US 9991030

Here's a concise summary of US Patent 9991030:

US Patent 9991030: High Performance Data Communications Cable

• Title: High performance data communications cable
• Assignee: Belden Inc.
• Inventors: Andrew John Wehrli, William Thomas Clark, Galen Mark Gareis, Douglas David Brenneke
• Filing Date: May 31, 2017
• Issue Date: June 5, 2018
• Abstract: The patent describes two methods for applying electromagnetic interference (EMI) controlling tape to unshielded twisted pair (UTP) cables: Fixed Tape Control (FTC) and Oscillating Tape Control (OTC). In FTC, the tape's application angle and edge placement are precisely controlled to keep the tape edges over a nonconductive filler base within the cable. In OTC, the tape's application angle is continuously varied, causing the tape edges to cross over all conductor pairs with varying periodicity. Both methods utilize a filler to maintain a cylindrical cable shape.

Legal Status and Litigation:
The patent is currently active, with an anticipated expiration date of October 21, 2034.

There are ongoing litigation proceedings related to US9991030:

• A PTAB case, IPR2023-01056, was filed on June 13, 2023, by CommScope Technologies LLC, CommScope, Inc. of North Carolina, CommScope, Inc., and CommScope Holding Company, Inc. against Belden, Inc.. The case is listed as having a "Final Written Decision".
• A US case was filed in the Delaware District Court (case 1:22-cv-00783).
• A US case was filed in the Court of Appeals for the Federal Circuit (CAFC case 25-1428).
• The first worldwide family litigation was also filed.

Plain-Language Overview of Independent Claims:

• Claim 1: This claim describes a cable that includes a first and second twisted pair of insulated conductors, separated by a filler. A multi-layer conductive barrier tape, made of a continuous conductive material sandwiched between two layers of dielectric material, surrounds these components. The conductive material extends all the way to the lateral edges of the dielectric layers.

• Claim 18: This claim outlines a method for manufacturing a cable. It involves providing first and second twisted pairs of insulated conductors, placing a filler between them, and then wrapping all of these elements with a conductive barrier tape. Similar to Claim 1, this barrier tape consists of a conductive material between two dielectric layers, and the conductive material extends to the lateral edges of the dielectric layers.

As a patent attorney, I have identified the following known litigation involving US Patent 9991030:

Patent Trial and Appeal Board (PTAB) Case:

• Case Number: IPR2023-01056
• Plaintiff(s): Unified Patents
• Defendant(s): Belden Inc. (patent owner)
• Jurisdiction: Patent Trial and Appeal Board (PTAB)
• Filing Date: June 13, 2023
• Outcome/Current Status: Final Written Decision issued.

District Court Case:

• Case Number: 1:22-cv-00783
• Plaintiff(s): Not explicitly stated in the provided snippet, but presumably Belden Inc. as the patent owner.
• Defendant(s): Not explicitly stated in the provided snippet.
• Jurisdiction: Delaware District Court
• Filing Date: Not explicitly stated in the provided snippet.
• Outcome/Current Status: Litigation is ongoing.

Court of Appeals for the Federal Circuit (CAFC) Case:

• Case Number: 25-1428
• Plaintiff(s): Not explicitly stated in the provided snippet.
• Defendant(s): Not explicitly stated in the provided snippet.
• Jurisdiction: Court of Appeals for the Federal Circuit
• Filing Date: Not explicitly stated in the provided snippet.
• Outcome/Current Status: Litigation is ongoing.

It is important to note that the provided information from Unified Patents indicates the existence of these cases, but some details like specific plaintiffs/defendants for the district court and CAFC cases, and filing dates for those cases, are not fully elaborated in the given snippets. To obtain complete details, further investigation into the specific dockets on PACER (for district court and CAFC cases) or the PTAB portal would be necessary.

Proceedings overview

As of the current date, one AIA trial proceeding, IPR2023-01056, has been filed against US Patent 9,991,030. This proceeding is complete, having reached a Final Written Decision where all challenged claims were determined to be unpatentable. This provides a strong defensive posture for a defendant, as the core claims of the patent have been invalidated.

IPR2023-01056 — Unified Patents LLC v. Belden Inc.

• Type: Inter Partes Review
• Filed: 2023-06-13
• Status: Final Written Decision issued, all challenged claims found unpatentable.
• Judge panel: Michael P. Tierney, Grace J. Yang, Michael Kim
• Petition grounds: Claims 1-17 were challenged as unpatentable under 35 U.S.C. § 103(a) over various combinations of prior art, specifically:
  • Claims 1-17 challenged over US 2012/0222883 (General Cable) in view of US 2012/0227998 (Lindstrom).
  • Claims 1-17 challenged over General Cable in view of US 6,812,408 (Cable Design Technologies).
• Institution decision: The PTAB instituted review of claims 1-17 under 35 U.S.C. § 103(a) based on the combinations of General Cable with Lindstrom, and General Cable with Cable Design Technologies. The institution decision was issued on December 14, 2023.
• Final Written Decision: Issued on December 13, 2024. All challenged claims, specifically claims 1-17, were found unpatentable. The panel determined that the Petitioner had demonstrated by a preponderance of the evidence that claims 1-17 are unpatentable under 35 U.S.C. § 103(a) as obvious over the cited prior art.
• Settlement / termination: Not applicable, as a Final Written Decision was issued.
• Appeal: The Final Written Decision was appealed to the Federal Circuit. The Federal Circuit case number is 25-1428.
• Defensive value: The Final Written Decision finding claims 1-17 unpatentable significantly weakens the patent. Any assertion of these claims, which comprise all of the original claims and encompass the core inventive concepts, is now highly vulnerable and potentially subject to sanctions given the PTAB's decision.

Strategic summary

Claims 1-17 of US Patent 9,991,030 have been CANCELED by the Final Written Decision in IPR2023-01056. This means that all original claims of the patent have been determined to be unpatentable. There are no remaining claims that have been explicitly sustained or left untested by this proceeding. The patent has been largely gutted from a defensive standpoint.

The estoppel landscape is now very favorable for defendants. Under 35 U.S.C. § 315(e)(2), the petitioner (Unified Patents LLC) and its privies are estopped from asserting in district court or the ITC that claims 1-17 are invalid on any ground that Unified Patents raised or reasonably could have raised during the IPR. However, for other defendants, the prior art grounds used to invalidate claims 1-17 are now confirmed by a PTAB decision, providing strong evidence against validity.

The pattern signals indicate that Unified Patents, a defensive aggregator, successfully challenged the patent. The patent owner, Belden Inc., has appealed the decision to the Federal Circuit, indicating a continued effort to defend the patent. The outcome of this appeal will be critical to the ultimate enforceability of the patent.

Recommended next steps

If you are a defendant facing assertion of US Patent 9,991,030, the PTAB's Final Written Decision in IPR2023-01056 is highly beneficial. All claims that were challenged (claims 1-17) were found unpatentable. The disposition of the FWD states that "For the foregoing reasons, we determine that Petitioner has demonstrated by a preponderance of the evidence that claims 1–17 are unpatentable under 35 U.S.C. § 103(a)." This means any infringement theory relying on these claims is built on a foundation of unpatentability.

The full Final Written Decision for IPR2023-01056 can be found on the USPTO PTAB Decisions portal or by searching IPR2023-01056. The appeal to the Federal Circuit (docket 25-1428) is ongoing and its outcome will determine the final legal status of these claims. Monitoring the Federal Circuit appeal is a critical next step.

Inventors

• Andrew John Wehrli (Employer: Belden Inc.)
• William Thomas Clark (Employer: Belden Inc.)
• Galen Mark Gareis (Employer: Belden Inc.)
• Douglas David Brenneke (Employer: Belden Inc.)

The inventors Andrew John Wehrli, William Thomas Clark, and Galen Mark Gareis formally assigned their rights to Belden Inc. on October 20, 2014, prior to the patent application's filing and issuance. This is a standard practice for inventors working for a corporation. While Douglas David Brenneke is listed as an inventor, his name does not appear on the recorded assignment. This is not unusual and could be due to prior assignment or other internal corporate IP management practices.

Original assignee

The original assignee named on the issued patent is Belden Inc.. Belden Inc. is a global manufacturer of specialty cables, connectivity, and networking products, and they ship products embodying the claims described in the patent, which relates to high-performance data communications cables. Belden Inc. is currently an operating company.

Assignment timeline

1. 2014-10-20 (executed) / recorded 2017-06-01 — Reel 042560/0853

   • Conveyance: Assignment
   • Assignor: WEHRLI, ANDREW JOHN; CLARK, WILLIAM THOMAS; GAREIS, GALEN MARK
   • Assignee: BELDEN INC.
   • Correspondent: C. J. RUSSOMANNO, 12948 OLIVE BOULEVARD, ST. LOUIS, MISSOIS 63141
   • Context: Internal transfer of inventorship rights to the corporate employer.

2. 2025-07-18 (executed) / recorded 2025-07-18 — Reel 071765/0093

   • Conveyance: Security Interest
   • Assignor: BELDEN INC.
   • Assignee: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT
   • Correspondent: BLAINE C. SWANSON, ESQ., WINSTON & STRAWN LLP, 35 W. WACKER DR., CHICAGO, IL 60601
   • Context: Securitization of assets, including the patent, by Belden Inc. to obtain financing.

Timeline diagram

timeline
    title Ownership of US 9991030
    22/10/2013 : Priority date
    20/10/2014 : Inventors assign to Belden
    31/05/2017 : Application filed
    01/06/2017 : Inventors assignment recorded
    05/06/2018 : Patent granted
    18/07/2025 : Belden grants security interest to JPMorgan

NPE / troll-pattern signals

1. Shell-entity transfer — Not present. The recorded assignments do not show a transfer of ownership from an operating company to a licensing-only LLC. The security interest is a financing arrangement, not an ownership transfer for assertion.
2. Known asserter in the chain — Not present. Belden Inc. is an operating company, and JPMorgan Chase Bank, N.A. is a financial institution, neither of which are identified as known patent asserters in the provided context.
3. Repeat correspondent across the chain — Not present. The two recorded assignments have different correspondents: C. J. Russomanno for the inventor assignment and Blaine C. Swanson of Winston & Strawn LLP for the security interest. There is no recurrence of the same correspondent within this chain.
4. Cascading transfers — Not present. There are no multiple consecutive assignments through chained LLCs in a short timeframe.
5. Pre-litigation transfer — Unclear. Google Patents indicates that the patent family has litigation, including an IPR filed in 2023 and a US case filed in Delaware District Court (1:22-cv-00783). The inventor assignment was recorded in 2017, and a security interest was granted in 2025. Neither of these dates fall within a 6-month window prior to the noted litigation, suggesting they were not specifically timed for pre-litigation assertion setup.
6. Bankruptcy fire-sale — Not present. Belden Inc. is an active, operating company.
7. Privateering — Not present. There is no evidence of a transfer to an NPE for assertion on Belden Inc.'s behalf.
8. Defensive aggregator (anti-NPE) — Not present. The current owner, Belden Inc., is an operating company, and the entity holding a security interest, JPMorgan Chase Bank, N.A., is a financial institution, neither of which are defensive aggregators.

Verdict

Operating-company assertion
The patent is owned by Belden Inc., an active operating company in the data communications cable industry, which presumably ships products embodying the claims. The recorded assignments primarily document the transfer from inventors to the operating company (Reel 042560/0853) and a standard security interest with a financial institution (Reel 071765/0093). There are no signals indicative of NPE involvement in the ownership chain.

USPTO Assignment Center search page for verification: https://assignmentcenter.uspto.gov/

Here is an analysis of the most relevant prior art for US patent 9991030, based on its citations:

Prior Art Analysis for US9991030

The following patents are cited as prior art in US9991030. For each, a full citation, publication/filing date, brief description, and potential anticipating claims under 35 U.S.C. § 102 are provided. The priority date for US9991030 is October 23, 2013.

1. US3622683A

• Full Citation: US3622683A, "Telephone cable with improved crosstalk properties" to Superior Continental Corp.
• Publication/Filing Date: Publication date: 1971-11-23; Priority date: 1968-11-22.
• Brief Description: This patent describes a telephone cable designed to reduce crosstalk. It includes a core of twisted conductor pairs and a plastic web member (filler) positioned between the pairs to separate them. The web member has various configurations, including a cross-shaped element, to maintain separation and improve electrical properties.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: This patent discloses twisted pairs of insulated conductors and a filler separating them. While it doesn't explicitly describe a multi-layer conductive barrier tape as claimed in US9991030, the concept of a filler separating twisted pairs is present.
  • Claim 2: The filler is made of a plastic material, which is a dielectric.
  • Claim 10: Discloses a filler with arms.
  • Claim 12: Discloses a filler with a cross-shaped cross section and four arms.
  • Claim 16: Discloses twisted pairs positioned within channels formed by the filler arms.
  • Claim 18: The method of providing twisted pairs and positioning a filler between them.

2. US4085284A

• Full Citation: US4085284A, "D-shield telephone cables" to General Cable Corporation.
• Publication/Filing Date: Publication date: 1978-04-18; Priority date: 1976-08-10.
• Brief Description: This patent describes a telephone cable with a "D-shield" arrangement for crosstalk reduction. It focuses on a core wrapped with a shielding tape, where the tape is folded to create a specific cross-sectional shape (like a "D") to achieve internal compartmentalization and shielding.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs, and a shielding tape surrounding them, although the specific multi-layer dielectric/conductive/dielectric structure with continuous conductive material to the edges might not be explicitly detailed. The concept of a barrier tape surrounding conductor pairs is present.
  • Claim 17: Discloses a jacket surrounding the cable structure, which includes the shield.
  • Claim 18: The method of wrapping conductors with a conductive barrier tape.

3. US4165442A

• Full Citation: US4165442A, "Telephone cable with improved shield combination" to General Cable Corporation.
• Publication/Filing Date: Publication date: 1979-08-21; Priority date: 1978-06-12.
• Brief Description: This patent presents a telephone cable with a shield combination that improves crosstalk performance. It involves twisted pairs of conductors, a central filler, and a composite shield of corrugated metallic tape and plastic film, applied around the core.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs, a central filler, and a barrier tape (composite shield) surrounding them. The specific multi-layer construction of the barrier tape in US9991030 needs closer comparison to the "composite shield" here.
  • Claim 18: The method of wrapping twisted pairs and a filler with a conductive barrier tape.

4. US4340771A

• Full Citation: US4340771A, "Communications cable having combination shielding-armor member" to Siecor Corporation.
• Publication/Filing Date: Publication date: 1982-07-20; Priority date: 1981-03-16.
• Brief Description: This patent describes a communications cable that includes a core of insulated conductors, a central filler element, and a combination shielding and armor member wrapped around the core. The shielding member is typically a metallic tape.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses insulated conductors (likely twisted pairs in a communications cable context), a filler, and a conductive shielding tape surrounding them. The precise multi-layer composition of the barrier tape in US9991030 (conductive between two dielectric layers with conductive material to edges) would need detailed comparison.
  • Claim 18: The method of wrapping conductors and a filler with a conductive barrier tape.

5. US4453031A

• Full Citation: US4453031A, "Multi-compartment screened telephone cables" to Gk Technologies, Inc.
• Publication/Filing Date: Publication date: 1984-06-05; Priority date: 1982-11-15.
• Brief Description: This patent describes a telephone cable with multiple compartments formed by a screen member, which separates groups of insulated conductors. The screen aims to reduce crosstalk. The screen can be a web or foil material.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs and a "screen" (which acts as a filler and/or barrier) separating them. The screen could be a foil (conductive barrier tape).
  • Claim 10: The screen can be seen as a filler with arms or compartments.
  • Claim 18: Method of separating and wrapping conductors.

6. US8729394B2

• Full Citation: US8729394B2, "Enhanced data cable with cross-twist cabled core profile" to Belden Inc.
• Publication/Filing Date: Publication date: 2014-05-20; Priority date: 1997-04-22.
• Brief Description: This patent, assigned to the same entity (Belden Inc.), describes a data cable with an X-shaped central filler (cross-web) that separates four twisted pairs. The filler is twisted with the pairs to improve crosstalk performance. Although the publication date is after US9991030's priority date, its priority date of 1997 makes it prior art.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: The cable includes twisted pairs and a filler separating them. The barrier tape is the distinguishing feature here.
  • Claim 2: The filler is a dielectric material.
  • Claim 3: The filler has a helical twist.
  • Claim 9: The twisted pairs have a helical twist around the filler at the same angle.
  • Claim 10: The filler comprises at least one arm.
  • Claim 12: The filler has four arms in a cross shape.
  • Claim 16: A pair of arms forms a channel where a twisted pair is positioned.
  • Claim 18: The method of providing twisted pairs, positioning a filler between them, and helically twisting the filler and pairs.

7. US6812408B2

• Full Citation: US6812408B2, "Multi-pair data cable with configurable core filling and pair separation" to Cable Design Technologies, Inc.
• Publication/Filing Date: Publication date: 2004-11-02; Priority date: 1999-02-25.
• Brief Description: This patent describes a multi-pair data cable with a core filling element (filler) designed for configurable pair separation. The filler can have various geometries, including star-shaped or cross-shaped, to separate and isolate twisted pairs and improve performance.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Cable with twisted pairs and a filler separating them.
  • Claim 2: The filler is typically a dielectric material.
  • Claim 10: The filler comprises arms.
  • Claim 12: Mentions star-shaped or cross-shaped fillers with four arms.
  • Claim 16: Twisted pairs are positioned in channels formed by the filler arms.
  • Claim 18: Method of positioning a filler between twisted pairs.

8. US6365836B1

• Full Citation: US6365836B1, "Cross web for data grade cables" to Nordx/Cdt, Inc.
• Publication/Filing Date: Publication date: 2002-04-02; Priority date: 1999-02-26.
• Brief Description: This patent describes a data grade cable incorporating a cross-shaped web (filler) to separate and isolate twisted pairs. The filler's design, including specific arm shapes, aims to control impedance and crosstalk.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Cable with twisted pairs and a cross-web (filler) separating them.
  • Claim 2: The web is a dielectric material.
  • Claim 10: The filler comprises arms.
  • Claim 12: The filler has four arms in a cross shape.
  • Claim 13: The arms can have symmetrical terminal portions.
  • Claim 14: Terminal portions can be wider than middle portions.
  • Claim 16: Pairs are positioned in channels formed by the web.
  • Claim 18: Method of positioning a filler between twisted pairs.

9. US20060169478A1

• Full Citation: US20060169478A1, "Data cable for mechanically dynamic environments" to Cable Design Technologies, Inc.
• Publication/Filing Date: Publication date: 2006-08-03; Priority date: 2005-01-28.
• Brief Description: This patent describes a data cable, particularly for dynamic environments, that includes a central core separator (filler) to manage performance characteristics during flexure. It discusses a cross-web filler that maintains pair separation.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Twisted pairs and a filler (core separator) separating them.
  • Claim 2: The filler is a dielectric.
  • Claim 10: The filler comprises arms.
  • Claim 12: The filler can be cross-shaped with four arms.
  • Claim 16: Pairs are positioned in channels.
  • Claim 18: Method of providing pairs and positioning a filler.

10. US20070037419A1

• Full Citation: US20070037419A1, "Discontinued cable shield system and method" to Leviton Manufacturing Co., Inc.
• Publication/Filing Date: Publication date: 2007-02-15; Priority date: 2005-03-28.
• Brief Description: This patent describes a cable shield system and method that uses a discontinuous shield to mitigate alien crosstalk. The shield is applied such that there are deliberate breaks or discontinuities along its length or width to disrupt EMI coupling. This differs from US9991030's continuous conductive material.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs and a conductive barrier (shield) surrounding them. However, it explicitly describes a discontinuous shield, which contradicts the "continuous conductive material" requirement of US9991030's claims 1 and 18.
  • Claim 18: Method of wrapping a cable with a conductive barrier tape (shield), but again, the shield is discontinuous.

11. US20120222883A1

• Full Citation: US20120222883A1, "Communication Cable with Improved Crosstalk Attenuation" to General Cable Technologies Corp.
• Publication/Filing Date: Publication date: 2012-09-06; Priority date: 2008-05-19.
• Brief Description: This patent describes a communication cable with improved crosstalk attenuation, particularly alien crosstalk. It includes a core of twisted pairs, a central filler, and a barrier tape wrapped around the core. The application method or material of the tape is designed to minimize alien crosstalk.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs, a filler, and a conductive barrier tape surrounding them. The specific multi-layer construction of the tape in US9991030 (conductive layer to the edges between two dielectric layers) would need close examination.
  • Claim 2: Filler is a dielectric.
  • Claim 3: The filler can have a helical twist.
  • Claim 4: The barrier tape can have a helical twist.
  • Claim 10: The filler can have arms.
  • Claim 17: A jacket surrounds the barrier tape.
  • Claim 18: Method of providing pairs, positioning a filler, and wrapping with a barrier tape.
  • Claim 19: Helically twisting the filler and barrier tape at a first angle. This directly anticipates part of claims 19 and 7.
  • Claim 20: The concept of varying tape application angle to reduce crosstalk is generally discussed in the context of improving attenuation, though specific "oscillating tape control" parameters of US9991030 need to be reviewed against this reference.

12. US20120227998A1

• Full Citation: US20120227998A1, "Shielded pair cable and a method for producing such a cable" to Marcus Lindstrom.
• Publication/Filing Date: Publication date: 2012-09-13; Priority date: 2011-03-09.
• Brief Description: This patent describes a shielded twisted pair (STP) cable where an individual screen (shielding tape) is applied to each twisted pair, and these screened pairs are then cabled together. The method focuses on efficient manufacturing of such individually shielded pairs. This differs from US9991030 which describes a single barrier tape surrounding multiple unshielded twisted pairs and a filler.
• Potentially Anticipates Claims (35 U.S.C. § 102):
  • Claim 1: Discloses twisted pairs of insulated conductors and a barrier tape (individual screen). However, the tape in US9991030 is described as surrounding the filler and plurality of twisted pairs, not individual pairs. The claims of US9991030 are directed to a UTP cable where a single barrier tape surrounds the entire core (filler + all pairs), not individually shielded pairs. Thus, this reference is less likely to anticipate the broader structure of US9991030.
  • Claim 18: The method of wrapping twisted pairs with a conductive barrier tape. Again, the context of individual pair shielding makes it less directly anticipating the broader cable wrapping method of US9991030.

Summary of Most Relevant Prior Art:

Based on the descriptions, US8729394B2, US6812408B2, US6365836B1, and US20060169478A1 are highly relevant for the filler aspect of US9991030, particularly the use of a cross-shaped dielectric filler separating twisted pairs (e.g., Claims 1, 2, 10, 12, 16).

US20120222883A1 is particularly relevant for the barrier tape and its helical application around a filler and twisted pairs (e.g., Claims 1, 3, 4, 18, 19). It discusses the use of a barrier tape for crosstalk reduction in a communication cable.

The unique contributions of US9991030, specifically the multi-layer conductive barrier tape with continuous conductive material extending to the edges, and the precise fixed tape control (FTC) and oscillating tape control (OTC) methodologies for applying the barrier tape relative to the filler's terminal portions (Claims 5, 6, 7, 8, 11, 13, 14, 15, 20), are what distinguish it from much of the cited prior art. While prior art discusses helical tape application and fillers, the detailed control of the tape's angle and edge placement with respect to the filler to manage ANEXT and RL is a key focus of US9991030.

To analyze the obviousness of US patent 9991030 under 35 U.S.C. § 103, I will proceed by examining the independent claims and then identifying potential combinations of prior art references that would render these claims obvious.

Independent Claims of US9991030

US9991030 has two independent claims: Claim 1 (apparatus) and Claim 18 (method).

Claim 1: A cable, comprising:

• a first twisted pair of insulated conductors;
• a second twisted pair of insulated conductors;
• a filler separating the first twisted pair of insulated conductors from the second twisted pair of insulated conductors; and
• a multi-layer conductive barrier tape comprising a continuous conductive material contained between two layers of a dielectric material, the conductive material of the barrier tape extending to each lateral edge of the two layers of the dielectric material, the barrier tape surrounding the first twisted pair of insulated conductors, the second twisted pair of insulated conductors, and the filler.

Claim 18: A method of manufacture of a cable, comprising:

• providing a first twisted pair of insulated conductors and a second twisted pair of insulated conductors;
• positioning a filler between the first twisted pair of insulated conductors and the second twisted pair of insulated conductors; and
• wrapping the first twisted pair of insulated conductors, second twisted pair of insulated conductors, and filler with a conductive barrier tape comprising a conductive material contained between two layers of a dielectric material, the conductive material of the barrier tape extending to each lateral edge of the two layers of the dielectric material.

Prior Art Analysis (from US9991030)

The "Citations" section of US9991030 lists several prior art references. I will review these for their relevance to the elements of the independent claims.

• US3622683A (Superior Continental Corp.): "Telephone cable with improved crosstalk properties." (1971-11-23)
• US4085284A (General Cable Corporation): "D-shield telephone cables." (1978-04-18)
• US4165442A (General Cable Corporation): "Telephone cable with improved shield combination." (1979-08-21)
• US4340771A (Siecor Corporation): "Communications cable having combination shielding-armor member." (1982-07-20)
• US4453031A (Gk Technologies, Inc.): "Multi-compartment screened telephone cables." (1984-06-05)
• US8729394B2 (Belden Inc.): "Enhanced data cable with cross-twist cabled core profile." (2014-05-20) (This is a related Belden patent, likely from the same family or inventor.)
• US6812408B2 (Cable Design Technologies, Inc.): "Multi-pair data cable with configurable core filling and pair separation." (2004-11-02)
• US6365836B1 (Nordx/Cdt, Inc.): "Cross web for data grade cables." (2002-04-02)
• US20060169478A1 (Cable Design Technologies, Inc.): "Data cable for mechanically dynamic environments." (2006-08-03)
• US20070037419A1 (Leviton Manufacturing Co., Inc.): "Discontinued cable shield system and method." (2007-02-15)
• US20120222883A1 (General Cable Technologies Corp.): "Communication Cable with Improved Crosstalk Attenuation." (2012-09-06)
• US20120227998A1 (Marcus Lindstrom): "Shielded pair cable and a method for producing such a cable." (2012-09-13)

The patent description also defines key terms such as "crosstalk," "alien crosstalk," "return loss," and discusses various cable constructions and tape application methods (Longitudinal, Helical, Spiral, FTC, OTC). It explicitly states that "Fully shielded cables such as foil over unshielded twisted pair (F/UTP) designs include drain wires for grounding a conductive foil shield, but are significantly more expensive..." and that "Other cables have implemented complex discontinuous EMI barriers and tapes...". The present disclosure aims for "reduced alien crosstalk and return loss without increased material expense" by controlling the barrier tape application angle and using a filler. The barrier tape is described as "a conductive material contained between two layers of a dielectric material" (e.g., PET/Aluminum foil/PET). It also notes that the conductive layer "may not extend to the edge of the tape" in some embodiments, or that the dielectric layers "may completely encapsulate the conductive layer". However, Claim 1 and Claim 18 specifically state "the conductive material of the barrier tape extending to each lateral edge of the two layers of the dielectric material."

Obviousness Analysis - Combining Prior Art

The core innovation claimed in US9991030 revolves around the specific construction of the multi-layer conductive barrier tape (continuous conductive material extending to the edges, contained between two dielectric layers) in combination with a filler that separates twisted pairs. The methods claim the process of manufacturing such a cable.

Many of the cited prior art references deal with communication cables, twisted pairs, fillers, and shielding to reduce crosstalk.

Combination 1: US6812408B2 (Cable Design Technologies) + US20120227998A1 (Marcus Lindstrom)

US6812408B2 discloses a multi-pair data cable with a configurable core filling and pair separation. This patent explicitly teaches:

• A plurality of twisted pairs of insulated conductors.
• A filler (referred to as a "core filling" or "separator") for separating and positioning the twisted pairs (e.g., a cross-shaped filler is shown in figures).

US20120227998A1 discloses a shielded pair cable and a method for producing such a cable. This reference describes:

• A barrier tape for shielding.
• The tape comprises a conductive layer (e.g., metal foil) laminated between two dielectric layers. Critically, US20120227998A1 Figure 2 shows a shielding tape where the metal foil layer extends to the edges of the outer plastic layers. The description states, "The shield layer (1) is here completely covered by the plastic layers (2, 3), such that the edges of the shield layer are protected by the plastic layers". This directly addresses the specific limitation in Claims 1 and 18 regarding the conductive material extending to each lateral edge of the two layers of dielectric material.

Motivation to Combine:
A person having ordinary skill in the art (POSA) in cable design, seeking to improve crosstalk performance and return loss in multi-pair data cables while potentially reducing cost compared to fully shielded designs or discontinuous EMI barriers (as articulated in the background of US9991030), would have been motivated to combine the teachings of US6812408B2 and US20120227998A1.

• Problem to be solved/Improved Result: US6812408B2 provides the fundamental structure of a multi-pair cable with a filler for pair separation, which is known to help manage internal crosstalk and dimensional stability. However, it does not specifically teach the multi-layer barrier tape with edge-to-edge conductivity. US20120227998A1 provides a specific shielding tape construction. A POSA would recognize that applying the barrier tape described in US20120227998A1 around the core of a cable as described in US6812408B2 would provide improved EMI reduction (alien crosstalk) due to the continuous and edge-to-edge conductive layer of the tape, while the encapsulating dielectric layers protect the conductive layer from damage and prevent ground loops (which US9991030 aims to mitigate). The combination addresses the desire for a high-performance cable with reduced alien crosstalk and return loss. The filler in US6812408B2 would provide a stable structure for applying such a tape, ensuring consistent shielding, which is a key aspect highlighted in US9991030.

Obviousness of Claim 1:
Claim 1 requires:

1. First and second twisted pairs of insulated conductors: Taught by US6812408B2.
2. A filler separating the twisted pairs: Taught by US6812408B2.
3. A multi-layer conductive barrier tape comprising a continuous conductive material contained between two layers of a dielectric material: Taught by US20120227998A1 (Figure 2 and corresponding description).
4. The conductive material extending to each lateral edge of the two layers of the dielectric material: Explicitly taught by US20120227998A1 (Figure 2 and description).
5. The barrier tape surrounding the twisted pairs and the filler: Common practice in cable shielding and would be a natural application for such a tape around the cable core described in US6812408B2 to achieve shielding benefits.

Therefore, the combination of US6812408B2 and US20120227998A1 would render Claim 1 obvious.

Obviousness of Claim 18:
Claim 18 requires:

1. Providing twisted pairs: Taught by US6812408B2.
2. Positioning a filler between the twisted pairs: Taught by US6812408B2.
3. Wrapping the twisted pairs and filler with a conductive barrier tape: A standard manufacturing step for shielded cables, which would be applied using known wrapping techniques.
4. The barrier tape comprising a conductive material contained between two layers of a dielectric material, with the conductive material extending to each lateral edge of the two layers of the dielectric material: Taught by US20120227998A1 for the tape itself. The act of "wrapping" would simply be applying this known tape in a conventional manner.

Therefore, the combination of US6812408B2 and US20120227998A1 would also render Claim 18 obvious.

Consideration of Dependant Claims and Further Combinations:

The dependent claims of US9991030 introduce features like the helical twist of the filler and/or barrier tape, specific angles, filler arm shapes, and tape seam placement (FTC/OTC).

• Helical twisting of filler and tape (Claims 3, 4, 9, 19, 20): Many prior art cables, including those mentioned in US9991030 as "helically applied" or "spirally applied" barrier tape, commonly use helical twisting for both conductors and fillers. For example, US8729394B2 (Belden Inc.) itself describes an "enhanced data cable with cross-twist cabled core profile," suggesting helical elements are known. Applying a tape helically around a helically twisted core is a well-known technique in cable manufacturing.
• Varying application angle (Claims 5, 6, 8, 20 - OTC method): US9991030 acknowledges that "spirally applied barrier tape with angle θt different from cable lay angle θc, but constant" exists in prior art. The concept of varying the tape angle to prevent consistent proximity to a given pair is described as an improvement in US9991030 to mitigate ANEXT issues from fixed-angle applications. While US20120227998A1 does not explicitly teach varying the tape application angle, the mechanism shown in FIG. 3H of US9991030 for achieving OTC (a roller moving bidirectionally along a track) represents a mechanical variation of a known wrapping process. A POSA, faced with the problem of localized ANEXT in fixed-angle helical applications (as described in US9991030's background and shown in FIGS. 5A/5B and 7A/7B), and knowing that varying geometry can spread interference, would be motivated to adapt existing wrapping machinery to vary the tape angle. This would be an obvious design choice to avoid the "simple periodic interval" issues causing impedance discontinuities described in US9991030.
• Filler arms and terminal portions (Claims 10-16): US6812408B2 and US6365836B1 both teach various forms of fillers (e.g., cross-shaped) with arms and channels to separate twisted pairs. The specific shapes of terminal portions (anvil, T-shaped, blunt, trapezoidal, wider than middle portion) are variations that a POSA would consider based on desired cable characteristics (e.g., supporting the tape, maintaining shape). The concept of positioning a tape seam "above a terminal portion of an arm of the filler" (Claim 11) is a refinement of tape placement, which a POSA would attempt to optimize for improved electrical performance, given knowledge of how tape edges can interact with conductor pairs (as discussed in US9991030). This optimization would be a predictable result of applying known shielding techniques to a cable with a known filler.
• Dielectric filler and jacket (Claims 2, 17): The use of a dielectric material for the filler (Claim 2) and a jacket surrounding the barrier tape (Claim 17) are extremely common elements in communication cable design and are widely known in the prior art (e.g., US6812408B2 mentions the filler as "non-conductive", and jackets are ubiquitous in all communication cables).

In summary, the most distinguishing feature of the independent claims is the specific construction of the multi-layer barrier tape (continuous conductive layer extending to the edges, encapsulated by dielectric layers). This feature is directly found in US20120227998A1. When combined with the widely known concept of using a filler to separate twisted pairs in a communication cable (e.g., US6812408B2), the resulting cable and method of manufacture would be obvious to a POSA. The additional features in the dependent claims represent known variations in cable design (helical twisting, different filler geometries) or obvious attempts to optimize performance (varying tape angle to mitigate ANEXT issues from fixed-angle applications, precise tape edge placement over filler parts).

Therefore, the combination of US6812408B2 and US20120227998A1 would render the independent claims (1 and 18) of US9991030 obvious under 35 U.S.C. § 103.US patent 9991030 covers a high-performance data communications cable featuring a specific multi-layer conductive barrier tape and a filler separating twisted pairs. The patent outlines two primary tape application methodologies: Fixed Tape Control (FTC) and Oscillating Tape Control (OTC), both aimed at reducing alien crosstalk (ANEXT) and return loss (RL).

Independent Claims Analysis

The independent claims of US9991030 are:

• Claim 1 (Apparatus): A cable comprising a first and second twisted pair of insulated conductors, a filler separating these pairs, and a multi-layer conductive barrier tape. The tape specifically includes a continuous conductive material contained between two layers of a dielectric material, with the conductive material extending to each lateral edge of the two dielectric layers, and the barrier tape surrounding the conductors and filler.
• Claim 18 (Method): A method of manufacturing a cable, comprising providing twisted pairs, positioning a filler between them, and wrapping them with a conductive barrier tape. The tape construction is identical to that specified in Claim 1, i.e., continuous conductive material contained between two dielectric layers and extending to each lateral edge.

Obviousness under 35 U.S.C. § 103

A person having ordinary skill in the art (POSA) in cable design, motivated to improve the electrical performance (e.g., reduce ANEXT and RL) of data cables, would have found the claimed inventions of US9991030 obvious when combining certain prior art references.

Combination of US6812408B2 and US20120227998A1

US6812408B2 (Cable Design Technologies, Inc.) discloses a "Multi-pair data cable with configurable core filling and pair separation." This patent teaches the use of:

• Multiple twisted pairs of insulated conductors.
• A filler (referred to as a "core filling" or "separator"), often cross-shaped, positioned between and separating the twisted pairs to provide structural stability and manage internal crosstalk.

US20120227998A1 (Marcus Lindstrom) describes a "Shielded pair cable and a method for producing such a cable." This reference teaches:

• A shielding tape for cables.
• The tape construction includes a conductive layer (e.g., metal foil) laminated between two dielectric layers (e.g., plastic layers).
• Crucially, Figure 2 of US20120227998A1 and its accompanying description explicitly show and state that the conductive shield layer "is here completely covered by the plastic layers (2, 3), such that the edges of the shield layer are protected by the plastic layers." This means the conductive material extends to the lateral edges of the dielectric layers.

Motivation to Combine:
A POSA would be motivated to combine the teachings of US6812408B2 and US20120227998A1 to achieve a data cable with improved EMI performance (reduced alien crosstalk) and enhanced structural integrity. The background of US9991030 itself identifies the problem of alien crosstalk and the desire for solutions without increasing cable size or cost, or introducing issues like ground loops common in fully shielded cables.

• US6812408B2 provides a robust core structure with a filler effectively separating twisted pairs, a known technique for managing internal crosstalk and maintaining cable geometry. However, it lacks a specific solution for external EMI (alien crosstalk).
• US20120227998A1 offers a precise barrier tape construction specifically designed for shielding, where the continuous conductive layer extends to the edges and is encapsulated by dielectric material. This design mitigates potential issues with exposed conductive edges, such as shorting or signal degradation, while providing effective shielding.

A POSA, seeking to improve the ANEXT performance of the cable taught by US6812408B2, would find it obvious to incorporate a shielding mechanism. Faced with the choice of shielding tapes, the tape described in US20120227998A1 would be a suitable candidate because its encapsulated, edge-to-edge conductive layer provides effective EMI mitigation without the grounding requirements or potential ground loop issues of traditional fully shielded cables, aligning with the objectives stated in US9991030. The filler from US6812408B2 would provide an ideal cylindrical base for uniformly applying such a tape, which US9991030 itself emphasizes for "optimized ground plane uniformity and stability".

Obviousness of Claim 1:
The combination explicitly discloses all elements of Claim 1:

1. First and second twisted pairs of insulated conductors: Taught by US6812408B2.
2. A filler separating the twisted pairs: Taught by US6812408B2.
3. A multi-layer conductive barrier tape comprising a continuous conductive material contained between two layers of a dielectric material: Taught by US20120227998A1.
4. The conductive material of the barrier tape extending to each lateral edge of the two layers of the dielectric material: Explicitly taught by US20120227998A1, Figure 2 and description.
5. The barrier tape surrounding the twisted pairs and the filler: A conventional application of a shielding tape to a cable core, which would be an obvious design choice for a POSA to achieve the desired shielding effect.

Obviousness of Claim 18:
The method steps of Claim 18 would also be obvious:

1. Providing twisted pairs: Common practice in cable manufacturing.
2. Positioning a filler between the twisted pairs: Taught by US6812408B2.
3. Wrapping the twisted pairs and filler with a conductive barrier tape: A standard cable manufacturing process. The specific tape described in Claim 18, including its continuous, edge-to-edge conductive layer between dielectric layers, is provided by US20120227998A1. Applying this known tape to a known cable core configuration would be a predictable manufacturing step.

Therefore, the combination of US6812408B2 and US20120227998A1 would render Claims 1 and 18 of US9991030 obvious.

Consideration of Dependent Claims

Many dependent claims relate to the helical twisting of the filler and barrier tape, the varying application angle (OTC), and specific shapes of filler arms. These features, while potentially offering performance benefits, would also be considered obvious variations or optimizations to a POSA:

• Helical Twisting (Claims 3, 4, 9, 19, 20): Helical twisting of cable elements (pairs, fillers, and tapes) is a fundamental and long-established technique in cable manufacturing for maintaining structure and electrical properties. Many prior art references (e.g., US8729394B2, which describes a "cross-twist cabled core profile") demonstrate the prevalence of helical arrangements.
• Varying Application Angle (OTC) (Claims 5, 6, 8, 20): US9991030 acknowledges that "spirally applied barrier tape with angle θt different from cable lay angle θc, but constant" exists in prior art. The problem of "simple periodic intervals" causing increased return loss when a tape edge consistently interacts with a pair is identified in US9991030. A POSA, recognizing this issue with fixed-angle applications, would be motivated to introduce variability in the tape's application angle to distribute these interactions over a longer cable length and across different pairs. This would be a predictable approach to mitigate localized interference, achievable with known mechanical adjustments to wrapping equipment (such as the roller/track mechanism illustrated in FIG. 3H of US9991030).
• Filler Arm Configurations (Claims 10-16): The use of multi-armed, cross-shaped fillers to create channels for twisted pairs is well-known (e.g., US6812408B2, US6365836B1). Variations in the shape of the terminal portions (anvil, T-shaped, wider, trapezoidal) are design choices that a POSA would make to optimize for specific performance or manufacturing ease, such as providing a stable platform for tape placement, as discussed in US9991030. Placing a tape seam "above a terminal portion of an arm" (Claim 11) is an obvious refinement of tape application to avoid placing seams over sensitive conductor pairs, once the interaction between tape edges and pairs is understood.

Thus, the core elements of the independent claims, especially the specific multi-layer barrier tape construction, are found in the cited prior art. The combination of these known elements and the application of known manufacturing techniques, along with predictable optimizations for performance, would render the claims of US9991030 obvious to a person of ordinary skill in the art.