Multifolded composite tape for use in cable manufacture and methods for making same
First Claim
1. A composite tape for use in cable manufacture, the composite tape comprising:
- a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material to form a first folded laminate with a first folded edge and a first open end;
a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate with a second folded edge and a second open end;
the first folded edge of the first folded laminate being aligned with the second folded edge of the second folded laminate to position the first and second folded laminates folded edge to folded edge;
a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the aligned first and second folded laminates;
a fourth laminate constructed similar to the third laminate, the dielectric material of the fourth laminate bonded to a second opposing plane formed by the dielectric material of the aligned first and second folded laminates; and
the first and the second folded laminates being opened at the first open end and the second open end to define four channels.
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Abstract
The invention provides a composite wrapping and shielding tape for use in cable manufacture. Embodiments of the composite tape include a single tape configuration to separate and shield individual pairs of insulated conductors housed within a cable such as a high-speed data communications cable. The single tape configurations of the invention are multifolded and assembled from foil/film laminates to form a plurality of longitudinal channels or grooves to accommodate one or more pairs of insulated conductors and a variety of cable designs. During cable manufacture, one or more pairs of insulated conductors is wrapped within a continuous shield provided by each longitudinal channel or groove, thereby separating and shielding each pair of insulated conductors and, hence, isolating or at least substantially reducing crosstalk between pairs of insulated conductors contained within the cable. The invention also provides methods for making a multifolded composite tape. The invention further provides a communications cable including a multifolded composite tape to separate and shield insulated conductors.
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Citations
29 Claims
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1. A composite tape for use in cable manufacture, the composite tape comprising:
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a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material to form a first folded laminate with a first folded edge and a first open end;
a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate with a second folded edge and a second open end;
the first folded edge of the first folded laminate being aligned with the second folded edge of the second folded laminate to position the first and second folded laminates folded edge to folded edge;
a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the aligned first and second folded laminates;
a fourth laminate constructed similar to the third laminate, the dielectric material of the fourth laminate bonded to a second opposing plane formed by the dielectric material of the aligned first and second folded laminates; and
the first and the second folded laminates being opened at the first open end and the second open end to define four channels. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A composite tape for use in cable manufacture, the composite tape comprising:
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a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material to form a first folded laminate having a conductive material interface with a first folded edge and a first open end;
a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate having a conductive material interface with a second folded edge and a second open end;
the first folded edge of the first folded laminate aligned with the second folded edge of the second folded laminate to position the first and second folded laminates folded edge to folded edge;
at least a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the aligned first and second folded laminates; and
the first and the second folded laminates being opened at the first open end and the second open end to define a plurality of channels.
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15. A composite tape for use in cable manufacture, the composite tape comprising:
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at least one sheet of dielectric material bonded to at least one sheet of conductive material to form a laminate, the laminate being accordion-folded across its width into a multiple of longitudinal pleats, each pleat having a dielectric material interface and a conductive material interface disposed therein, each of the dielectric material interfaces being bonded to seal the dielectric material interface, and each of the conductive material interfaces being opened such that the multiple of longitudinal pleats unfolds to form a plurality of fin-like shielding members extending radially from a center axis and longitudinally along the center axis to define a plurality of channels.
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16. A method for making a composite tape for use in cable manufacture, the method comprising:
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providing a first laminate of at least one layer of conductive material bonded to at least one layer of dielectric material;
folding the first laminate conductive material-to-conductive material to form a first folded laminate with a first folded edge and a first open end;
providing a second folded laminate constructed and folded similar to the first folded laminate to form a second folded laminate with a second folded edge and a second open end;
aligning the first folded edge of the first folded laminate to the second folded edge of the second folded laminate;
providing a third laminate and a fourth laminate, the third laminate and the fourth laminate each having at least one layer of conductive material bonded to at least one layer of dielectric material;
bonding the layer of dielectric material of the third laminate to a first plane of dielectric material formed by the dielectric material of the aligned first and second folded laminates;
bonding the layer of dielectric material of the fourth laminate to a second opposing plane of dielectric material formed by the dielectric material of the aligned first and second folded laminates; and
opening the first and the second folded laminates at the first open end and the second open end to form a plurality of fin-like shielding members that extend radially from a center axis and longitudinally along the center axis to define a plurality of channels. - View Dependent Claims (17, 18, 19, 20, 21)
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22. A method for making a composite tape for use in cable manufacture, the method comprising:
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providing a laminate of at least one layer of conductive material bonded to at least one layer of dielectric material, the laminate having a length and a width;
folding the laminate across its width repeatedly to form a multiple of longitudinal accordion pleats, each pleat having a dielectric material interface and a conductive material interface disposed therein;
bonding each of the dielectric material interfaces; and
opening each of the conductive material interfaces to form a plurality of fin-like shielding members extending radially from a center axis and longitudinally along the center axis to define a plurality of channels. - View Dependent Claims (23, 24, 25, 26)
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27. A composite tape for use in cable manufacture, the composite tape comprising:
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a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material to form a first folded laminate having a conductive material interface with a first folded edge and a first open end;
a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate having a conductive material interface with a second folded edge and a second open end, the first folded edge of the first folded laminate aligned with the second folded edge of the second folded laminate to position the first and second folded laminates folded edge to folded edge;
at least a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the aligned first and second folded laminates; and
the first and the second folded laminates being opened at the first open end and the second open end to form a plurality of fin-like shielding members extending radially from a center axis of the tape and extending longitudinally along the center axis to define a plurality of channels. - View Dependent Claims (28, 29)
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Specification