cover For a Cable Harness with Different Color Layers
US Patent 11569006
Published January 31, 2023
Inventors: Jacob Przyojski, Howard City, MI, USA; and Andreas Meier, Grand Rapids, MI, USA
Assignee: tesa SE, Norderstedt, Germany
A cover for a cable harness including: (i) a first layer comprising a first color; (ii) a second layer layered adjacent to the first layer, the second layer comprising a second color that is different than the first color; and (iii) an adhesive layer adhered to the first layer, at least a portion of the adhesive is not covered by the second layer. The first color can black, while the second color is white. The second layer comprises fibers that can be substantially free of dye. At least one of the first layer and the second layer can be polyethylene terephthalate. The cover can cover a plurality of cables of a cable harness. If wear forms a hole through the first layer, the second color of the second layer is visible from an environment external to the covered cable harness through the hole through the first layer.

US Patent 11569005
Published January 31, 2023
Inventors: Masashi Moriyama, Tokyo, Japan; Detian Huang, Tokyo, Japan; Yoshinori Tsukamoto, Tokyo, Japan; and Masanori Kobayashi, Tokyo, Japan
Assignee: Hitachi Metals, Ltd., Tokyo, Japan
A cable includes a cable core including a linear filler, and a plurality of core wires for signal transmission, a shield layer covering around the cable core, and a sheath covering around the shield layer. The filler includes a first filler provided at a cable center, and a plurality of second fillers provided around the first filler to form a cross-shape with the first filler in a cross-section perpendicular to a cable longitudinal direction. The cable core is configured in such a manner that the plurality of core wires and the plurality of second fillers are spirally twisted around the first filler to be alternately arranged in a circumferential direction.

Lead Alloy Barrier Tape Splice for Downhole Power Cable
US Patent 11562834
Published January 24, 2023
Inventor: Christopher Von Fange, Lawrence, KS, USA
Assignee: Schlumberger Technology Corporation, Sugar Land, TX, USA
A technique facilitates splicing of a power cable including splicing of a protective lead barrier. According to the technique, the power cable comprises conductors which form individual phases of a multi-phase conductor assembly. The conductors may be individually spliced for each phase of the multi-phase conductor assembly. Subsequently, splicing of the protective lead barrier may be performed by utilizing a lead based tape which is wrapped, e.g., helically wrapped, around the conductors. The wrapping technique provides a gas seal with respect to each individual insulated conductor within the multi-phase conductor assembly. Depending on the specifics of a given application and environment, additional layers may be added to ensure formation of a desirable splice.

Power Cable, Method for Production and Use Thereof
US Patent 11562833
Published January 24, 2023
Inventor: Bernt Henrik Hellesøe, Bergen, Norway
Assignee: Blue Sea Norway AS, Bergen, Norway
The present invention concerns a power cable, comprising a tension member (1), placed in the centre of said power cable; a first insulation layer (3), the tension member (1) being embedded in the first insulation layer (3); and an outer protective sheath (9); wherein said power cable further comprises one or more first aluminum conductors (4), embedded within the first insulation layer (3). The present invention also concerns a process for producing the inventive power cable, the process comprising the step of extruding a first polymeric insulation layer (3) onto the tension member (1) and the one or more conductors (4) in one single step. Finally, the present invention concerns the use of the inventive power cable, in medium-voltage to high-voltage subsea applications such as an offshore windmill cable infrastructure or driving of subsea pumps.

Metal-Clad Multi-Circuit Electrical Cable Assembly
US Patent 11557408
Published January 17, 2023
Inventors: Troy D. Skidmore, McKinney, TX, USA; Paul Abernathy, McKinney, TX, USA; David W. Maxey, Gunter, TX, USA; and William T. Bigbee, Jr., Melissa, TX, USA
Assignee: Encore Wire Corporation, McKinney, TX, USA
An electrical cable assembly, comprising a first electrical circuit further comprising a first plurality of insulated conductors longitudinally disposed to one another, wherein the first plurality of insulated conductors are cabled together in a bundle. The electrical cable assembly further comprises a second electrical circuit longitudinally disposed to the first electrical circuit, the second electrical circuit comprising a second plurality of insulated conductors longitudinally disposed to one another and cabled together in a bundle and a nonmetallic jacket surrounding the second plurality of insulated conductors and wherein the nonmetallic jacket isolating the first electrical circuit from the second electrical circuit. The electrical cable assembly further comprises a flexible interlocking metallic armor encasing the first and second electrical circuits.

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