Claims:CLAIMS

What is claimed is:

1. A cable (100) comprising:

at least one twisted pair of conductors (102), wherein the at least one twisted pair of conductors (102) has a pair lay length and a pair impedance, wherein the at least one twisted pair of conductors (102) has a frequency ratio between 4.77 - 12.25, wherein the frequency ratio is ratio of the pair impedance to the pair lay length; and

a sheath (110) encapsulating the at least one twisted pair of conductors (102), wherein the cable (100) can operate between 0.1MHz to 20 MHz.

2. The cable (100) as claimed in claim 1, wherein the cable (100) is a Single-Pair Ethernet cable.

3. The cable (100) as claimed in claim 1, further comprising an insulation layer (104) at least partially covering each conductor of the at least one twisted pair of conductors (102).

4. The cable (100) as claimed in claim 1, further comprising an insulation layer (104) at least partially covering each conductor of the at least one twisted pair of conductors (102), wherein the insulation layer (104) has at least one solid insulation layer and a foam insulation layer.

5. The cable (100) as claimed in claim 1, further comprising an insulation layer (104) at least partially covering each conductor of the at least one twisted pair of conductors (102), wherein the insulation layer (104) has at least one layer of polyolefin.

6. The cable (100) as claimed claim 1, further comprising a first metal layer (106) at least partially covering the at least one twisted pair of conductors (102).

7. The cable (100) as claimed in claim 6, further comprising a second metal layer (108) at least partially covering the first metal layer (106), wherein the second metal layer (108) does not fully cover the first metal layer (106).

8. The cable (100) as claimed in claim 1, wherein the at least one twisted pair of conductors (102) are twisted such that length of conductor is 105-115% of cable length.

9. The cable (100) as claimed in claim 1, wherein the cable (100) has an impedance greater than or equal to 80 Ω.

10. The cable (100) as claimed in claim 1, wherein the frequency ratio is greater than equal to 4.77
, Description:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)


TITLE OF THE INVENTION

“SINGLE PAIR ETHERNET CABLE”

APPLICANTS:

Name: Sterlite Technologies Limited

Nationality: Indian

Address: 3rd Floor, Plot No. 3, IFFCO Tower, Sector 29
Gurugram, Haryana -
122002

The following specification describes the invention and the manner in which it is to be performed:-
 
TECHNICAL FIELD
[0001] The present disclosure relates to the field of Ethernet cables. More specifically, the present disclosure relates to Single Pair Ethernet cables operating between 0.1MHz-20MHz frequency.

BACKGROUND
[0002] Ethernet cables are used to transmit broadband signals between modem, router, and computer. The conventional Ethernet cables have either 2 or 4 pairs of conductors based on the transmission rate. With the technological advancements, Single Pair Ethernet cables evolved. The Single Pair Ethernet cables are lean, lightweight, and material saving ethernet cables. In addition, the Single Pair Ethernet cables enable fast and easy installation. Further, the use of single-pair ethernet cable reduces the chances of error in the assembly. The Single Pair Ethernet cables were initially developed to meet the demands of the automotive industry. As technology evolved, the use of Single Pair Ethernet cables spread to various other industries apart from the automotive industry. The Internet of Things (IOT) is one of the leading industries making use of the benefits of the Single Pair Ethernet cables. The use of Single Pair Ethernet cable helps the network professionals to connect devices to networks. Furthermore, the low frequency operation of the Single Pair Ethernet cable results in return losses due to higher impedance. The impedance increases at lower frequencies and results in failure of electrical performance. Also, the higher impedance reduces the output of the Single Pair Ethernet cable.

[0003] One of the current solutions to mitigate the problems of return losses in Ethernet cables is to provide a Single Pair Ethernet for the industrial internet of things. In this work, accurate measurement setups have been developed in order to determine the per-unit-length parameters of Single Pair Ethernet (SPE) transmission lines in the frequency range 0 Hz − 1.0 GHz. However, the conductors are not insulated using foam or solid solutions. In addition, the Single Pair Ethernet cable does not work between 0.1-20MHz. Another solution to the problem of return losses is to provide a Single Pair Ethernet for industrial applications with bandwidth from 0.1-20MHz. However, the impedance is not reduced to operate the Single Pair Ethernet cable between 0.1-20 MHz.

[0004] In the light of the above stated discussion, there is a need to ameliorate one or more of the aforementioned disadvantages by providing a Single Pair Ethernet cable with a lower impedance value.

OBJECT OF THE DISCLOSURE

[0005] A primary objective of the present disclosure is to provide a cable operating between 0.1 MHz – 20 MHz frequency.

[0006] Another objective of the present disclosure is to provide the cable with an impedance to lay length ratio between 4.77 to 12.25 which reduces the return loss at low frequency.

[0007] Another objective of the present disclosure is to minimize alien crosstalk.

[0008] Another objective of the present disclosure is to provide a cable of small diameter cable with less weight.

[0009] Another objective of the present disclosure is to provide a cable with good electrical performance.

[0010] Another objective of the present disclosure is to enable easy installation of the cable.

SUMMARY
[0011] In an aspect, the present disclosure provides a cable. The cable includes at least one twisted pair of conductors and a sheath. The at least one twisted pair of conductors has a pair lay length and a pair impedance. The at least one twisted pair of conductors has a frequency ratio between 4.77 - 12.25. The frequency ratio is the ratio of the pair impedance to the pair lay length. The sheath encapsulates the at least one twisted pair of conductors. The cable can operate between 0.1MHz to 20 MHz.

STATEMENT OF THE DISCLOSURE
[0012] The present disclosure talks about a cable. The cable includes at least one twisted pair of conductors and a sheath. The at least one twisted pair of conductors has a pair lay length and a pair impedance. The at least one twisted pair of conductors has a frequency ratio between 4.77 - 12.25. The frequency ratio is ratio of the pair impedance to the pair lay length. The sheath encapsulates the at least one twisted pair of conductors. The cable can operate between 0.1MHz to 20 MHz.

BRIEF DESCRIPTION OF THE FIGURES
[0013] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0014] FIG. 1 illustrates a cross sectional view of a cable, in accordance with various aspects of the present disclosure; and

[0015] FIG. 2 illustrates a perspective view of a cable showing net like structure surrounding conductors, in accordance with various aspects of the present disclosure.

[0016] It should be noted that the accompanying figures are intended to present illustrations of exemplary depictions of the present disclosure. These figures are not intended to limit the scope of the present disclosure.

DETAILED DESCRIPTION
[0017] Reference in this specification to “one aspect” means that a particular feature, structure, or characteristic described in connection with the aspects included in at least one aspect of the present technology. The appearance of the phrase “in one aspect” in various places in the specification are not necessarily all referring to the same aspect, nor are separate or alternative aspects mutually exclusive of other aspects. Moreover, various requirements are described which may be requirements for some aspects but no other aspects.

[0018] Reference will now be made in detail to selected aspects of the present disclosure in conjunction with accompanying figures. The aspects described herein are not intended to limit the scope of the disclosure, and the present disclosure should not be construed as limited to the aspects described. This disclosure may be embodied in different forms without departing from the scope and spirit of the disclosure. It should be understood that the accompanying figures are intended and provided to illustrate aspects of the disclosure described below and are not necessarily drawn to scale. In the drawings, like numbers refer to like elements throughout, and thicknesses and dimensions of some components may be exaggerated for providing better clarity and ease of understanding.

[0019] Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present technology. Similarly, although many of the features of the present technology are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present technology is set forth without any loss of generality to, and without imposing limitations upon, the present technology.

[0020] It should be noted that the terms “first”, “second”, and the like, herein do not denote any order, ranking, quantity, or importance, but rather are used to distinguish on the element from another. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.

[0021] FIG.1 illustrates a cross sectional view of a cable 100, in accordance with various aspects of the present disclosure. FIG. 2 illustrates a perspective view of a cable showing net like structure surrounding conductors, in accordance with various aspects of the present disclosure. In an aspect of the present disclosure, the cable 100 is a Single-Pair Ethernet cable. The Single Pair Ethernet cable carries data and power. The Single pair Ethernet uses one pair of wires (or conductors) to transmit data at speeds of up to 10 Mbps (potentially up to 1 Gb/s in the future). The Single Pair Ethernet is designed for industrial users. The single-pair cabling can support up to 52 watts of dc power, covering a range of devices that need both power and data at distances up to 1,000 meters. In general, an ideal range of a Single Pair Ethernet cable to transmit power is 0.1MHz to 20MHz.

[0022] The cable 100 can operate between a frequency range of 0.1MHz to 20 MHz. The cable 100 suffers from return losses at the frequency of 0.1MHz to 20MHz. The cable 100 is lean, lightweight and includes material saving Ethernet development. In addition, the cable 100 is used in multiple applications such as internet of Things (IoT) applications, Smart City applications and Automation Industries. Further, the cable 100 can be installed faster and easier on site. Furthermore, the cable 100 reduces chances of errors in assembly. In an aspect, the cable 100 is an Outer Foil Shield/Unshielded Twisted Pair (F/UTP) cable.

[0023] The cable 100 includes at least one twisted pair of conductors 102. In FIG. 1, there is only one pair of conductors; however, there may be more than one pair of conductors. The at least one twisted pair of conductors 102 extend substantially along a longitudinal axis of the cable 100. In an aspect of the present disclosure, at least one twisted pair of conductors 102 is helically twisted along a length of the at least one twisted pair of conductors 102. The at least one twisted pair of conductors 102 are helically twisted together to minimize cross talk in the cable 100. The at least one twisted pair of conductors 102 are twisted together for purpose of cancelling out electromagnetic interference from internal and external sources.

[0024] The at least one twisted pair of conductors 102 is characterized by a cross-sectional diameter. In an aspect, the cross-sectional diameter of the at least one twisted pair of conductors 102 is about 18-24 AWG. In another aspect of the present disclosure, the cross-sectional diameter of each of the at least one twisted pair of conductors 102 may vary. In an aspect, the at least one twisted pair of conductors 102 is made of copper.

[0025] In an aspect of the present disclosure, the cable 100 includes an insulation layer 104. The insulation layer 104 at least partially covers each conductor of the at least one twisted pair of conductors 102. In an aspect of the present disclosure, the insulation layer 104 has at least one layer of polyolefin. In general, insulators are used in electrical equipment to support and separate electrical conductors. The electric current in the at least one twisted pair of conductors 102 cannot pass through the corresponding insulation layer 104. The insulation layer 104 is a protective coating layer over the corresponding at least one twisted pair of conductors 102. The insulation layer 104 provides electrical isolation for each of the corresponding at least one twisted pair of conductors 102. In an aspect, the insulation layer 104 has a thickness. In another aspect of the present disclosure, the insulation layer 104 may have any other suitable thickness.

[0026] In an aspect, the insulation layer 104 has at least one solid insulation layer and a foam insulation layer. The foam insulation layer and the solid insulation layer shield the at least one twisted pair of conductors 102. In general, the solid insulation covers the foam insulation. The foam insulation layer shields the at least one twisted pair of conductors 102. The solid insulation layer is provided to protect foam insulation layer because foam is soft and can be crushed easily.

[0027] In an aspect, the cable 100 includes a first metal layer 106. The first metal layer 106 at least partially covers the at least one twisted pair of conductors 102. The first metal layer 106 includes a shielding of pair with aluminum/PET Tape. The shielding of aluminum tape is used to minimize alien crosstalk. The alien crosstalk is electromagnetic noise occurring in the cable 100 running alongside one or more other signal-carrying cables. In an aspect of the present disclosure, the cable 100 has a small diameter. The shielding of aluminum/PET Tape around the small diameter cable reduces the alien crosstalk.

[0028] In an aspect, the cable 100 further includes a second metal layer 108. The second metal layer 108 at least partially covers the first metal layer 106. The second metal layer 108 does not fully cover the first metal layer 106. The second metal layer 108 has a net like structure to surround the first metal layer 106 (as shown in FIG. 2). The second metal layer 108 has tinned copper braiding. The second metal layer with the tinned copper braiding provides strength and grounding to the cable 100. In addition, the second metal layer 108 with the tinned copper braiding eliminates the need for a separate mechanism for grounding the cable 100. In an aspect, the braid layer is made of tinned copper to provide tensile strength to the cable 100. The cable 100 becomes lean and strong after providing strength and grounding.

[0029] The cable 100 includes a sheath 110. The sheath 110 encapsulates the at least one twisted pair of conductors 102. The sheath 110 tightly surrounds the core. In addition, the sheath 110 reduces the diameter of the cable 100. The reduction in diameter helps in easy installation of the cable 100. In an aspect, the sheath 110 is a low smoke zero halogen jacket. In general, the low smoke zero halogen jacket (LSZH) is a kind of cable built with a jacket material free from halogenic materials.

[0030] In an aspect, the cable 100 may or may not include one or more ripcords. The one or more ripcords include a ripcord 112. In an aspect, the cable 100 may include more ripcords. In an aspect, the ripcord 112 is placed between the second metal layer 108 and the sheath 110. The ripcord 112 lies substantially along a longitudinal axis of the cable 100. In an aspect, the ripcord 112 facilitates stripping of the sheath 110. In an aspect, the ripcord 112 is made of a polyester material. In another aspect, the ripcord 112 may be made of any suitable material. In an aspect, the ripcord 112 has circular cross-section.

[0031] The at least one twisted pair of conductors 102 has a pair lay length and a pair impedance. In general, the cable 100 includes a single pair of conductors to carry data and power. The lay length is a distance when one revolution of the conductor is completed. The twisting of the cable 100 increases with the decrease in the lay length. In addition, the tighter twisting of the cable 100 increases the length of the at least one twisted pair of conductors 102. In general, tighter twisting refers to a pair of conductors twisted tightly such that the area between the conductors is reduced and the length of the conductor is increased. In addition, the increase in length of the cable 100 improves the electrical performance. In an aspect, the increased length of the at least one twisted pair of conductors 102 decreases the inductance of the cable 100. In an aspect, the pair lay length must be between 8-18 mm.

[0032] The pair impedance is based on diameter over dielectric (DoD) and diameter of the conductors. Also, air gaps produced in between the conductors while twisting and bunching affects the impedance of the pair of conductors. In an aspect of the present disclosure, the cable 100 has the pair impedance greater than or equal to 80 Ω. If the pair impedance is below the value of 80 Ω, return losses will be increased within the defined frequency of 0.1-20MHz. In an aspect of the present disclosure, the pair impedance is between 80-110 Ω.

[0033] The at least one twisted pair of conductors 102 has a frequency ratio between 4.77 - 12.25. In an aspect, the frequency ratio is greater than equal to 4.77. The frequency ratio is ratio of the pair impedance to the pair lay length. In general, the frequency ratio is below 12.25 for the cable 100 to function efficiently at low frequencies of 0.1-20MHz. In an aspect of the present disclosure, the twisting around the at least one twisted pair of conductors 102 is tight to achieve low frequency ratio. The tight twisting of the at least one twisted pair of conductors 102 helps in increasing the length of the conductor. The increase in length of the at least one twisted pair of conductors 102 decreases the impedance value and helps achieve the required frequency ratio in the range of 4.77-12.25.

[0034] If the frequency ratio value falls in between the range of 4.77-12.25; then, the cable 100 performs efficiently (without any significant amount of return loss) in the low frequency range of 0.1-20MHz. If the frequency ratio is greater than 12.25; then, the return losses in the cable 100 increase which hampers the performance of the cable 100 in low frequency range of 0.1-20MHz. This means that the cable 100 is not compliant with the TIA 42.7 standard. If the frequency ratio is lesser than 4.77; then, the return losses as well as the insertion losses in the cable 100 increase which hampers the performance of the cable 100 in low frequency range of 0.1-20MHz. This means that the cable 100 is not compliant with the TIA 42.7 standard. Also, the frequency ratio between 4.77 to 12.25 helps in achieving a marginal difference in return loss with respect to TIA 42.7 standard.

[0035] In an aspect, the at least one twisted pair of conductors 102 are twisted such that length of conductor is 105-115% of cable length. The twisting around the at least one twisted pair of conductors 102 is tight enough to reduce the area between the at least one twisted pair of conductors 102. The tight twisting of the at least one twisted pair of conductors 102 increases the length of the at least one twisted pair of conductors 102 between 5%-15%. The cable 100 faces return losses if the value of the increase in length is less than 5%. In addition, the cable 100 faces insertion losses if the value of the length increases more than 15%. In an aspect, the at least one twisted pair of conductors 102 helps in reducing the diameter of the cable 100. In general, the length of the conductor is inversely proportional to the inductance of the cable. In four pair twisted conductors, if the conductors are tightly twisted, the length of the conductor is increased minimally by 9.2%. In an example: for a 100mm length of the cable 100, the conductors are tightly twisted to maintain the frequency ratio between 4.77-12.25. As soon as the ratio is achieved between this range, the conductor length is increased between 105-115 mm.

[0036] The foregoing descriptions of pre-defined aspects of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The aspects were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various aspects with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.