Data transmission cable pairs and cables and methods for forming the same

1. A data transmission pair comprising:

first and second longitudinally extending electrical conductors each having a longitudinally extending, substantially flat side surface, wherein the first and second conductors are paired such that their respective flat side surfaces face one another; and

an insulation cover having a separator portion and surrounding the first and second conductors, the separator portion being interposed between and separating the respective flat side surfaces of the first and second conductors;

wherein the first and second conductors are helically twisted about one another;

wherein the insulation cover includes the separator portion and an outer insulation portion surrounding each of the first and second conductors, and the separator portion is unitarily extruded with the outer insulation portion; and

wherein the spacing distance between the first and second conductors is at least about 0.01 inches.

2. The pair of claim 1 wherein the opposed flat side surfaces of the first and second conductors are oriented substantially parallel to one another.

3. The pair of claim 1 wherein each of the first and second conductors has a cross-sectional shape that is asymmetric.

4. The pair of claim 3 wherein the first and second conductors are each substantially D-shaped in cross-section.

5. The pair of claim 1 wherein the first and second conductors are helically twisted about one another such that the flat side surfaces take the form of helically wound flat surfaces that are substantially parallel to one another along the length of the cable and the separator portion of the insulation cover forms a helically wound ribbon interposed between the flat side surfaces of the first and second conductors.

6. The pair of claim 1 wherein each of the flat side surfaces does not deviate from fully flat by more than 10 mils.

7. The pair of claim 1 wherein a maximum separation distance between the flat side surfaces of the first and second conductors is not more than 15% greater than a minimum separation distance between the flat side surfaces of the first and second conductors.

8. The pair of claim 1 wherein the insulation cover includes pockets defined in the separator portion between the flat side surfaces of the first and second conductors, and the pockets contain gas.

9. The pair of claim 1 wherein the first conductor is between the separator portion and the outer insulation portion of the insulation cover, and wherein a thickness of the outer insulation portion is less than a thickness of the separator portion.

10. A data transmission cable comprising:

first and second longitudinally extending electrical conductors each having a longitudinally extending, substantially flat side surface, wherein the first and second conductors are paired such that their respective flat side surfaces face one another; and

a first insulation cover having a separator portion and surrounding the first and second conductors, the separator portion being interposed between and separating the respective flat side surfaces of the first and second conductors;

wherein the first and second conductors are helically twisted about one another; and

wherein the first insulation cover further includes an outer insulation portion surrounding each of the first and second conductors, and the separator portion is unitarily extruded with the outer insulation portion;

third and fourth longitudinally extending electrical conductors each having a longitudinally extending, substantially flat side surface, wherein the third and fourth conductors are paired such that their respective flat side surfaces face one another; and

a second insulation cover having a second separator portion and surrounding the third and fourth conductors, the second separator portion being interposed between and separating the respective flat side surfaces of the third and fourth conductors;

fifth and sixth longitudinally extending electrical conductors each having a longitudinally extending, substantially flat side surface, wherein the fifth and sixth conductors are paired such that their respective flat side surfaces face one another;

a third insulation cover having a third separator portion and surrounding the fifth and sixth conductors, the third separator portion being interposed between and separating the respective flat side surfaces of the fifth and sixth conductors;

seventh and eighth longitudinally extending electrical conductors each having a longitudinally extending, substantially flat side surface, wherein the seventh and eighth conductors are paired such that their respective flat side surfaces face one another; and

a fourth insulation cover having a fourth separator portion and surrounding the seventh and eighth conductors, the fourth separator portion being interposed between and separating the respective flat side surfaces of the seventh and eighth conductors; and

an outer cable jacket surrounding the first, second, third and fourth insulation covers;

wherein the spacing distance between each of the first and second conductors, the third and fourth conductors, the fifth and sixth conductors, and the seventh and eighth conductors, is at least about 0.01 inches.

11. The data transmission cable of claim 10 wherein the first conductor is between the separator portion and the outer insulation portion of the first insulation cover, and wherein a thickness of the outer insulation portion of the first insulation cover is less than a thickness of the separator portion of the first insulation cover.

12. The data transmission cable of claim 10 wherein the cable further includes a divider strip that separates at least some of the first through fourth insulation covers from other of the first through fourth insulation covers, and wherein the first through fourth insulation covers are twisted about one another.

13. A data transmission pair comprising:

first and second longitudinally extending electrical conductors paired together and each having a cross-sectional shape that is asymmetric; and

an insulation cover having a separator portion and surrounding the first and second conductors, the separator portion being interposed between and separating the first and second conductors;

wherein the first and second conductors are each substantially D-shaped in cross-section; and

wherein the first and second conductors are helically twisted about one another;

wherein the first conductor is between the separator portion and an outer portion of the insulation cover, and wherein a thickness of the outer portion is less than a thickness of the separator portion.

14. The pair of claim 13 wherein the separator portion of the insulation cover forms a helically wound ribbon interposed between the first and second conductors.

15. The pair of claim 13 wherein the thickness of the separator portion between the flat side surfaces of the first and second conductors is in the range of from about 0.01 to 0.03 inch.