Conductive polymer material and cable having the same

Abstract

A polymeric material includes a polymeric core having opposing first and second sides. The polymer core includes pores extending through the first side and the second side of the polymer core such that the polymer core is porous. The polymeric material includes a first metal layer extending on the first side of the polymeric core, a second metal layer extending on the second side of the polymeric core, and a metal connection extending from the first metal layer through the aperture to the second metal layer, such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

Description

Background Art

[0001] Some known cables are electrically shielded by weaving a wire mesh or wrapping wire around the core of the cable. The shielding is intended to minimize the leakage of radio frequency interference (RFI) and prevent electromagnetic interference (EMI) disturbances from distorting the signals carried by the cable. However, gaps formed during the weaving of the wire mesh or wrapping wire around the cable core and / or the looseness of the resulting braid may still cause some RFI leakage and / or signal distortion. Summary of the invention

[0002] In one aspect, the polymer material comprises a polymer core having a first side and a second side opposite to each other. The polymer core comprises a hole extending through the first side and the second side of the polymer core, such that the polymer core is porous. The polymer material comprises a first metal layer extending on the first side of the polymer core, a second metal layer extending on the second side of the polymer core, and a metal connector extending from the first metal layer through the hole to the second metal layer, such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

[0003] In another aspect, the polymer material comprises a polymer core having a first side and a second side opposite each other. The polymer core extends from the first side to the thickness of the second side. The polymer core is porous, wherein the pores extend through the thickness of the polymer core. The polymer material comprises a first metal layer and a second metal layer extending on the first side and the second side of the polymer core, respectively. The polymer material comprises an internal metal structure extending within the pores, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

[0004] On the other hand, a method for manufacturing a polymer material includes: installing an internal metal structure within the pores of a porous polymer core; and forming a first metal layer and a second metal layer on opposite first and second sides of the polymer core, respectively, wherein the internal metal structure connects the first metal layer and the second metal layer together so that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

[0005] In another aspect, the cable includes an inner conductor, a dielectric layer extending around the inner conductor, and a polymer material extending around the dielectric layer. The polymer material includes a polymer core, the polymer core including a first side and a second side opposite to each other. The polymer core includes a hole extending through the first side and the second side of the polymer core, such that the polymer core is porous. The polymer material includes a first metal layer and a second metal layer extending on the first side and the second side of the polymer core, respectively. The polymer material includes a metal connector extending from the first metal layer through the hole to the second metal layer, such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

[0006] In another aspect, the cable comprises an inner conductor, a dielectric layer extending around the inner conductor, and an outer conductor extending around the dielectric layer. The outer conductor comprises a polymer material, the polymer material comprising a polymer core having a first side and a second side opposite each other. The polymer core extends from the first side to the thickness of the second side. The polymer core is porous, wherein the holes extend through the thickness of the polymer core. The polymer material comprises a first metal layer and a second metal layer extending on the first side and the second side of the polymer core, respectively. The polymer material comprises an internal metal structure extending within the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

[0007] In another aspect, the cable comprises an inner conductor, a dielectric layer extending around the inner conductor, and an outer conductor extending around the dielectric layer. The outer conductor comprises a polymer material comprising a polymer core having opposing first and second sides. The polymer core is porous, wherein holes extend through the first and second sides of the polymer core. The polymer material comprises a first metal layer and a second metal layer extending on the first and second sides of the polymer core, respectively. The polymer material comprises internal metal layers extending within the holes and configured such that the polymer material is conductive over the entire thickness of the polymer material. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is an isometric schematic diagram of a segment of a polymeric material according to an embodiment.

[0009] Figure 2 According to the implementation method Figure 1 Schematic cross-section of the polymer material shown.

[0010] Figure 3 is an isometric diagram showing an exemplary microstructure of a polymer core of a polymer material according to an embodiment.

[0011] Figure 4 is an isometric schematic diagram of a segment of a polymeric material according to an embodiment.

[0012] Figure 5 is an isometric schematic diagram of a segment of a polymeric material according to an embodiment.

[0013] Figure 6 According to the implementation method Figure 5 Schematic cross-section of the polymer material shown.

[0014] 7 includes isometric schematic diagrams illustrating one example of fabrication of a polymer material according to an embodiment.

[0015] Figure 8is a flow chart illustrating a method for manufacturing a polymer material according to an embodiment.

[0016] Fig. 9 is a partial cross-sectional elevation view of a cable according to an embodiment.

[0017] Fig.10 According to the implementation method Fig. 9 A cross-section of the cable is shown.

[0018] Fig.11 is a cross-sectional view of a cable according to an embodiment.

[0019] Fig.12 is a cross-sectional view of a cable according to an embodiment.

[0020] Fig.13 is a cross-sectional view of a cable according to an embodiment.

[0021] Fig.14 is a cross-sectional view of a cable according to an embodiment.

[0022] Fig.15 is a flow chart illustrating a method for assembling a cable according to an embodiment.

[0023] Fig.16 An exemplary microstructure of a polymer core of a polymer material according to one example is shown.

[0024] Fig.17 yes Fig.16 A magnified view of the polymer core is shown.

[0025] Fig.18 After forming a copper layer on the polymer core according to this example Fig.16 and Fig.17 The microstructure of the polymer material shown.

[0026] Fig.19 This example shows Fig.18 A plan view of the surface of the copper layer of the polymer material is shown.

[0027] Fig. 20 According to this example, a silver layer is formed thereon. Fig.18 The microstructure of the polymer material shown.

[0028] Fig.21 This example shows Fig. 20 A plan view of the surface of the silver layer of the polymer material is shown.

[0029] Fig. 22 An exemplary microstructure of a polymer material according to another example is shown.

[0030] Fig.23 This example shows Fig. 22 A plan view of the surface of the copper layer of the polymer material is shown. DETAILED DESCRIPTION

[0031] The foregoing summary of the invention, as well as the following detailed description of certain embodiments, will be better understood when read in conjunction with the accompanying drawings. Although various spatial and directional terms such as "top", "bottom", "upper", "lower", "vertical", etc. are used to describe embodiments of the present application, it should be understood that such terms are used only with respect to the orientation shown in the accompanying drawings. The orientation can be reversed, rotated, or otherwise changed so that if the structure is flipped 180°, the top side becomes the bottom side, if the structure is pivoted 90°, the top side becomes the left side or right side, and so on.

[0032] Technological advances in electronics and signal transmission have caused signals to propagate at higher and higher frequencies, thereby putting forward new requirements for wire and cable products. Some cables are electrically shielded by weaving a wire mesh or winding wire around the core of the cable. The intention of the shield is to prevent radio frequency interference (RFI) from leaking from the cable and to prevent electromagnetic interference (EMI) disturbances from distorting the signal. However, the gaps generated due to the looseness of the braiding application process and / or the resulting braid may still cause RFI leakage and / or signal distortion caused by EMI disturbances. Therefore, some cables include flat wires or metal foils wound spirally around the cable core. Adjacent windings of the wire or foil overlap each other so that if there is a gap, very few gaps are retained in the shield along the length of the cable. However, the process for applying (e.g., wrapping, etc.) flat wires or metal foils around the cable core is challenging, inconsistent, and includes variations, which lead to, for example, attenuation behavior and transmission loss (e.g., particularly for coaxial and twinax cables) and / or reflection loss inconsistencies and instability of phase and / or time delay when the cable moves and / or bends. Furthermore, as cables transmit signals at higher and higher frequencies, the diameter of the cables must be reduced. As the diameter is reduced to, for example, transmit signals at frequencies above 70 GHz, the challenges of using existing technologies (e.g., using flat wires and metal foils, etc.) are magnified.

[0033] The embodiments described and / or illustrated herein attempt to solve, reduce and / or similarly alleviate the above challenges, such as methods that use a porous polymer core that has been metallized to produce a conductive polymer material so that the resulting polymer material is conductive throughout its thickness. For example, certain embodiments provide a polymer material comprising a polymer core having a first side and a second side opposite to each other. The polymer core comprises a hole that extends through the first side and the second side of the polymer core so that the polymer core is porous. The polymer material comprises a first metal layer extending on the first side of the polymer core and a second metal layer extending on the second side of the polymer core. In some embodiments, the polymer material comprises a metal connector that extends from the first metal layer through the hole to the second metal layer so that the metal connector provides a conductive path between the first metal layer and the second metal layer. In some embodiments, the polymer material comprises an internal metal structure extending in the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together. In some embodiments, the polymer material comprises an internal metal layer that extends in the hole and is configured so that the polymer material is conductive throughout the thickness of the polymer material.

[0034] Certain embodiments provide polymer materials that operate in unconventional ways to provide improved electrical properties of the polymer materials (e.g., improved conductivity, improved electrical shielding capabilities, reduced undesirable capacitive behavior, etc.). For example, certain embodiments provide polymer materials that operate in unconventional ways to provide improved electrical shielding materials. For example, compared to flat wires or metal foils, the challenges of applying (e.g., wrapping, etc.) the polymer materials disclosed herein to the cable core are less, especially when the diameter of the cable core is reduced. For example, the polymer materials disclosed herein can be applied around the cable core using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). The polymer materials disclosed herein reduce or eliminate the challenges, inconsistencies, and variations of applying flat wires or metal foils to the cable core, resulting in improved electrical shielding (e.g., more effective shielding at relatively high frequencies, etc.). For example, application of the polymeric material to the cable core reduces or eliminates attenuation behavior and inconsistencies in transmission loss (e.g., particularly for coaxial and twinaxial cables) and / or reflection loss and instabilities in phase and / or time delay when the cable moves and / or bends (e.g., compared to cables including wrapped flat wires or metal foils, etc.). Thus, incorporating the polymeric materials disclosed herein as electrical shielding components into cables results in improved signal propagation characteristics of the cables, particularly at relatively high frequencies, while maintaining relatively high flexibility and less signal distortion due to bending (e.g., compared to at least some known cables, etc.). In certain embodiments, the polymeric materials disclosed herein are used in combination with conventional braided shields (e.g., wire mesh or wrapped wire, etc.) that provide tensile strength to the resulting cable construction.

[0035] Referring now to the drawings, isometric and cross-sectional views of a polymer material 100 are provided at Figure 1 and Figure 2 . The polymer material 100 includes a polymer core 102, metal layers 104 and 106, and a metal connector 108. As will be described in more detail below, the metal connector 108 provides a conductive path between the metal layers 104 and 106, for example, so that the polymer material 100 is conductive over the entire thickness T of the polymer material 100. The polymer core 102 includes opposite sides 110 and 112. The polymer core 102 extends a thickness T1 from the side 110 to the side 112, and vice versa. In other words, the polymer core 102 extends a thickness T1 between the sides 110 and 112. Each of the metal layers 104 and 106 may be referred to herein as a "first" metal layer and / or a "second" metal layer. Each of the sides 110 and 112 may be referred to herein as a "first" side and / or a "second" side.

[0036] The polymer core 102 is porous. For example, the polymer core 102 has a porous structure that includes pores 114 extending through the thickness T1 of the polymer core 102. In other words, the pores 114 extend through the sides 110 and 112 of the polymer core 102 and between the two. In some embodiments, the polymer core 102 is nanoporous and / or microporous, for example, having a microstructure in which the pores 114 are micropores (e.g., having a size equal to or less than about 2 nanometers, etc.). Figure 1 and Figure 2 The holes 114 shown in the drawings (e.g., simplification, etc.) are intended only as exemplary schematic (e.g., simplified, etc.) representations of the holes 114. It should be understood that the geometry of the holes 114 of the polymer core 102 may be more complex than the geometry shown herein. For example, the porous structure of the polymer core 102 may not be represented by individual concentric holes 114. For example, the holes 114 may intersect with each other and / or form a network of interconnected chambers within the thickness T1 of the polymer core 102. In addition, for clarity, the sizes of the holes disclosed herein may be exaggerated in the drawings. Figure 3 One non-limiting example of a microstructure of the polymer core 102 is shown, the microstructure comprising pores that intersect one another and form a network of interconnected chambers within the thickness of the polymer core 102 .

[0037] In some embodiments, the porosity of the polymer core 102 is selected to provide a configuration (e.g., size, shape, number, density, pattern, etc.) of pores 114 that helps provide a predetermined level of electrical conductivity to the polymer material 100 (e.g., by increasing the size, shape, and / or number of metal connectors 108, etc.). In some embodiments, the porosity of the polymer core 102 is selected to facilitate processing (e.g., manufacturing, producing, forming, etc.) of the polymer material 100 (e.g., by reducing the difficulty of installing the metal connectors 108 within the pores 114, etc.).

[0038] The predetermined porosity of the polymer core 102 can be selected, for example, via: material selection; treatment (e.g., stretching, foaming, expansion, cross-linking, etc.) of one or more selected materials; manufacturing parameters (e.g., processes, operations, variables, conditions, etc.), such as parameters at which the material is stretched, foamed, expanded, and / or similarly treated, etc.; etc. For example, the polymer core 102 and / or one or more various parameters of its manufacturing can be selected to increase (e.g., maximize, increase to a level below which the polymer core 102 and / or the polymer material 100 lose mechanical structural integrity, etc.) the porosity of the polymer core 102. For example, the parameters of manufacturing the polymer core 102 can affect the configuration (e.g., size, shape, number, density, pattern, etc.) of the pores 114 in the polymer core 102 (e.g., the temperature at which the polymer core 102 is stretched, foamed, expanded, and / or similarly treated can affect the configuration of the pores 114 of the polymer core 102, etc.).

[0039] In some embodiments, the polymer core 102 has a porosity of at least about 40%, about 50% (i.e., in some embodiments, the polymer core 102 is configured to include about 50% air), greater than about 50%, at least about 60%, etc. The polymer core 102 can include any number of pores 114, any density of pores 114, and each pore 114 can have any size and / or shape that provides the polymer core 102 with a predetermined porosity.

[0040] The polymer core 102 is composed of any suitable material that enables the polymer core 102 and / or the polymer material 100 to function, such as, but not limited to, polypropylene, polytetrafluoroethylene (PTFE), polysulfone, cellulose acetate, expanded polymers, foamed polymers, stretched polymers, linear stretched polymers, porous polyester films, etc. The polymer core 102 can have any geometry, thickness Ti, etc. that enables the polymer core 102 and / or the polymer material 100 to function, such as, for example, as described and / or shown herein. In some embodiments, the polymer core 102 is a tape, a film, a diaphragm, etc.

[0041] Referring now to the metal layers 104 and 106 of the polymer material 100, the metal layer 104 extends on the side 110 of the polymer core 102, and the metal layer 106 extends on the side 112 of the polymer core 102. Thus, the metal layers 104 and 106 define respective sides 116 and 118 of the polymer material 100. Each of the metal layers 104 and 106 includes one or more conductive metal materials, such that the metal layers 104 and 106 are each electrically conductive. The conductivity of the metal layers 104 and 106 provides the polymer material 100 with electrical conductivity along the sides 116 and 118 of the polymer material 100, respectively. For example, the conductivity of the metal layer 104 provides the side 116 of the polymer material 100 with an electrically conductive path along the width W of the polymer material 100 and along the length L. Also, for example, the conductivity of the metal layer 106 provides the side 118 of the polymer material 100 with an electrically conductive path along the width W and the length L of the polymer material 100.

[0042] Although metal layers 104 and 106 are Figure 1 and Figure 2 104 and 106 are each shown as a single layer, but each of metal layers 104 and 106 may include any number of sub-layers. In some embodiments, metal layer 104 and / or metal layer 106 includes only a single sub-layer (i.e., layer 104 and / or 106 is a single continuous layer), such as Figure 1 and Figure 2As shown. Each sub-layer may be composed of a single metal material, or may be a composite of two or more materials (wherein at least one of these materials is a conductive metal material). Each metal layer 104 and 106 may include any number of different materials and any number of different conductive metal materials. Examples of conductive metal materials that may be included in metal layers 104 and / or 106 include, but are not limited to, silver, copper, annealed copper, gold, steel, stainless steel, aluminum, beryllium, magnesium, zinc, cobalt, nickel, and the like. Examples of other materials that may be included in metal layers 104 and / or 106 include, but are not limited to, polymers, resins, epoxies, carbon, and the like.

[0043] exist Figure 4 In one example shown, polymer material 200 includes polymer core 202, metal layers 204 and 206 extending on opposite sides 210 and 212 of polymer core 202, respectively, and metal connectors 208 providing conductive paths between metal layers 204 and 206 (within holes 214 of polymer core 202). Each of metal layers 204 and 206 includes a respective copper sublayer 204a and 206a extending directly on respective sides 210 and 212, and a respective silver sublayer 204b and 206b extending directly on respective sublayers 204a and 206a (and thus extending indirectly on respective sides 210 and 212). For example, in some embodiments, polymer material 200 is a silver-plated copper film having polymer core 202. Each of metal layers 204 and 206 may be referred to herein as a "first" metal layer and / or a "second" metal layer. Each of the sides 210 and 212 may be referred to herein as a “first” side and / or a “second” side.

[0044] Reference again Figure 1 and Figure 2 , various parameters of the metal layers 104 and / or 106 and / or their fabrication may be selected to provide a predetermined level of electrical conductivity to the layers 104 and / or 106 and / or the polymer material 100. Examples of parameters of the metal layers 104 and / or 106 that may be selected to provide a predetermined level of electrical conductivity to the layers 104, 106 and / or the polymer material 100 include, but are not limited to, the thickness of the metal layers 104 and / or 106, the types of materials included within the metal layers 104 and / or 106, the number of different types of materials included within the metal layers 104 and / or 106, the porosity of the metal layers 104 and / or 106, etc. In some embodiments, the level of electrical conductivity and / or the level of resistance of the metal layers 104 and / or 106 are selected to enable the polymer material 100 to provide a predetermined level of electrical shielding.

[0045] As briefly described above, metal connector 108 provides a conductive path between metal layers 104 and 106. Figure 2 As best shown, each metallic connector 108 extends a length from an end portion 120 to an opposite end portion 122 within a corresponding aperture 114. The end portion 120 of each metallic connector 108 is connected to (e.g., joined to; in a continuous, integral structure with; fused to; connected to; etc.) the metal layer 104 extending over the side 110 of the polymer core 102. The end portion 122 of each metallic connector 108 is connected to (e.g., joined to; in a continuous, integral structure with; fused to; connected to; etc.) the metal layer 106 extending over the side 112 of the polymer core 102. Thus, the metallic connectors 108 include internal metallic structures that extend within the apertures 114 and mechanically connect (e.g., joined to; in a continuous, integral structure with; fused to; coupled to; etc.) the metal layers 104 and 106 together. In some embodiments, one or more of the metal connectors 108 include an internal metal layer that extends within the corresponding holes 114 and mechanically connects (e.g., engages; forms a continuous, integral structure with; fuses; couples; etc.) the metal layers 104 and 106 together. For example, one or more of the metal connectors 108 may include a layer extending on the inner surface 124 of the polymer core 102 that at least partially defines the corresponding holes 114. In some embodiments, one or more of the metal connectors 108 include an internal metal plug, leg, arm, rod, pin, chain, rope, rod, post, etc. that extends within the corresponding holes 114 and mechanically connects (e.g., engages; forms a continuous, integral structure with; fuses; couples; etc.) the metal layers 104 and 106 together.

[0046] Each metal connector 108 includes one or more conductive metal materials, so that each of the metal connectors 108 is conductive. The conductivity of the metal connector 108 provides a conductive path for the metal connector 108 along the length of the metal connector 108. Therefore, the metal connector 108 provides a conductive path from the metal layer 104 to the metal layer 106, and vice versa. In other words, the metal connector 108 provides a conductive path between the metal layers 104 and 106. The internal metal structure (e.g., layer, plug, leg, arm, rod, pin, chain, rope, rod, column, etc.) of the metal connector 108 conductively bridges the metal layers 104 and 106 together, for example, so that the polymer material 100 is conductive throughout the thickness T of the polymer material 100. In other words, the metal connector 108 is configured so that the polymer material 100 is conductive throughout its thickness T.

[0047] Although the internal metal structure of the metal connector 108 is Figure 1 and Figure 2108 as each having a single layer of internal metal layers, but each of the metal connectors 108 may include any number of sub-layers. In some embodiments, the metal connector 108 includes only a single sub-layer (i.e., the metal connector 108 is a single continuous layer), such as Figure 1 and Figure 2 As shown. Each sublayer can be composed of a single metal material, or can be a composite of two or more materials (wherein at least one of these materials is a conductive metal material). Each metal connector 108 can include any number of different materials and any number of different conductive metal materials. Examples of conductive metal materials that can be included in the metal connector 108 include, but are not limited to, silver, copper, annealed copper, gold, steel, stainless steel, aluminum, beryllium, magnesium, zinc, cobalt, nickel, etc. Examples of other materials that can be included in the metal connector 108 include, but are not limited to, polymers, resins, epoxies, carbon, etc.

[0048] exist Figure 1 and Figure 2 In the exemplary embodiment shown, the pores 114 of the polymer core 102 are partially filled with the metal connector 108, such that the pores 114 include voids 126. In other words, after the metal connector 108 has been installed (e.g., formed, inserted, constructed, etc.) within the pores 114, the voids 126 remain within the pores 114. Figure 2 As best shown in , voids 126 extend through the thickness T of polymeric material 100. In other words, voids 126 extend through and between sides 116 and 118 of polymeric material 100. Thus, voids 126 can provide porosity to polymeric material 100. In some embodiments, voids 126 (e.g., size, shape, number, density, pattern, etc.) are configured such that polymeric material 100 is nanoporous and / or microporous, e.g., having a microstructure in which pores 126 are micropores (e.g., having a size equal to or less than about 2 nanometers, etc.). Figure 1 and Figure 2 The voids 126 shown in , etc. are intended only as exemplary schematic (eg, simplified, etc.) representations of the voids 126. It should be understood that the geometry of the voids 126 may be more complex than that shown herein.

[0049] The predetermined porosity of the polymeric material 100 can be selected, for example, via the selection of the configuration (e.g., size, shape, number, density, pattern, etc.) of the voids 126; manufacturing parameters (e.g., processes, operations, variables, conditions, etc.), such as parameters for installing the metal connector 108, etc. For example, the polymeric material 100 and / or one or more various parameters of its manufacturing can be selected to increase (e.g., maximize, increase to a level below which the polymeric material 100 loses mechanical structural integrity, etc.) the porosity of the polymeric material 100. For example, the parameters for installing the metal connector 108 can affect the configuration (e.g., size, shape, number, density, pattern, etc.) of the voids 126.

[0050] In some embodiments, the polymeric material 100 has a porosity of at least about 40%, about 50% (i.e., in some embodiments, the polymeric material 100 is configured to include about 50% air), greater than about 50%, at least about 60%, etc. The polymeric material 100 can include any number of voids 126, any density of voids 126, and each void 126 can have any size and / or shape that provides the polymeric core 102 with a predetermined porosity.

[0051] Various parameters of the metal connector 108 and / or its fabrication may be selected to provide a predetermined level of electrical conductivity to the connector 108 and / or the polymer material 100. Examples of parameters of the metal connector 108 that may be selected to provide a predetermined level of electrical conductivity to the metal connector 108 and / or the polymer material 100 include, but are not limited to, the size of the metal connector 108 (e.g., thickness, width, diameter, etc.), the shape of the metal connector 108, the type of material included within the metal connector 108, the number of different types of materials included within the metal connector 108, the amount of pores 114 filled by the corresponding metal connector 108 (e.g., percentage, volume, etc.), the porosity of the polymer material 100, etc.

[0052] Various parameters of the voids 126, the metal connectors 108, and / or their manufacture may be selected to provide a predetermined level of resistivity to the conductive path provided by the metal connectors 108 between the metal layers 104 and 106 and / or the polymer material 100. Examples of parameters of the voids 126, the metal connectors 108, and / or their manufacture that may be selected to provide a predetermined level of resistivity to the conductive path provided by the metal connectors 108 between the metal layers 104 and 106 and / or the polymer material 100 include, but are not limited to, the size of the voids 126 (e.g., thickness, width, diameter, etc.), the shape of the voids 126, the size of the metal connectors 108 (e.g., thickness, width, diameter, etc.), the shape of the metal connectors 108, the type of materials included within the metal connectors 108, the number of different types of materials included within the metal connectors 108, the porosity of the polymer material 100, and the like. The presence of voids 126 can provide a relatively low level of resistivity to the conductive path provided by metal connectors 108 between metal layers 104 and 106, such as a resistance equal to or less than about 1 microohm, a resistance equal to or less than about 1 milliohm, etc. In some embodiments, the level of electrical conductivity and / or the level of resistance of one or more of metal connectors 108 is selected to enable polymer material 100 to provide a predetermined level of electrical shielding.

[0053] In some embodiments, the pores 114 of the polymer core 102 are substantially completely filled with the metallic connector 108. In some embodiments, one or more of the pores 114 are partially filled with the metallic connector 108, such that the pores 114 include voids 126, while one or more of the pores 114 are substantially completely filled with the metallic connector 108. Figure 5 and Figure 6 An example of a polymer material 300 is shown in which a hole 314 of a polymer core 302 is substantially completely filled by a corresponding metal connector 308. The polymer material 300 includes a polymer core 302, metal layers 304 and 306 extending on opposite sides 310 and 312 of the polymer core 302, respectively, and a metal connector 308 providing a conductive path between the metal layers 304 and 306. Each of the metal layers 304 and 306 may be referred to herein as a "first" metal layer and / or a "second" metal layer. Each of the sides 310 and 312 may be referred to herein as a "first" side and / or a "second" side.

[0054] like Figure 5 and Figure 6 As shown, the holes 314 of the polymer core 302 are each substantially completely filled with the corresponding metal connector 308, such as such that substantially no voids remain within the holes 314. Figure 5 and Figure 6In the illustrated embodiment, the metal connectors 308 define plugs that substantially completely fill the corresponding holes 314. In some other embodiments, one or more of the metal connectors 308 define plugs that substantially fill the corresponding holes 314 of the polymer core 302. Whether substantially completely filling or substantially filling the corresponding holes 314, the plugs of the metal connectors 308 can be, for example: manufactured by depositing one or more layers on the inner surface 324 of the polymer core 302 that at least partially defines the corresponding holes 314; inserted into the corresponding holes 314 (such as, but not limited to: magnetically; electrically, for example, using an electrical charge; mechanically, for example, using a pressure differential, using a vacuum, by dipping the plug into the corresponding hole 314, by pressing the plug into the corresponding hole 314, etc.; etc.) and electrically connected (e.g., fused, welded, brazed, etc.) to the metal layers 304 and 306; etc.

[0055] Various parameters of the metal connector 308 and / or its fabrication may be selected to provide a predetermined level of electrical conductivity to the connector 308 and / or the polymer material 300. Examples of parameters of the metal connector 308 that may be selected to provide a predetermined level of electrical conductivity to the metal connector 308 and / or the polymer material 300 include, but are not limited to, the size of the metal connector 308 (e.g., thickness, width, diameter, etc.), the shape of the metal connector 308, the type of materials included within the metal connector 308, the number of different types of materials included within the metal connector 308, and the like.

[0056] Various parameters of the metal connector 308 and / or its fabrication may be selected to provide a predetermined level of resistivity to the conductive path provided by the metal connector 308 between the metal layers 304 and 306 and / or the polymer material 300. Examples of parameters of the metal connector 308 and / or its fabrication that may be selected to provide a predetermined level of resistivity to the conductive path provided by the metal connector 308 between the metal layers 304 and 306 and / or the polymer material 300 include, but are not limited to, the size of the metal connector 308 (e.g., thickness, width, diameter, etc.), the shape of the metal connector 308, the type of material included within the metal connector 308, the number of different types of materials included within the metal connector 308, etc. Substantially complete filling of the hole 314 with the metal connector 308 may provide a relatively high level of resistivity (e.g., compared to the metal connector 108 of the polymer material 100), such as a resistance equal to or greater than about 1 microohm, a resistance equal to or greater than about 1 milliohm, etc., to the conductive path provided by the metal connector 308 between the metal layers 304 and 306. In some embodiments, the conductivity level and / or resistance level of one or more of the metallic connectors 308 is selected to enable the polymer material 300 to provide a predetermined level of electrical shielding.

[0057] Reference again Figure 1and Figure 2 , the conductive polymer material 100 includes a porous polymer core 102 that has been metallized with a metal connector 108 and metal layers 104 and 106, such that the polymer material 100 is conductive throughout its thickness T. The porosity of the polymer core 102 enables its metallization to conductively bridge the opposing sides 116 and 118 (e.g., metal layers 104 and 106, etc.) together, resulting in the polymer material 100 being conductive throughout its thickness T. In the absence of the conductive bridging provided by the metal connector 108, the polymer material 100 would include two conductive layers (e.g., metal layers 104 and 106, etc.) separated by an electrical insulator, and thus could function as a capacitor. Thus, for example, the metal connector 108 can increase the conductivity of the polymer material 100, increase electrical shielding capabilities, reduce capacitance, etc., compared to a polymer material including two conductive layers separated by an electrical insulator. The polymer material 100 thus operates in unconventional ways, for example, to provide improved electrical properties of the polymer material (eg, improved electrical conductivity, improved electrical shielding capabilities, reduced undesirable capacitive behavior, etc.).

[0058] Although the illustrated segment of polymeric material 100 is generally square, polymeric material 100 can have any geometry, thickness T, etc. that enables polymeric material 100 to function, e.g., as described and / or illustrated herein. In some embodiments, polymeric material 100 is elongated, e.g., along length L, along width W, etc. In some embodiments, polymeric material 100 is a tape, a film, a membrane, etc.

[0059] The polymer material 100 may be manufactured (e.g., metallized polymer core 102, etc.) using any suitable method, process, operation, treatment, etc., such as, but not limited to, forming (e.g., deposition, coating, painting, adhesion, galvanizing, wrapping, additive manufacturing, construction, etc.), inserting, etc. Examples of deposition processes that may be used to manufacture the polymer material 100 include, but are not limited to, plating, wet plating, vapor deposition, chemical deposition, ion deposition, sputtering (e.g., physical sputtering, cold sputtering, electron sputtering, potential energy sputtering, chemical sputtering, etc.), electrodeposition (e.g., electroplating, electrochemical deposition, pulse plating, brush plating, electroless deposition, etc.), electroforming, etc. Examples of additive manufacturing processes that may be used to manufacture the polymer material 100 include, but are not limited to, solid state additive manufacturing, stereolithography type technology, selective laser sintering (SLS), fused filament fabrication (FFF), selective laser melting (SLM) processes, etc. Examples of insertion processes that may be used to manufacture the polymer material 100 include, but are not limited to, magnetic, electric (e.g., using electric charge, etc.), mechanical (e.g., using pressure difference, using vacuum, impregnation, pressing, etc.), etc. For example, metal connector 108 can be inserted into hole 114 and then electrically connected (e.g., fused, welded, brazed, etc.) to metal layers 104 and 106. In some embodiments (e.g., for relatively hydrophobic polymers, etc.), one or more surface treatments (e.g., plasma discharge, corona discharge, etc.) can be applied to polymer core 102, for example to improve the bonding of metal connector 108 and / or metal layers 104 and / or 106 to corresponding surfaces of polymer core 102 (e.g., to activate the surface for adsorption of metal atoms, etc.).

[0060] FIG. 7 shows an example of a forming process including a method for making a polymer material disclosed herein, according to an embodiment. Figure 4 An example of a forming process of the polymer material 200 shown. FIG. 7a shows a polymer core 202 of the polymer material 200 before the polymer core 202 is metallized. FIG. 7b shows the polymer core 202 after a vapor deposition process has been performed to deposit copper onto the sides 210 and 212 of the polymer core 202 and within the hole 214 of the polymer core 202. Optionally, one or more plating processes are performed to deposit additional copper thickness on the sides 210, the sides 212 and / or within the hole 214. The resulting polymer material 200 including the metal layers 204 and 206 and the metal connector 208 is shown in FIG. 7c. Optionally, silver is deposited on the copper sublayers 204a and 206a to produce silver sublayers 204b and 206b of the metal layers 204 and 206, for example to prevent oxidation of the copper.

[0061] In the exemplary embodiment shown in FIG. 7c, the holes 214 of the polymer core 202 are partially filled with the metal connectors 208, such that the holes 214 include voids 226. Optionally, (e.g., before forming the optional silver sublayers 204b and 206b, etc.), one or more plating processes are performed to deposit additional copper to substantially completely fill the holes 214 of the polymer core 202 with the metal connectors 208, e.g., such that substantially no voids remain within the holes 214. The resulting polymer material 300 in which the holes 314 are substantially completely filled is shown in FIG. 7d. Thus, FIG. 7a-7d also shows a method for manufacturing a polymer material 300 including a method for manufacturing a polymer material 300. Figure 5 and Figure 6 An example of a forming process for a polymer material 300 is shown.

[0062] Figure 8 A method for manufacturing a polymer material (e.g., Figure 1 and Figure 2 The polymer material 100 shown, Figure 4 and the polymer material 200 shown in FIG. 7c, Figure 5 , Figure 6 7d, etc.) of the polymer core. The method 400 includes installing an internal metal structure within the pores of the porous polymer core at 402. At 404, the method 400 includes forming a first metal layer and a second metal layer on opposite first and second sides of the polymer core, respectively, wherein the internal metal structure connects the first metal layer and the second metal layer together, so that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

[0063] Optionally, installing the internal metal structure within the hole of the polymer core at 402 includes forming the internal metal structure on an inner surface of the hole at 402a. In some embodiments, installing the internal metal structure at 402 or forming at least one of the first metal layer and the second metal layer at 404 includes using a deposition process at 402b or 404a, respectively. In some embodiments, forming the first metal layer and the second metal layer at 404 includes using a plating process at 404b.

[0064] Optionally, installing the internal metal structure at 402 and forming the first and second metal layers at 404 include depositing metal simultaneously within the hole and on the first and second sides at 402c. In some embodiments, installing the internal metal structure at 402 and forming the first and second metal layers at 404 include depositing metal simultaneously within the hole and on the first and second sides of the polymer core at 404c; and forming the first and second metal layers at 404 also includes plating the metal deposited on the first and second sides at 404d.

[0065] In some embodiments, installing the internal metal structure at 402 includes substantially completely filling the hole with the internal metal structure at 402e. In some embodiments, installing the internal metal structure at 402 includes installing a plug that substantially fills the hole of the polymer core at 402f. Optionally, installing the internal metal structure at 402 includes partially filling the hole with the internal metal structure at 402g such that a void remains within the hole.

[0066] Reference now Fig. 9 and Fig.10 , provides an elevation view and a cross-sectional view of a cable 550 to illustrate the polymer materials disclosed herein (e.g., Figure 1 and Figure 2 The polymer material 100 shown, Figure 4 and the polymer material 200 shown in FIG. 7c, Figure 5 , Figure 6 and polymer material 300 shown in FIG. 7d, etc.) is an exemplary application. Cable 550 extends along longitudinal axis 552 from end portion 554 ( Fig.10 Length from the opposite end portion (not shown). Fig. 9 and Fig.10 In the exemplary embodiment shown, the cable 550 includes an inner conductor 556, a dielectric layer 558, a polymer material 500, an optional shield 560, and a jacket 562. The combination of the inner conductor 556 and the dielectric layer 558 may be referred to herein as a "cable core." Fig. 9 As best shown in FIG. 5 , the inner conductor 556 extends along the longitudinal axis 552 from the end portion 564 ( Fig.10 The dielectric layer 558 extends around the inner conductor 556, and the polymer material 500 extends around the dielectric layer 558. The shield 560 extends around the polymer material 500, and the jacket 562 extends around the shield 560. Starting from the end portion 554 of the cable 550, these portions of the dielectric layer 558, the polymer material 500, the shield 560, and the jacket 562 have been extended from Fig. 9 The structure of the cable 550 is gradually removed to more clearly show the structure of the cable 550.

[0067] The dielectric layer 558 extends radially (relative to the longitudinal axis 552) between the inner conductor 556 and the polymer material 500 such that the dielectric layer 558 electrically insulates the inner conductor 556 from the polymer material 500. The dielectric layer 558 can be applied around the inner conductor 556 in any arrangement, configuration, manner, in any geometry, etc. that enables the dielectric layer 558 to function, e.g., as described and / or shown herein. For example, the dielectric layer 558 can be: wrapped axially around the inner conductor 556; wrapped helically around the inner conductor 556; manufactured (e.g., via extrusion, etc.) as a tube, a jacket, etc.; etc.

[0068] Polymer material 500 includes polymer core 502, metal layers 504 and 506, and metal connector 508. For clarity, Fig. 9 The polymer core 502, the metal layers 504 and 504, and the metal connector 508 are not shown in FIG. The metal connector 508 provides a conductive path between the metal layers 504 and 506, for example, so that the polymer material 500 is conductive throughout the thickness T of the polymer material 500. Fig. 9 and Fig.10 As shown, polymer material 500 extends around inner conductor 556. As described above with respect to polymer materials disclosed herein (e.g., Figure 1 and Figure 2 The polymer material 100 shown, Figure 4 and the polymer material 200 shown in FIG. 7c, Figure 5 , Figure 6 7d, etc.), polymer material 500 is conductive. Therefore, polymer material 500 is configured to electrically shield inner conductor 556, for example to facilitate minimizing leakage of radio frequency interference (RFI) and / or reducing or preventing electromagnetic interference (EMI) disturbances from distorting the signal carried by cable 550. In some embodiments, polymer material 500 performs one or more functions of the outer conductor of cable 550. In other words, in some embodiments, polymer material 500 defines the outer conductor of cable 550 (i.e., the outer conductor of cable 550 includes polymer material 500). Each of metal layers 504 and 506 may be referred to herein as a "first" metal layer and / or a "second" metal layer.

[0069] The optional shield 560 is configured to provide mechanical axial strength to the cable 550 and / or to constrain the layers of the cable 550 (e.g., inner conductor 556, dielectric layer 558, polymer material 500, etc.) around which the shield 560 extends. In some embodiments, the shield 560 includes a plurality of wires and / or strands that are braided and / or twisted together. Optionally, the shield 560 is conductive, for example to provide electrical shielding of the inner conductor 556. Exemplary materials for the shield 560 include, but are not limited to, silver-plated copper, silver-plated copper-clad steel, stainless steel, carbon fiber, etc. In some embodiments, the shield 560 performs one or more functions of the outer conductor of the cable 550 (e.g., in addition to or as an alternative to the polymer material 500, etc.).

[0070] The jacket 562 is optionally made of an electrically insulating material. In addition or alternatively, the jacket 562 can be made of a conductive material, for example to provide electrical shielding. The jacket 562 is optionally made of a material that is conducive to protecting the internal structure of the cable 550 from environmental threats such as, but not limited to, dirt, debris, heat, cold, fluids, impact damage, etc. Suitable electrically insulating materials for the jacket 562 include, but are not limited to, polyimides, polyesters, thermoplastics, thermosetting plastics, etc.

[0071] In some embodiments, the cable 550 includes two or more layers of the polymer material 500. The cable 550 may include any number of layers of the polymer material 500. Fig. 9 and Fig.10 In the exemplary embodiment of , the cable 550 includes one (ie, a single) layer 500a of the polymer material 500. Fig. 9 and Fig.10 In the exemplary embodiment of the present invention, the polymer material layer 500a extends radially (relative to the longitudinal axis 552) between the dielectric layer 558 and the shield 560, but the polymer material 500 is not limited to extending radially between the dielectric layer 558 and the shield 560. Instead, each layer of polymer material 500 included in the cable 550 can have any radial position within the cable 550 that enables the polymer material 500 to function, such as as described and / or shown herein (e.g., to electrically shield the inner conductor 556, etc.). For example, in some embodiments, in addition to or as an alternative to the polymer material layer 500a, the cable 550 includes one or more layers of polymer material 500 that extend around the shield 560 (e.g., radially between the shield 560 and the jacket 562, etc.).

[0072] For example, Fig.11 An embodiment of a cable 650 is shown that includes an inner conductor 656, a dielectric layer 658, an optional shield 660, a polymer material 600, and a jacket 662. The combination of the inner conductor 656 and the dielectric layer 658 may be referred to herein as a "cable core." The dielectric layer 658 extends around the inner conductor 656, the shield 660 extends around the dielectric layer 658, the polymer material 600 extends around the shield 660, and the jacket 662 extends around the polymer material 600.

[0073] The polymer material 600 includes a polymer core 602, metal layers 604 and 606, and a metal connector 608. The metal connector 608 provides a conductive path between the metal layers 604 and 606, for example, so that the polymer material 600 is conductive throughout the thickness T of the polymer material 600. Fig.11As shown, polymer material 600 extends around inner conductor 656. Polymer material 600 is conductive. Therefore, polymer material 600 is configured to electrically shield inner conductor 656, for example to facilitate minimizing leakage of radio frequency interference (RFI) and / or reducing or preventing electromagnetic interference (EMI) disturbances from distorting the signal carried by cable 650. In some embodiments, polymer material 600 performs one or more functions of the outer conductor of cable 650. In other words, in some embodiments, polymer material 600 defines the outer conductor of cable 650 (i.e., the outer conductor of cable 650 includes polymer material 600). Polymer material 600 can be applied around inner conductor 656 and dielectric layer 658 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). Each of metal layers 604 and 606 may be referred to herein as a "first" metal layer and / or a "second" metal layer.

[0074] Another example includes Fig.12 Implementation of cable 750 shown. Cable 750 includes inner conductor 756, dielectric layer 758, polymer material layer 700a, optional shield 760, polymer material layer 700b, and jacket 762. The combination of inner conductor 756 and dielectric layer 758 may be referred to herein as a "cable core." Dielectric layer 758 extends around inner conductor 756, polymer material layer 700a extends around dielectric layer 758, shield 760 extends around polymer material layer 700a, polymer material layer 700b extends around shield 760, and jacket 762 extends around polymer material layer 700b.

[0075] The polymer material layers 700a and 700b include a polymer core 702, metal layers 704 and 706, and a metal connector 708. The metal connector 708 provides a conductive path between the metal layers 704 and 706, for example, so that the polymer material layers 700a and 700b are conductive over their entire thickness T. The polymer material layers 700a and 700b extend around the inner conductor 756. The polymer material layers 700a and 700b are conductive. Therefore, the polymer material layers 700a and 700b are configured to electrically shield the inner conductor 756, for example, to facilitate minimizing the leakage of radio frequency interference (RFI) and / or reduce or prevent electromagnetic interference (EMI) disturbances from distorting the signal carried by the cable 750. In some embodiments, the polymer material layer 700a and / or the polymer material layer 700b perform one or more functions of the outer conductor of the cable 750. In other words, in some embodiments, the polymer material layer 700a and / or the polymer material layer 700b define the outer conductor of the cable 750 (i.e., the outer conductor of the cable 750 includes the polymer material layer 700a and / or 700b). Each polymer material layer 700a and 700b can be applied around the inner conductor 756 and the dielectric layer 758 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). Each of the metal layers 704 and 706 may be referred to herein as a "first" metal layer and / or a "second" metal layer.

[0076] Reference again Fig. 9 and Fig.10 , each layer of polymeric material 500 can be applied around inner conductor 556 (and / or any intermediate layers of cable 550) in any arrangement, configuration, manner, in any geometry, etc. that enables polymeric material 500 to function, such as as described and / or illustrated herein (e.g., to electrically shield inner conductor 556, etc.). For example, each layer of polymeric material 500 can be: axially wrapped around inner conductor 556; helically wrapped around inner conductor 556 (e.g., Fig. 9 The spiral wrapping of the polymer material 500 is shown, Fig.11 The spiral wrapping of the polymer material 600 is shown, Fig.12 Spiral wrapping of polymer material layers 700a and 700b shown, etc.); manufactured (e.g., via extrusion, etc.) as a tube, jacket, etc.; etc. In some embodiments, polymer material 500 includes two or more layers applied around inner conductor 556 differently than one or more of each other.

[0077] When wrapped around inner conductor 556, the winding turns of the layer of polymer material 500 can have any layer angle, any winding direction, any amount of overlap of adjacent winding turns, any amount of spacing between adjacent winding turns, etc. that enables polymer material 500 to function, for example, as described and / or shown herein (e.g., to electrically shield inner conductor 556, etc.). In some embodiments, polymer material 500 includes two or more layers wrapped at different layer angles, different winding directions, different amounts of overlap, different amounts of spacing, etc., as compared to one or more of each other. For example, polymer material layers 700a and 700b may be arranged at different layer angles, different winding directions, different amounts of overlap, different amounts of spacing, etc., as compared to one or more of each other. Fig.12 The polymer material 500 can be applied around the inner conductor 556 and the dielectric layer 558 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.).

[0078] Although the exemplary embodiment of the cable 550 is shown as including one inner conductor 556 extending concentrically (about the longitudinal axis 552) relative to the polymer material 500 (such that the exemplary cable 550 is a coaxial cable), the cable 550 can include any number of inner conductors 556, such as two or more inner conductors 556. For example, the cable 550 can have any configuration that includes any number of inner conductors 556 surrounded by any number of outer conductors, with any number of dielectric layers extending radially therebetween. Examples of various configurations of the cable 550 include, but are not limited to, coaxial cables (e.g., the exemplary cable 550 shown herein, etc.), twinaxial cables, shielded parallel pairs, cables including one or more twisted pairs of inner conductors 556, cables including two or more cores each including one or more inner conductors 556 surrounded by at least one dielectric layer, and the like.

[0079] In embodiments of the cable 550 that include more than one inner conductor 556: at least one discrete dielectric layer 558 can be applied (e.g., wrapped, fed, formed, etc.) around each inner conductor 556 or each pair of inner conductors 556; and / or at least one dielectric layer 558 can extend around all of the inner conductors 556.

[0080] For example, Fig.13 An embodiment of a cable 850 is shown, which includes a pair of inner conductors 856, an optional dielectric layer 858, a polymer material 800, an optional shield 860, and a jacket 862. The combination of the inner conductor 856 and the dielectric layer 858 may be referred to herein as a "cable core." Optionally, the pair of inner conductors 856 is a twisted pair. Fig.13In an exemplary embodiment of the present invention, each inner conductor 856 is surrounded by a discrete insulating layer 866, and an optional dielectric layer 858 extends around the pair of inner conductors 856. In some other embodiments, the pair of inner conductors 856 do not include a discrete insulating layer 866.

[0081] The polymer material 800 includes a polymer core 802, metal layers 804 and 806, and a metal connector 808. The metal connector 808 provides a conductive path between the metal layers 804 and 806, for example, so that the polymer material 800 is conductive throughout the thickness T of the polymer material 800. The polymer material 800 is configured to electrically shield the inner conductor 856, for example to facilitate minimizing the leakage of radio frequency interference (RFI) and / or reduce or prevent electromagnetic interference (EMI) disturbances from distorting the signal carried by the cable 850. In some embodiments, the polymer material 800 performs one or more functions of the outer conductor of the cable 850. The polymer material 800 can be applied around the inner conductor 856 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). Each of the metal layers 804 and 806 may be referred to herein as a "first" metal layer and / or a "second" metal layer.

[0082] In another example, Fig.14 An embodiment is shown in which the cable 950 includes two cable cores 968 surrounded by a jacket 962. Each cable core 968 includes a pair of inner conductors 956, an optional dielectric layer 958, a polymer material 900, and an optional shield 960. Optionally, one or more of the pairs of inner conductors 956 are twisted pairs. Within each cable core 968, each inner conductor 956 is surrounded by a discrete insulation layer 966, and the optional dielectric layer 958 extends around the pair of inner conductors 956. In some other embodiments, within one or more of the cable cores 968, the pair of inner conductors 956 do not include a discrete insulation layer 966.

[0083] The polymer material 900 includes a polymer core 902, metal layers 904 and 906, and a metal connector 908. The metal connector 908 provides a conductive path between the metal layers 904 and 906, for example, so that the polymer material 900 is conductive throughout the thickness T of the polymer material 900. The polymer material 900 is configured to electrically shield the inner conductor 956, for example to facilitate minimizing the leakage of radio frequency interference (RFI) and / or reducing or preventing electromagnetic interference (EMI) disturbances from distorting the signal carried by the cable 950. In some embodiments, the polymer material 900 performs one or more functions of the outer conductor of the corresponding cable core 968. The polymer material 900 can be applied around the inner conductor 956 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). Each of the metal layers 904 and 906 may be referred to herein as a "first" metal layer and / or a "second" metal layer.

[0084] Reference again Fig. 9 and Fig.10 , the polymer material 500 and / or various parameters of its manufacture may be selected so that the polymer material 500 can provide a predetermined level of electrical shielding for the cable 550, for example, to facilitate minimizing the leakage of radio frequency interference (RFI) and / or reducing or preventing electromagnetic interference (EMI) disturbances from distorting signals carried by the cable 550. Examples of the polymer material 500 and / or various parameters of its manufacture that may be selected include, but are not limited to: the number of layers of the polymer material 500; the arrangement, construction, manner, geometry, etc. of how each layer of the polymer material 500 is applied to the inner conductor 556 (e.g., axial wrapping; helical wrapping; manufactured as a tube, sheath, etc.; layer angles; winding direction; the amount of overlap of adjacent winding turns; the amount of spacing between adjacent winding turns; etc.); the radial position of the layers of the polymer material 500 within the cable 550; the level of electrical conductivity of the polymer material 500 (e.g., throughout its thickness T, along its length, along its width, etc.); the level of resistivity of the polymer material 500 (e.g., throughout its thickness T, along its length, along its width, etc.); the size of the metal connector 508 (e.g., thickness, width, diameter, etc.); the shape of the metal connector 508; the type of material included in the metal connector 508; the number of different types of materials included in the metal connector 508; the amount (e.g., percentage, volume, etc.) of the corresponding hole (not shown) filled by the corresponding metal connector 508; the void (not shown; for example, Figure 1 and Figure 2the size (e.g., thickness, width, diameter, etc.) of the voids 126 shown, the shape of the voids; the porosity of the polymer material 500; the size (e.g., thickness, width, etc.) of the polymer material 500; and the like.

[0085] In some embodiments, the polymer core 502 of the polymer material 500 is cross-linked. Cross-linking reduces the temperature sensitivity (i.e., improves the heat resistance) of the polymer core 502 of the polymer material 100 (e.g., increases the glass transition temperature of the polymer core 502, etc.). Thus, cross-linking of the polymer core 502 enables the polymer material 500, and thereby the cable 550, to withstand higher temperatures. Thus, the cross-linked polymer core 502 is suitable for use in cabling applications, where the cable 550 is subjected to higher temperatures (during its use, termination, or construction). For example, cross-linking the polymer core 502 of the polymer material 500 can enable the cable 550 to withstand soldering, welding, laser welding, sintering, and / or other heating processes (e.g., for terminating the inner conductor 556, the polymer material 500, the shield 560, and / or other components of the cable 550 to various components, such as connectors, printed circuit boards, etc.; for extruding one or more other components of the cable 550, such as but not limited to the jacket 562, etc.; for shrinking one or more other components of the cable 550, such as the jacket 52, strain relief boots, etc.; etc.) without compromising the mechanical structural integrity and / or electrical signal transmission characteristics of the cable 550. In addition, for example, cross-linking the polymer core 502 of the polymer material 500 can enable the cable 550 to be used at higher ambient temperatures without compromising the mechanical structural integrity and / or electrical signal transmission characteristics of the cable 550. The polymer core disclosed herein can be cross-linked using any suitable method, process, structure, machine, means, etc., such as but not limited to cross-linking using electron beam technology, chemical cross-linking, etc.

[0086] The polymer material 500 operates in an unconventional manner, for example, to provide an improved electrical shielding material. For example, applying (e.g., wrapping, etc.) the polymer material 500 to the inner conductor 556 and the dielectric layer 558 is less challenging than flat wire or metal foil, particularly as the diameter of the cable core is reduced. For example, the polymer material 500 can be applied around the inner conductor 556 and the dielectric layer 558 using conventional (e.g., standard, etc.) dielectric tape wrapping equipment, thereby reducing the complexity and challenges of the wrapping process (e.g., spiral wrapping process, axial wrapping process, etc.). The polymer material 500 reduces or eliminates the challenges, inconsistencies, and variations of applying flat wire or metal foil to the cable core, resulting in improved electrical shielding (e.g., more effective shielding at relatively high frequencies, etc.). For example, application of the polymer material 500 to the inner conductor 556 and dielectric layer 558 reduces or eliminates attenuation behavior and inconsistencies in transmission loss (e.g., particularly for coaxial and twinaxial cables) and / or reflection loss and instabilities in phase and / or time delay when the cable moves and / or bends (e.g., compared to cables including wrapped flat wire or metal foil, etc.). Thus, incorporating the polymer material 500 as an electrical shielding component into the cable 550 results in improved signal propagation characteristics of the cable 550, particularly at relatively high frequencies, while maintaining relatively high flexibility and less signal distortion due to bending (e.g., compared to at least some known cables, etc.). In certain embodiments, the polymer material 500 used in combination with the shield 560 provides tensile strength to the resulting cable construction.

[0087] Fig.15 A method for assembling a cable (e.g., Fig. 9 and Fig.10 The cable 550 shown, Fig.11 The cable 650 shown, Fig.12 The cable 750 shown, Fig.13 The cable 850 shown, Fig.14 950, etc.) of the present invention. The method 1000 includes applying a dielectric layer around an inner conductor of the cable at 1002. At 1004, the method 1000 includes applying a polymer material (e.g., polymer material 100, 200, 300, 500, 600, 700, 800, and / or 900, etc.) around the dielectric layer to form an electrical shielding layer around the inner conductor, wherein the polymer material includes a polymer core that is metallized such that the polymer material is electrically conductive throughout a thickness of the polymer material.

[0088] In some embodiments, applying the polymeric material around the dielectric layer at 1004 includes wrapping the polymeric material helically around the dielectric layer at 1004a. In some embodiments, applying the polymeric material around the dielectric layer at 1004 includes wrapping the polymeric material axially around the dielectric layer at 1004b.

[0089] In some embodiments, method 1000 further includes performing at least one of a heating, soldering, welding, or sintering operation on the cable at 1006. Optionally, method 1000 further includes terminating the cable to at least one of an electrical connector, a circuit board, another cable, or an electrical conductor at 1008. In some embodiments, method 1000 further includes shrink-wrapping the jacket around the polymer material at 1010.

[0090] Optionally, method 1000 further includes applying a shield around the polymer material at 1012. In some embodiments, method 1000 further includes applying a jacket around the polymer material at 1014.

[0091] The polymeric materials disclosed herein (e.g., Figure 1 and Figure 2 The polymer material 100 shown, Figure 4 and the polymer material 200 shown in FIG. 7c, Figure 5 , Figure 6 7d, etc.) are not limited to use in cables. On the contrary, the cables disclosed herein (e.g., cables 550, 50, 750, 850, 950, etc.) are merely one example of the application of the polymer materials disclosed herein. Examples of other applications of the polymer materials disclosed herein include, but are not limited to:

[0092] Biological systems and / or processes (e.g., tissue regeneration, bone regeneration, hemodialysis, artificial kidney, biocatalysts, chemical biological processes and / or reactions, etc.);

[0093] Micro-support structures and / or nano-support structures (e.g., microporous frameworks, nanoporous frameworks, etc. for making electrodes);

[0094] Liquid and / or gas separation (e.g., separation of biological materials, oil-water separation, etc.);

[0095] Hydrogen recovery system;

[0096] Fuel cells;

[0097] Pollution control;

[0098] Drug delivery system;

[0099] ·etc.

[0100] In some embodiments, the polymeric materials disclosed herein provide increased surface area (e.g., compared to at least some known materials, etc.) for attaching one or more chemical and / or biological groups to perform one or more chemical and / or biological reactions. Experimental examples of the polymeric materials disclosed herein will now be described. Fig.16 and Fig.17 An exemplary microstructure of a polymer core of a polymer material according to one example is shown. In other words, Fig.16 and Fig.17 A polymer core of a polymer material before the polymer core is metallized according to the disclosure herein is shown. A minimal amount of metal (e.g., gold and / or palladium) may be formed on the polymer core to enable collection of Fig.16 and Fig.17 (ie, enabling visualization of the microstructure of the polymer core). Fig.16 and Fig.17 They have a field of view of approximately 13.8 μm and 6.92 μm respectively.

[0101] Fig.18 The microstructure of the polymer material is shown after a vapor deposition process to deposit approximately 300 angstroms of copper onto the sides of the polymer core and within the pores of the polymer core. Fig.19 is a plan view of one of the sides of the polymer material showing the surface of the copper layer deposited on the polymer core according to this example. Fig.16 and Fig.18 As can be clearly seen from the comparison of , the copper layer deposited on the polymer core reduces the pore size of the polymer material compared to the pore size of the polymer core before the copper layer is formed thereon. Fig.18 Both sides of the polymer material shown are conductive (e.g., have a resistance of less than about 10,000 ohms), but Fig.18 The metal connectors formed within the holes of the illustrated approximately 300 angstrom copper layer of the polymer material do not provide adequate conductivity (eg, having a resistance equal to or greater than approximately 10,000 ohms) between opposing sides of the polymer material (ie, throughout the thickness of the polymer material). Fig.18 It has a field of view of approximately 13.8 μm.

[0102] Fig. 20 The microstructure of the polymer material is shown after an electroplating process is performed to form silver on an approximately 300 angstrom copper layer of the polymer material. Fig.21 is a plan view of one of the sides of the polymer material, showing the surface of the silver layer according to this example. Fig.18 and Fig. 20It can be clearly seen from the comparison of that the silver layer further reduces the pore size of the polymer material compared to the pore size of the polymer material having the copper layer but before the silver layer is formed thereon. Fig. 20 Both sides of the polymer material shown are conductive (e.g., have a resistance of less than about 10,000 ohms). Fig. 20 The metal connections formed within the holes by the copper and silver layers of the polymer material shown also provide sufficient conductivity (eg, less than about 10,000 ohms of resistance) between the opposing sides of the polymer material. Fig. 20 It has a field of view of approximately 13.8 μm.

[0103] Now it will be relative to Fig. 22 and Fig.23 Another experimental example of the polymeric material disclosed herein is described. Fig. 22 The invention shows a vapor deposition process for depositing about 3000 angstroms of copper onto a polymer core (e.g., Fig.16 and Fig.17 The microstructure of the polymer material on the side of the polymer core (shown) and within the pores of the polymer core. Fig.13 is a plan view of one of the sides of the polymer material showing the surface of the copper layer deposited on the polymer core according to this example. Fig.16 and Fig. 22 As can be clearly seen from the comparison of , the copper layer deposited on the polymer core appears to almost completely fill the pores of the polymer core. Fig. 22 Both sides of the polymer material shown are conductive (e.g., have a resistance of less than about 10,000 ohms). Fig. 22 The metal connector formed within the hole by the approximately 3000 angstrom copper layer of the polymer material shown also provides sufficient conductivity (e.g., a resistance of less than about 10,000 ohms) between the opposing sides of the polymer material. For example, in this example, the resistance of the polymer material between the opposing sides (i.e., throughout the thickness of the polymer material) was measured to be approximately 0.0 ohms. Fig. 22 It has a field of view of approximately 13.8 μm.

[0104] The following clauses describe additional aspects:

[0105] Clause Set A:

[0106] A1. A polymer material, comprising:

[0107] a polymeric core comprising opposing first and second sides, the polymeric core comprising pores extending through the first and second sides of the polymeric core such that the polymeric core is porous;

[0108] a first metal layer extending on the first side of the polymer core;

[0109] a second metal layer extending on the second side of the polymer core; and

[0110] A metal connector extends from the first metal layer through the hole to the second metal layer such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

[0111] A2. A polymer material according to any preceding clause, wherein the pores of the polymer core comprise an inner surface of the polymer core, the metal connector comprising a layer extending over the inner surface.

[0112] A3. A polymer material according to any preceding clause, wherein the pores of the polymer core are substantially completely filled with the metal connectors.

[0113] A4. A polymer material according to any preceding clause, wherein the metal connector defines a plug that substantially fills the pore of the polymer core.

[0114] A5. A polymer material according to any preceding clause, wherein the pores of the polymer core are partially filled by the metal connectors such that the pores comprise voids.

[0115] A6. A polymer material according to any preceding clause, wherein the metal connector conductively bridges the first metal layer and the second metal layer together.

[0116] A7. A polymer material according to any preceding clause, wherein the metal connector is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

[0117] A8. A polymer material according to any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0118] A9. A polymer material according to any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the metal connector comprises at least one of copper or silver.

[0119] A10. A polymer material according to any preceding clause, wherein the polymer material is microporous.

[0120] Clause Set B:

[0121] B1. A polymer material, comprising:

[0122] a polymeric core comprising opposing first and second sides, the polymeric core extending through a thickness from the first side to the second side, the polymeric core being porous wherein pores extend through the thickness of the polymeric core;

[0123] a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and

[0124] An internal metal structure extends within the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

[0125] B2. A polymer material according to any preceding clause, wherein the internal metal structure connects the first metal layer and the second metal layer together such that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

[0126] B3. A polymer material according to any preceding clause, wherein the internal metal structure is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

[0127] B4. A polymer material according to any preceding clause, wherein the pores of the polymer core comprise an inner surface of the polymer core, the internal metallic structure comprising a layer extending over the inner surface.

[0128] B5. A polymer material according to any preceding clause, wherein the pores of the polymer core are substantially completely filled with the internal metallic structure.

[0129] B6. A polymer material according to any preceding clause, wherein the internal metal structure defines a plug that substantially fills the pores of the polymer core.

[0130] B7. A polymer material according to any preceding clause, wherein the pores of the polymer core are partially filled with the internal metal structure such that the pores comprise voids.

[0131] B8. A polymer material according to any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0132] B9. A polymer material according to any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the internal metal structure comprises at least one of copper or silver.

[0133] B10. A polymer material according to any preceding clause, wherein the polymer material is microporous.

[0134] Clause Set C:

[0135] C1. A polymer material, comprising:

[0136] a polymeric core comprising opposing first and second sides, the polymeric core being porous, wherein pores extend through the first and second sides of the polymeric core;

[0137] a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and

[0138] An inner metal layer extends within the hole and is configured to render the polymer material electrically conductive throughout the thickness of the polymer material.

[0139] C2. A polymer material according to any preceding clause, wherein the inner metal layer conductively bridges the first metal layer and the second metal layer together.

[0140] C3. A polymer material according to any preceding clause, wherein the internal metal layer connects the first metal layer and the second metal layer together such that the internal metal layer provides a conductive path between the first metal layer and the second metal layer.

[0141] C4. A polymer material according to any preceding clause, wherein the polymer material is microporous.

[0142] C5. A polymer material according to any preceding clause, wherein the pores of the polymer core comprise an inner surface of the polymer core, the inner metal layer extending over the inner surface.

[0143] C6. A polymer material according to any preceding clause, wherein the pores of the polymer core are substantially completely filled with the inner metal layer.

[0144] C7. A polymer material according to any preceding clause, wherein the inner metal layer defines a plug that substantially fills the pores of the polymer core.

[0145] C8. A polymer material according to any preceding clause, wherein the pores of the polymer core are partially filled by the inner metal layer such that the pores comprise voids.

[0146] C9. A polymer material according to any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0147] C10. A polymer material according to any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the inner metal layer comprises copper. C11. A polymer material according to any preceding clause, wherein at least one of the first metal layer or the second metal layer comprises silver.

[0148] Clause set D:

[0149] D1. A method for producing a polymer material, the method comprising:

[0150] installing an internal metal structure within the pores of the porous polymer core; and

[0151] A first metal layer and a second metal layer are formed on opposite first and second sides of the polymer core, respectively, wherein the internal metal structure connects the first metal layer and the second metal layer together so that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

[0152] D2. The method of any preceding clause, wherein mounting the internal metal structure within the hole of the polymer core comprises forming the internal metal structure on an inner surface of the hole.

[0153] D3. The method of any preceding clause, wherein installing the internal metal structure or forming at least one of the first metal layer and the second metal layer comprises using a deposition process.

[0154] D4. The method according to any preceding clause, wherein forming the first metal layer and the second metal layer comprises using a plating process.

[0155] D5. A method according to any preceding clause, wherein installing the internal metal structure and forming the first metal layer and the second metal layer include depositing metal within the hole and on the first side and the second side simultaneously.

[0156] D6. A method according to any of the preceding clauses, wherein installing the internal metal structure and forming the first metal layer and the second metal layer include depositing metal simultaneously within the hole and on the first side and the second side of the polymer core, and wherein forming the first metal layer and the second metal layer also includes plating the metal deposited on the first side and the second side.

[0157] D7. A method according to any preceding clause, wherein installing the internal metal structure includes substantially completely filling the hole with the internal metal structure.

[0158] D8. A method according to any preceding clause, wherein installing the internal metal structure comprises installing a plug, the plug substantially filling the hole of the polymer core.

[0159] D9. A method according to any preceding clause, wherein installing the internal metal structure includes partially filling the hole with the internal metal structure so that a void remains within the hole.

[0160] Clause Set E:

[0161] E1. A cable, comprising:

[0162] Inner conductor;

[0163] a dielectric layer extending around the inner conductor; and

[0164] a polymer material extending around the dielectric layer, the polymer material comprising:

[0165] a polymeric core comprising opposing first and second sides, the polymeric core comprising pores extending through the first and second sides of the polymeric core such that the polymeric core is porous;

[0166] a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and a metal connector, the metal connector extending from the first metal layer through the hole to the second metal layer, so that the metal connector provides a conductive path between the first metal layer and the second metal layer.

[0167] E2. The cable according to any preceding clause, wherein the hole of the polymer core comprises an inner surface of the polymer core, the metal connector comprising a layer extending on the inner surface.

[0168] E3. The cable according to any preceding clause, wherein the pores of the polymer core are substantially completely filled with the metal connector.

[0169] E4. The cable of any preceding clause, wherein the metal connector defines a plug that substantially fills the hole of the polymer core.

[0170] E5. The cable according to any preceding clause, wherein the pores of the polymer core are partially filled by the metal connector such that the pores comprise voids.

[0171] E6. The cable of any preceding clause, wherein the metallic connector conductively bridges the first and second metal layers together.

[0172] E7. A cable according to any preceding clause, wherein the metal connector is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

[0173] E8. The cable of any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0174] E9. The cable of any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the metal connector comprises at least one of copper or silver.

[0175] E10. The cable according to any preceding clause, wherein the polymer material is microporous.

[0176] E11. A cable according to any preceding clause, wherein the polymer material defines an outer conductor of the cable.

[0177] E12. The cable according to any preceding clause, further comprising a shield extending around the polymer material.

[0178] E13. The cable according to any preceding clause, further comprising a shield extending around the dielectric layer, the polymer material extending around the shield.

[0179] E14. The cable according to any preceding clause, further comprising a sheath extending around the polymer material.

[0180] E15. A cable according to any preceding clause, wherein the polymer material is helically wrapped around the inner conductor.

[0181] E16. A cable according to any preceding clause, wherein the polymer material is wrapped axially around the inner conductor.

[0182] E17. The cable according to any preceding clause, wherein the inner conductor comprises a first inner conductor and a second inner conductor, and the dielectric layer comprises a first dielectric layer extending around the first inner conductor and a second dielectric layer extending around the second inner conductor.

[0183] E18. The cable of any preceding clause, wherein the cable is a coaxial cable having the inner conductor coaxially aligned with the polymer material.

[0184] Clause set F:

[0185] F1. A cable, comprising:

[0186] Inner conductor;

[0187] a dielectric layer extending around the inner conductor; and

[0188] an outer conductor extending around the dielectric layer, the outer conductor comprising a polymer material, the polymer material comprising:

[0189] a polymeric core comprising opposing first and second sides, the polymeric core extending through a thickness from the first side to the second side, the polymeric core being porous wherein pores extend through the thickness of the polymeric core;

[0190] A first metal layer and a second metal layer, the first metal layer and the second metal layer extend on the first side and the second side of the polymer core respectively; and an internal metal structure, the internal metal structure extends within the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

[0191] F2. A cable according to any preceding clause, wherein the internal metal structure connects the first metal layer and the second metal layer together such that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

[0192] F3. A cable according to any preceding clause, wherein the internal metallic structure is constructed such that the polymer material is electrically conductive throughout the thickness of the polymer material.

[0193] F4. A cable according to any preceding clause, wherein the hole of the polymer core comprises an inner surface of the polymer core, the internal metallic structure comprising a layer extending on the inner surface.

[0194] F5. A cable according to any preceding clause, wherein the pores of the polymer core are substantially completely filled with the internal metallic structure.

[0195] F6. A cable according to any preceding clause, wherein the internal metallic structure defines a plug, which substantially fills the hole of the polymer core.

[0196] F7. A cable according to any preceding clause, wherein the pores of the polymer core are partially filled with the internal metallic structure such that the pores comprise voids.

[0197] F8. A cable according to any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0198] F9. A cable according to any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the internal metal structure comprises at least one of copper or silver.

[0199] F10. A cable according to any preceding clause, wherein the polymer material is microporous.

[0200] F11. A cable according to any preceding clause, further comprising a shield extending around the outer conductor.

[0201] F12. A cable according to any preceding clause, further comprising a shield extending around the dielectric layer, the outer conductor extending around the shield.

[0202] F13. A cable according to any preceding clause, further comprising a sheath extending around the outer conductor.

[0203] F14. A cable according to any preceding clause, wherein the polymer material is helically wrapped around the inner conductor.

[0204] F15. A cable according to any preceding clause, wherein the polymer material is wrapped axially around the inner conductor.

[0205] F16. A cable according to any preceding clause, wherein the inner conductor comprises a first inner conductor and a second inner conductor, and the dielectric layer comprises a first dielectric layer extending around the first inner conductor and a second dielectric layer extending around the second inner conductor.

[0206] F17. A cable according to any preceding clause, wherein the cable is a coaxial cable having the inner conductor coaxially aligned with the outer conductor.

[0207] Clause set G:

[0208] G1. A cable, comprising:

[0209] Inner conductor;

[0210] a dielectric layer extending around the inner conductor; and

[0211] an outer conductor extending around the dielectric layer, the outer conductor comprising a polymer material, the polymer material comprising:

[0212] a polymeric core comprising opposing first and second sides, the polymeric core being porous, wherein pores extend through the first and second sides of the polymeric core;

[0213] A first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core respectively; and an internal metal layer, the internal metal layer extending within the hole and being configured so that the polymer material is conductive throughout the entire thickness of the polymer material.

[0214] G2. The cable of any preceding clause, wherein the inner metal layer conductively bridges the first metal layer and the second metal layer together.

[0215] G3. A cable according to any preceding clause, wherein the inner metal layer connects the first metal layer and the second metal layer together such that the inner metal layer provides a conductive path between the first metal layer and the second metal layer.

[0216] G4. A cable according to any preceding clause, wherein the polymer material is microporous.

[0217] G5. A cable according to any preceding clause, wherein the hole of the polymer core comprises an inner surface of the polymer core, and the inner metal layer extends on the inner surface.

[0218] G6. A cable according to any preceding clause, wherein the holes of the polymer core are substantially completely filled by the inner metal layer.

[0219] G7. A cable according to any preceding clause, wherein the inner metallic layer defines a plug that substantially fills the hole of the polymer core.

[0220] G8. A cable according to any preceding clause, wherein the pores of the polymer core are partially filled by the inner metallic layer such that the pores comprise voids.

[0221] G9. A cable according to any preceding clause, wherein the polymer core comprises at least one of a tape or a film.

[0222] G10. The cable of any preceding clause, wherein at least one of the first metal layer, the second metal layer, or the inner metal layer comprises copper.

[0223] G11. The cable of any preceding clause, wherein at least one of the first metal layer or the second metal layer comprises silver.

[0224] G12. A cable according to any preceding clause, further comprising a shield extending around the outer conductor.

[0225] G13. A cable according to any preceding clause, further comprising a shield extending around the dielectric layer, the outer conductor extending around the shield.

[0226] G14. A cable according to any preceding clause, further comprising a sheath extending around the outer conductor.

[0227] G15. A cable according to any of the preceding clauses, wherein the polymer material is helically wrapped around the inner conductor.

[0228] G16. A cable according to any preceding clause, wherein the polymer material is wrapped axially around the inner conductor.

[0229] G17. A cable according to any of the preceding clauses, wherein the inner conductor includes a first inner conductor and a second inner conductor, and the dielectric layer includes a first dielectric layer extending around the first inner conductor and a second dielectric layer extending around the second inner conductor.

[0230] G18. A cable according to any preceding clause, wherein the cable is a coaxial cable having the inner conductor coaxially aligned with the outer conductor.

[0231] Set of terms H:

[0232] H1. A method for assembling a cable, the method comprising:

[0233] applying a dielectric layer around an inner conductor of the cable; and

[0234] A polymer material is applied around the dielectric layer to form an electrical shield around the inner conductor, wherein the polymer material includes a polymer core that is metallized such that the polymer material is electrically conductive throughout a thickness of the polymer material.

[0235] H2. A method according to any preceding clause, further comprising performing at least one of a heating, soldering, welding or sintering operation on the cable.

[0236] H3. A method according to any preceding clause, the method also comprising terminating the cable to at least one of an electrical connector, a circuit board, another cable, or an electrical conductor.

[0237] H4. A method according to any of the preceding clauses, further comprising shrink-wrapping a sheath around the polymer material.

[0238] H5. A method according to any of the preceding clauses, wherein applying the polymer material around the dielectric layer comprises spirally wrapping the polymer material around the dielectric layer.

[0239] H6. A method according to any of the preceding clauses, wherein applying the polymer material around the dielectric layer comprises axially wrapping the polymer material around the dielectric layer.

[0240] H7. A method according to any of the preceding clauses, further comprising applying a shield around the polymer material.

[0241] H8. A method according to any preceding clause, further comprising applying a sheath around the polymer material.

[0242] As used herein, a structure, limitation, or element "configured to" perform a task or operation is specifically structurally formed, constructed, or adapted in a manner corresponding to the task or operation. For the purposes of clarity and avoidance of doubt, an object that can only perform a task or operation if modified is not "configured to" perform a task or operation as used herein.

[0243] It will be apparent to one skilled in the art that any range or value given herein may be expanded or altered without losing the effect sought.

[0244] Although the subject matter is described in language specific to structural features and / or methodological acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Instead, the specific features and acts described above are disclosed as exemplary forms of implementing the claims.

[0245] It should be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to embodiments that solve any or all of the problems described or embodiments that have any or all of the benefits and advantages described. It should be understood that reference to "an" item refers to one or more of those items.

[0246] Unless otherwise specified, the order of execution or performance of the operations in the examples of the present application shown and described herein is not important. That is, unless otherwise specified, operations can be performed in any order, and the examples of the present application may include more or less operations than the operations disclosed herein. For example, it is expected that a specific operation is performed or performed before, simultaneously or after another operation (e.g., different steps, etc.) within the scope of the aspects and embodiments of the present application.

[0247] The term "comprising" is used in this specification to mean including the features or actions that follow, without excluding the presence of one or more additional features or actions. The terms "comprising", "including" and "having" are intended to be inclusive and indicate that there may be additional elements other than the listed elements. In other words, the use of "comprising", "including", "having", "containing", "involving" and variations thereof is intended to cover the items and additional items listed thereafter. Therefore, and for example, unless explicitly stated to the contrary, an embodiment that "comprising" or "having" an element or multiple elements with a particular attribute may include additional elements that do not have that attribute. In addition, reference to "an embodiment" or "an embodiment" is not intended to be interpreted as excluding the presence of additional embodiments that also include the features. The term "exemplary" is intended to mean "an example of...".

[0248] When introducing elements of aspects of the present application or examples thereof, the articles "a", "an", "the" and "said" are intended to indicate the presence of one or more elements. In other words, the indefinite articles "a", "an", "the" and "said" used in the specification and claims are to be understood to mean "at least one", unless expressly stated to the contrary. Thus, and for example, as used herein, an element or step recited in the singular and preceded by the word "a" or "an" is to be understood as not necessarily excluding a plurality of elements or steps.

[0249] The phrase "one or more of: A, B, and C" means "at least one of A and / or at least one of B and / or at least one of C". The phrase "and / or" as used in the specification and claims should be understood to mean "either or both" of the elements so combined, i.e., elements that are present in combination in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and / or" clause, other elements may optionally be present, whether related or unrelated to those specifically identified. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising", a reference to "A and / or B" may refer to only A (optionally including elements other than B) in one embodiment; only B (optionally including elements other than A) in another embodiment; both A and B (optionally including other elements) in yet another embodiment; and so on.

[0250] As used in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, that is, including multiple elements or at least one element in a list of elements, but also including more than one element, and optionally including additional unlisted items. Only when the term has a clear description to the contrary, such as "only one of..." or "exactly one of...", or when used in the claims, "consisting of..." will refer to including exactly one element in a list of multiple elements or elements. Generally speaking, when there are exclusive terms such as "any one", "one of...", "only one of..." or "exactly one of..." in front, the term "or" used should only be interpreted as indicating exclusive alternatives (i.e. "one or the other but not two"). When used in the claims, "essentially consisting of..." should have its ordinary meaning used in the field of patent law.

[0251] As used in the specification and claims, the phrase "at least one" with respect to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one element of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows that elements other than the elements specifically identified in the list of elements referred to by the phrase "at least one" may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently, "at least one of A and / or B") may refer to at least one A, optionally including more than one A, and no B (and optionally including elements other than B) in one embodiment; may refer to at least one B, optionally including more than one B, and no A (and optionally including elements other than A) in another embodiment; may refer to at least one A, optionally including more than one A, and at least one B, optionally including more than one B (and optionally including other elements) in yet another embodiment; and so on.

[0252] The use of ordinal terms such as "first," "second," "third," etc., to modify claim elements in the claims does not by itself imply any priority, precedence, or order of one claim element over another claim element, or a temporal order of the acts of performing a method. Ordinal terms are used merely as labels to distinguish one claim element having a particular name from another element having the same name (but using an ordinal term) to distinguish the claim elements.

[0253] Having described various aspects of the application in detail, it will be apparent that modifications and variations are possible without departing from the scope of the various aspects of the application as defined in the appended claims. As various changes may be made to the above-described constructions, products and methods without departing from the scope of the various aspects of the application, all matter contained in the above description and shown in the accompanying drawings is intended to be interpreted as illustrative rather than restrictive.

[0254] It should be understood that the above description is intended to be illustrative rather than restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. In addition, without departing from the scope of the present application, many modifications can be made to adapt specific situations or materials to the teachings of the various embodiments of the present application. Although the size and type of the material described herein are intended to limit the parameters of the various embodiments of the present application, these embodiments are by no means restrictive, but exemplary embodiments. After reading the above description, many other embodiments will be apparent to those of ordinary skill in the art. Therefore, the scope of the various embodiments of the present application should be determined with reference to the attached claims together with the complete scope of the equivalent forms of such claims having their rights. In the attached claims, the terms "including" and "wherein (in which)" are used as the concise English equivalents of the corresponding terms "including" and "wherein (wherein)". In addition, the terms "first", "second" and "third" etc. are only used as labels and are not intended to impose numerical requirements on their objects. Additionally, the following claim limitations are not written in a means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f) unless and until such claim limitations expressly use the phrase “means for…” followed by a recitation of function without additional structure.

[0255] This written description uses examples to disclose various embodiments of the present application, including the best mode, and also to enable a person of ordinary skill in the art to practice the various embodiments of the present application, including making and using any device or system and performing any included method. The patentable scope of the various embodiments of the present application is defined by the claims, and may include other examples that occur to a person of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if such other examples include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A polymer material, comprising: a polymeric core comprising opposing first and second sides, the polymeric core comprising pores extending through the first and second sides of the polymeric core such that the polymeric core is porous; a first metal layer extending on the first side of the polymer core; a second metal layer extending on the second side of the polymer core; as well as A metal connector extends from the first metal layer through the hole to the second metal layer such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

2. The polymer material of claim 1, wherein the pores of the polymer core comprise an inner surface of the polymer core, and the metal connector comprises a layer extending over the inner surface.

3. The polymer material of claim 1, wherein the pores of the polymer core are substantially completely filled with the metal connector.

4. The polymer material of claim 1, wherein the metal connector defines a plug that substantially fills the pores of the polymer core.

5. The polymer material of claim 1, wherein the pores of the polymer core are partially filled by the metal connectors such that the pores include voids.

6. The polymer material of claim 1, wherein the metal connector conductively bridges the first metal layer and the second metal layer together.

7. The polymer material of claim 1, wherein the metal connector is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

8. The polymer material of claim 1, wherein the polymer core comprises at least one of a tape or a film.

9. The polymer material of claim 1, wherein at least one of the first metal layer, the second metal layer, or the metal connector comprises at least one of copper or silver.

10. The polymer material of claim 1, wherein the polymer material is microporous.

11. A polymer material, comprising: a polymeric core comprising opposing first and second sides, the polymeric core extending through a thickness from the first side to the second side, the polymeric core being porous wherein pores extend through the thickness of the polymeric core; a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; as well as An internal metal structure extends within the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

12. The polymer material of claim 11, wherein the internal metal structure connects the first metal layer and the second metal layer together such that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

13. The polymer material of claim 11, wherein the internal metal structure is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

14. The polymer material of claim 11, wherein the pores of the polymer core comprise an inner surface of the polymer core, the internal metallic structure comprising a layer extending over the inner surface.

15. The polymer material of claim 11, wherein the pores of the polymer core are substantially completely filled with the internal metallic structure.

16. The polymer material of claim 11, wherein the internal metal structure defines a plug that substantially fills the pores of the polymer core.

17. The polymer material of claim 11, wherein the pores of the polymer core are partially filled with the internal metallic structure such that the pores comprise voids.

18. The polymer material of claim 11, wherein the polymer core comprises at least one of a tape or a film.

19. The polymer material of claim 11, wherein at least one of the first metal layer, the second metal layer, or the internal metal structure comprises at least one of copper or silver.

20. A method for producing a polymer material, the method comprising: installing an internal metal structure within the pores of the porous polymer core; as well as A first metal layer and a second metal layer are formed on opposite first and second sides of the polymer core, respectively, wherein the internal metal structure connects the first metal layer and the second metal layer together so that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

21. A cable, comprising: Inner conductor; a dielectric layer extending around the inner conductor; as well as a polymer material extending around the dielectric layer, the polymer material comprising: a polymeric core comprising opposing first and second sides, the polymeric core comprising pores extending through the first and second sides of the polymeric core such that the polymeric core is porous; a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and A metal connector extends from the first metal layer through the hole to the second metal layer such that the metal connector provides a conductive path between the first metal layer and the second metal layer.

22. The cable of claim 21, wherein the bore of the polymer core comprises an inner surface of the polymer core, the metal connector comprising a layer extending over the inner surface.

23. The cable of claim 21, wherein the pores of the polymer core are substantially completely filled with the metal connector.

24. The cable of claim 21, wherein the metal connector defines a plug that substantially fills the hole of the polymer core.

25. The cable of claim 21, wherein the pores of the polymer core are partially filled by the metal connector such that the pores include voids.

26. The cable of claim 21, wherein the metal connector conductively bridges the first metal layer and the second metal layer together.

27. The cable of claim 21, wherein the metal connector is configured such that the polymer material is conductive throughout the thickness of the polymer material.

28. The cable of claim 21, wherein the polymer core comprises at least one of a tape or a film.

29. The cable of claim 21, wherein at least one of the first metal layer, the second metal layer, or the metal connector comprises at least one of copper or silver.

30. The cable of claim 21, wherein the polymer material is microporous.

31. The cable of claim 21 , wherein the polymer material defines an outer conductor of the cable.

32. A cable, comprising: Inner conductor; a dielectric layer extending around the inner conductor; as well as an outer conductor extending around the dielectric layer, the outer conductor comprising a polymer material, the polymer material comprising: a polymeric core comprising opposing first and second sides, the polymeric core extending through a thickness from the first side to the second side, the polymeric core being porous wherein pores extend through the thickness of the polymeric core; a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and An internal metal structure extends within the hole, wherein the internal metal structure conductively bridges the first metal layer and the second metal layer together.

33. The cable of claim 32, wherein the internal metal structure connects the first metal layer and the second metal layer together such that the internal metal structure provides a conductive path between the first metal layer and the second metal layer.

34. The cable of claim 32, wherein the internal metal structure is configured such that the polymer material is electrically conductive throughout the thickness of the polymer material.

35. A cable, comprising: Inner conductor; a dielectric layer extending around the inner conductor; as well as an outer conductor extending around the dielectric layer, the outer conductor comprising a polymer material, the polymer material comprising: a polymeric core comprising opposing first and second sides, the polymeric core being porous, wherein pores extend through the first and second sides of the polymeric core; a first metal layer and a second metal layer, the first metal layer and the second metal layer extending on the first side and the second side of the polymer core, respectively; and An inner metal layer extends within the hole and is configured to render the polymer material electrically conductive throughout the thickness of the polymer material.

36. The cable of claim 35, wherein the inner metal layer conductively bridges the first metal layer and the second metal layer together.

37. The cable of claim 35, further comprising a shield extending around the outer conductor.

38. The cable of claim 35, further comprising a shield extending around the dielectric layer, the outer conductor extending around the shield.

39. The cable of claim 35, further comprising a jacket extending around the outer conductor.

40. The cable of claim 35, wherein the inner conductor comprises a first inner conductor and a second inner conductor, and the dielectric layer comprises a first dielectric layer extending around the first inner conductor and a second dielectric layer extending around the second inner conductor.

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