How it's Made: Copper Communications Cables

Summary

Superior Essex manufactures a wide range of copper communications cables across multiple U.S. facilities, following a highly precise and refined process. Starting with large copper rods, the material is drawn, annealed, and coated with plastic insulation before being twisted and stranded into cable units. Multi-unit cores are combined for large designs, then covered with carefully selected jackets for various applications. Advanced monitoring ensures diameter, tensile strength, and insulation quality meet strict tolerances. Finished cables undergo printing, coiling, and rigorous testing before shipment. With over 50 years of continuous refinement, Superior Essex produces more than 5,000 high-performance copper cable products for diverse communications needs.

Takeaways

• 🏭 Superior Essex manufactures a wide range of copper communication cables across multiple U.S. facilities.
• 🛠️ The manufacturing process starts with rod breakdown, reducing 5/16 inch copper rods to smaller gauges using diamond dies.
• ⚡ Copper is annealed by passing an electrical current through the wire and cooling it, which softens the metal and ensures precise diameter control.
• 🎛️ Insulation is applied via extruders with high precision, and the process is continuously monitored for quality, including tensile strength, elongation, compression, and strip force.
• 🔄 Twisted pairs are created to minimize crosstalk interference, with each pair having a unique twist length depending on the cable type.
• 🧵 Stranding combines multiple twisted pairs to form a cable unit, with separators added to improve performance in high-speed data cables like Category 6.
• 🔗 For large cable designs, multiple units are grouped to form multi-unit cores using color-coded binders for identification.
• 🧥 The jacketing process applies the outer protective layer using materials chosen for the cable's intended application, including UV-grade PVC, polyethylene, and fluoropolymers.
• -
• 💧 Additional features like shielding, water-blocking compounds, and armoring are added during jacketing to enhance cable durability.
• 🖨️ Printing and packaging are tailored for cable type, including hot foil printing for large cables and inkjet printing with footage markings for premises cables.
• ✅ Finished cables undergo rigorous final testing for mechanical and electrical performance, with test records used to continuously improve quality.
• 📈 Superior Essex has refined its manufacturing process over 50 years, producing over 5,000 different high-performance copper cable products.

Q & A

What is the first step in the manufacturing process of copper cables?

The first step is called 'rod breakdown.' Copper is received in 5,000-pound coils of 5/16 inch diameter rod, which is drawn through a series of diamond dies to reduce its size.

Why is a lubricant used during the rod breakdown process?

A special lubricant is used to reduce friction between the dies and the copper, ensuring a smooth, high-quality wire.

What happens during the second drawing operation?

In the second drawing operation, the copper wire is further reduced in gauge, and it is also annealed. This process softens the copper by passing an electrical current through it and then cooling it with water.

How is the diameter of the copper wire controlled during the annealing process?

The diameter is carefully controlled using laser measuring heads to ensure precision during the annealing process.

What is the purpose of the insulation process in copper cable manufacturing?

The insulation process involves applying a plastic coating to the copper wire, which is monitored for strict tolerances to ensure high-quality insulation that meets tensile strength, elongation, compression, and strip force specifications.

What is the significance of twisted pairs in copper communication cables?

Twisted pairs help reduce crosstalk interference. Each pair in a cable bundle has a unique twist length, which helps prevent signal interference between the pairs.

What happens during the stranding process?

During stranding, pairs of twisted wires are combined to form a cable unit. In the case of category 6 cables, separator tape is inserted to improve crosstalk performance.

What is the purpose of the cabling process in copper cable manufacturing?

The cabling process involves grouping several cable units together to form a multi-unit cable core. This step is essential for manufacturing larger cables, with designs that may contain up to 4,200 pairs of wires.

What materials are used for the outer cable jackets in copper communication cables?

For outside plant cables, black polyethylene or UV-grade PVC is commonly used. For premises cables, varying grades of PVC and fluoropolymers are used, depending on the cable’s intended application and required flame safety rating.

How is the finished copper cable tested before shipment?

Before shipment, the completed cable undergoes a final test inspection, where it is checked against a set of mechanical and electrical performance specifications. The test results are retained and analyzed to refine the cable's performance.