Shielded electrical cable and method of making the same

Abstract

A shielded cable includes a plurality of conductor sets extending along a length of the cable and substantially surrounded, in one-to-one correspondence, by a plurality of electrically conductive inner shields. The conductor sets and the inner shields, in combination, are substantially surrounded by an electrically conductive outer shield. Each of the conductor sets includes two or more insulated conductors extending along the length of the cable. Each of the two or more insulated conductors includes an electrically conductive central conductor surrounded by an electrically insulative material. The outer shield is intentionally and substantially uniformly wrinkled along at least the length of the outer shield.

Description

[0001] SHIELDED ELECTRICAL CABLE AND METHOD OF MAKING THE SAME

[0002] Technical Field

[0003] The present disclosure relates generally to electrical cables, and in particular, to shielded electrical cables and a method of making such cables.

[0004] Background

[0005] Due to increasing data transmission speeds used in modem electronic devices, there is a demand for electrical cables that can effectively transmit high speed electromagnetic signals. One type of cable used for these purposes is coaxial cables. Coaxial cables generally include an electrically conductive wire surrounded by an insulator. The wire and the insulator are surrounded by a shield, and the wire, the insulator, and the shield may be surrounded by a jacket. Some types of electrical cables may include one or more insulated signal conductors surrounded by a shielding layer formed, for example, by a metal foil.

[0006] Summary

[0007] In a first aspect, the present disclosure provides a shielded electrical cable including a plurality of separate individual substantially planar conductor sets. The plurality of separate individual substantially planar conductor sets extends along a length of the cable and, in combination, is substantially surrounded by a same electrically conductive multilayer first shielding film. The electrically conductive multilayer first shielding film includes at least an electrically insulative first substrate layer and an electrically conductive first metal layer. Each of the substantially planar conductor sets includes two or more insulated conductors extending along the length of the cable and arranged side-by-side along a width of the conductor set and substantially surrounded by an electrically conductive second shielding film. Each of the two or more insulated conductors of the conductor set includes an electrically conductive central conductor surrounded by an electrically insulative material. Each of the substantially planar conductor sets includes opposing first and second outermost surfaces extending across the width of the conductor set between the central conductors of opposing endmost insulated conductors of the two or more insulated conductors of the conductor set and along the length of conductor set. Further, at least one of the first and second outermost surfaces is intentionally and substantially uniformly wrinkled along the width and the length of the outermost surface.

[0008] In a second aspect, the present disclosure provides a shielded electrical cable including a plurality of conductor sets extending along a length of the cable and substantially surrounded, in one- to-one correspondence, by a plurality of electrically conductive inner shields. The conductor sets and the inner shields, in combination, are substantially surrounded by an electrically conductive outer shield. Each of the conductor sets includes two or more insulated conductors extending along the length of the cable. Each of the two or more insulated conductors includes an electrically conductive central conductor surrounded by an electrically insulative material. The outer shield is intentionally and substantially uniformly wrinkled along at least the length of the outer shield.

[0009] In a third aspect, the present disclosure provides a method of making a cable. The method includes providing a plurality of conductor sets extending longitudinally along substantially a same first direction, each of the conductor sets including a plurality of insulated conductors. Each of the insulated conductors includes an electrically conductive central conductor surrounded by an electrically insulative material. The method further includes substantially surrounding each of the conductor sets with, and bonding the conductor set to, one or more internal layers along the length of the conductor set. The method further includes forming a cable bundle by substantially surrounding the conductor sets and the one or more internal layers of the conductor sets with one or more external layers along the lengths of the conductor sets such that each of the conductor sets is substantially free to slide back and forth within the one or more external layers along the first direction. The method further includes forming the cable by intentionally and substantially uniformly wrinkling at least a first major side of the one or more external layers of the cable bundle along the length of the one or more external layers.

[0010] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

[0011] Brief Description of the Drawings

[0012] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0013] FIG. 1A shows a schematic sectional view of a shielded electrical cable, according to an embodiment of the present disclosure;

[0014] FIG. IB shows a photograph of a sectional view of the shielded electrical cable, according to an embodiment of the present disclosure;

[0015] FIG. 2 shows a schematic sectional view of a substantially planar conductor set, according to an embodiment of the present disclosure;

[0016] FIG. 3 A shows a schematic sectional perspective view of the substantially planar conductor set, according to an embodiment of the present disclosure;

[0017] FIG. 3B shows a schematic sectional view of an inner shied of the substantially planar conductor set, according to an embodiment of the present disclosure;

[0018] FIG. 4 shows a flow chart of a method of making a cable, according to an embodiment of the present disclosure;

[0019] FIGS. 5 A and 5B show schematic views depicting a process of bending a cable bundle, according to an embodiment of the present disclosure; FIGS. 6 A and 6B show photographs of portions of a comparative cable and a wrinkled cable, respectively, according to an embodiment of the present disclosure;

[0020] FIG. 7 shows a graph depicting variations in heights of the comparative cable and the wrinkled cable when at least one of first and second outermost surfaces of the wrinkled cable is intentionally and substantially uniformly wrinkled along a length of the outermost surface, according to an embodiment of the present disclosure; and

[0021] FIG. 8 shows a graph depicting variations in heights of various comparative cables and wrinkled cables when an outer shield of the wrinkled cables is intentionally and substantially uniformly wrinkled along a length of the outer shield, according to an embodiment of the present disclosure.

[0022] Detailed Description

[0023] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0024] In the following disclosure, the following definitions are adopted.

[0025] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0026] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0027] The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 10% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0028] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0029] As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be construed as limiting this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

[0030] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0031] As used herein, the term “intumescent material” refers to a material having properties that cause it to expand (or intumesce) to at least 1.5 times its original size when exposed to high temperatures typically associated with fire-like conditions, to prevent the spread of flames and smoke to other parts of a cable.

[0032] As used herein, the term “flame retardant material” refers to a material having properties by which it inhibits or resists the spread of fire.

[0033] Due to increasing data transmission speeds used in modem electronic devices, there is a demand for electrical cables that can effectively transmit high speed electromagnetic signals. One type of cable used for these purposes is coaxial cables. Coaxial cables generally include an electrically conductive wire surrounded by an insulator. The wire and the insulator are surrounded by a shield, and the wire, the insulator, and the shield are surrounded by a jacket. Some types of electrical cables include one or more insulated signal conductors surrounded by a shielding layer formed, for example, by a metal foil.

[0034] In some cases, a flexibility in the electrical cables may be desired, for example, for allowing the electrical cable to be placed more easily into a curvilinear outer jacket, or to be folded in any suitable configuration to be bent and placed in tight places.

[0035] Therefore, a suitable solution may be required which may be immune to bends or curves in a path of transmission and may provide sufficient flexibility to the cables to prevent any possible transmission losses that may otherwise be caused due to rupture of the shielding layer or any breakage caused by bending of the cable.

[0036] The present disclosure relates to a shielded electrical cable including a plurality of separate individual substantially planar conductor sets. The plurality of separate individual substantially planar conductor sets extends along a length of the cable, and, in combination, is substantially surrounded by a same electrically conductive multilayer first shielding film. The electrically conductive multilayer first shielding film includes at least an electrically insulative first substrate layer and an electrically conductive first metal layer. Each of the substantially planar conductor sets includes two or more insulated conductors extending along the length of the cable and arranged side-by-side along a width of the conductor set and is substantially surrounded by an electrically conductive second shielding film. Further, each of the two or more insulated conductors of the conductor set includes an electrically conductive central conductor surrounded by an electrically insulative material. Each of the substantially planar conductor sets includes opposing first and second outermost surfaces extending across the width of the conductor set between the central conductors of opposing endmost insulated conductors of the two or more insulated conductors of the conductor set and along the length of conductor set. Further, at least one of the first and second outermost surfaces is intentionally and substantially uniformly wrinkled along the width and the length of the outermost surface.

[0037] The intentional and substantially uniform wrinkling of the first and second outermost surfaces of the substantially planar conductor sets may provide additional flexibility to the shielded cable to bend. This may allow easy sliding of individual conductors sets within the first shielding film and may enhance flexibility of the shielded cables. Accordingly, the shielded electrical cable may be more immune to bends, curves, or tight spaces in the path of transmission. This may also allow the shieled cable to be placed more easily into a curvilinear outer jacket or to be folded in any suitable configuration. Further, an electrical performance of the shielded electrical cable may not be negatively affected due to the bending.

[0038] Referring now to figures, FIG. 1A shows a schematic sectional view of a shielded electrical cable 300, according to an embodiment of the present disclosure. FIG. IB shows a photograph of a sectional view of the shielded electrical cable 300, according to an embodiment of the present disclosure. The shielded electrical cable 300 may be interchangeably referred to as “the cable 300” herein.

[0039] The shielded electrical cable 300 defines mutually orthogonal x, y, and z-axes. The x-axis is disposed along a thickness of the shielded electrical cable 300, the y-axis is disposed along a width of the shielded electrical cable 300, and the z-axis is disposed along a length of the shielded electrical cable 300. In some embodiments, the shielded electrical cable 300 has a transverse round cross-section. In some embodiments, the shielded electrical cable 300 has a transverse circular cross-section. In some embodiments, the shielded electrical cable 300 has a transverse oval cross-section. In some embodiments, the shielded electrical cable 300 has a transverse elliptical cross-section.

[0040] Referring to FIGS. 1A and IB, the shielded electrical cable 300 includes a plurality of conductor sets 10. The plurality of conductor sets 10 extends along the length of the cable 300. In other words, the plurality of conductor sets 10 extends along the z-axis. The plurality of conductor sets 10 may be interchangeably referred to as “the conductor sets 10” herein.

[0041] In some embodiments, the plurality of conductor sets 10 is substantially planar. Therefore, in such embodiments, the plurality of conductor sets 10 may be interchangeably referred to as “the plurality of substantially planar conductor sets 10” or “the substantially planar conductor sets 10” herein.

[0042] In some embodiments, the conductor sets 10 are separate individual conductor sets substantially free to slide relative to one another along the length (i.e., substantially along the z-axis) of the cable 300. In such embodiments, the plurality of conductor sets 10 may be interchangeably referred to as “the plurality of separate individual substantially planar conductor sets 10” herein.

[0043] In some embodiments, the plurality of conductor sets 10 includes at least 4 conductor sets 10. In some embodiments, the plurality of conductor sets 10 may include at least 6, at least 8, or at least 10 of the conductor sets 10.

[0044] The plurality of substantially planar conductor sets 10, in combination, is surrounded by a same electrically conductive multilayer first shielding film 20. The electrically conductive multilayer first shielding film 20 may be interchangeably referred as “the electrically conductive outer shield 20”, or “the external layer 20” herein. The one or more external layers 20 has first major sides 20a, 20b.

[0045] The conductor sets 10 are not bonded to the electrically conductive outer shield 20 and are substantially free to slide back and forth within the outer shield 20 along the length (i.e., along the z- axis) of the cable 300. Such free movement of the conductor sets 10 may provide flexibility in internal adjustment of the conductor sets 10 within the first shielding layer 20 in tight spaces, or bends in transmission paths. In some embodiments, an average thickness of the multilayer first shielding film 20 is between about 75 microns and about 350 microns. In some embodiments, each of the conductor sets 10 is substantially planar lying in a corresponding plane 100 (shown in FIG. IB). In some embodiments, the conductor sets 10 are so arranged that the planes 100 corresponding to the conductor sets 10 are substantially parallel with each other. In some embodiments, the plurality of substantially planar conductor sets 10 are so arranged inside the outer shield 20 that the planes 100 corresponding to the conductor sets 10 are substantially parallel with each other. In some embodiments, the planes 100 corresponding to the conductor sets 10 are within 30 degrees of each other. In some embodiments, the planes 100 corresponding to the conductor sets 10 are within 25 degrees, within 20 degrees, within 15 degrees, or within 10 degrees of each other.

[0046] The multilayer first shielding field 20 includes at least an electrically insulative first substrate layer 21 and an electrically conductive first metal layer 22.

[0047] In some embodiments, the first substrate layer 21 includes one or more of an acrylate, a methacrylate, a polyurethane, a polyester, a urethane, a polycarbonate, and a polysiloxane. In some embodiments, the first substrate layer 21 includes a flame retardant material. In some embodiments, the first substrate layer 21 includes an intumescent material. In other words, in some embodiments, the first substrate layer 21 is intumescent. In some embodiments, the intumescent first substrate layer 21 is an intumescent paint coating. In some embodiments, an average thickness of the intumescent first substrate layer 21 is between about 25 microns (pm) and about 300 microns. Hence, in case of a fire or a high surrounding temperature, the first substrate layer 21 may prevent the spread of flames and / or smoke to other parts of the cable 300.

[0048] In some embodiments, the multilayer first shielding film 20 further includes an electrically insulative second substrate layer 23. In some embodiments, the first metal layer 22 is disposed between the first substrate layer 21 and the second substrate layer 23. In some embodiments, the first substrate layer 21 is intumescent and faces the conductor sets 10, and the second substrate layer 23 is not intumescent and faces away from the conductor sets 10.

[0049] In some embodiments, the first shielding film 20 is helically wrapped around the plurality of separate individual conductor sets 10 along the length of the cable 300. In some embodiments, as shown in FIG. 1A, the first shielding film 20 is helically and overlappingly wrapped around the plurality of separate individual conductor sets 10 along the length of the cable 300. In some other embodiments, the first shielding film 20 is longitudinally wrapped around the plurality of separate individual conductor sets 10 so that opposing longitudinal edges of the first shielding film 20 overlap to form an overlap seam along the length of the cable 300.

[0050] The outer shield 20 is intentionally and substantially uniformly wrinkled along at least the length of the outer shield 20. In some embodiments, the substantially uniformly wrinkled outer shield 20 has a varying height along the at least the length of the outer shield 20. In some embodiments, the varying height has a root mean square (RMS) of greater than about 50 microns. In some embodiments, the varying height has the RMS of greater than about 55 microns, greater than about 60 microns, greater than about 65 microns, greater than about 70 microns, greater than about 75 microns, greater than about 80 microns, greater than about 85 microns, greater than about 90 microns, greater than about 95 microns, or greater than about 100 microns. In some embodiments, the varying height has the RMS of about 109.7 microns.

[0051] In some embodiments, the shielded electrical cable 300 further includes an electrically insulated jacket 80 disposed on and surrounding the multilayer first shielding firm 20 along the length of the cable 300. In some embodiments, the shielded electrical cable 300 further includes an electrically insulative braided sleeve 70 disposed on and surrounding the multilayer first shielding film 20 along at least a portion of the length of the cable 300. In some embodiments, the braided sleeve 70 includes one or more of a polyester, and a nylon.

[0052] FIG. 2 shows a schematic sectional view of one of the substantially planar conductor set 10 from the plurality of conductor sets 10, according to an embodiment of the present disclosure.

[0053] Each of the substantially planar conductor sets 10 includes two or more insulated conductors 30 extending along the length of the cable 300 and arranged side-by-side along the width of the conductor set 10. In some embodiments, each of the conductor sets 10 includes a plurality of insulated conductors 30. The width of the conductor set 10 extends substantially along the width of the cable 300. As discussed above, the width of the cable is along the y-axis. Therefore, the width of the conductor set 10 is also substantially along the y-axis.

[0054] Each of the substantially planar conductor sets 10 is substantially surrounded by an electrically conductive second shielding fdm 31. In some embodiments, for each of the conductor sets 10, the second shielding film 31 is wrapped at least once around the conductor set 10. In some embodiments, for each of the conductor sets 10, the second shielding film 31 is wrapped at least twice or at least thrice around the conductor set 10.

[0055] The electrically conductive second shielding film 31 may be interchangeably referred as “the second shielding film 31”, “the electrically conductive inner shield 31”, or “the internal layer 31” herein. Accordingly, the plurality of conductor sets 10 extends along the length of the cable 300, and is substantially surrounded, in one-to-one correspondence, by the plurality of electrically conductive inner shields 31.

[0056] The conductor sets 10 and the inner shields 31, in combination, are substantially surrounded by the electrically conductive outer shield 20 (shown in FIG. 1A). In some embodiments, any electrical connection between the first and second shielding films 20, 31 is only a capacitive connection. In some embodiments, each of the first and second shielding films 20, 31 includes one or more of copper, aluminum, and silver.

[0057] Each of the two or more insulated conductors 30 of the conductor set 10 includes an electrically conductive central conductor 32 surrounded by an electrically insulative material 33.

[0058] In some embodiments, the electrically insulative material 33 of each of the insulated conductors 30 has an average thickness of between about 10 pm and about 100 pm. In some embodiments, the electrically insulative material 33 of each of the insulated conductors 10 includes one or more of a polyolefin, a polyimide, a polyamide, a polyester, a polyurethane, and a fluoropolymer. In some embodiments, a wire diameter of each of the insulated conductors 30 of each of the conductor sets 10 is not greater than 20 American Wire Gauge (AWG). In some embodiments, the wire diameter of each of the insulated conductors 30 of each of the conductor sets 10 is not greater than 21 AWG, not greater than 22 AWG, not greater than 23 AWG, not greater than 24 AWG, not greater than 25 AWG, not greater than 26 AWG, not greater than 27 AWG, not greater than 28 AWG, not greater than 29 AWG, or not greater than 30 AWG.

[0059] In some embodiments, each of the insulated conductors 30 of each of the conductor set 10 has a nominal characteristic impedance in a range of between about 40 and about 60 ohms. In some embodiments, each of the insulated conductors 30 has the nominal characteristic impedance in a range of between about 45 and about 55 ohms.

[0060] In some other embodiments, each of the insulated conductors 30 of each of the conductor sets 10 has a nominal characteristic impedance in a range of between about 70 and about 110 ohms. In some embodiments, each of the insulated conductors 30 has the nominal characteristic impedance in a range of between about 80 and about 100 ohms.

[0061] In some embodiments, each of the conductor sets 10 further includes one or more uninsulated drain grounding conductors 34a, 34b disposed on a lateral side of the two or more insulated conductors 10. In some embodiments, the two or more insulated conductors 30 of the conductor set 10 include opposing endmost insulated conductors 30a, 30b.

[0062] Each of the substantially planar conductor sets 10 further includes opposing first and second outermost surfaces 40a, 40b extending across the width (i.e., along the y-axis) of the conductor set 10 between central conductors 32a, 32b of the opposing endmost insulated conductors 30a, 30b of the two or more insulated conductors 30 of the conductor set 10. The one or more internal layers 31 of each of the conductor sets 10 has first major sides 31c, 3 Id. In some embodiments, the first major side 31c is proximal to the first outermost surface 40a. In some embodiments, the first major side 3 Id is proximal to the first outermost surface 40b. In some embodiments, the second shielding film 31 of each of the substantially planar conductor sets 10 includes opposing top and bottom second shielding film portions 50a, 50b extending across the width of the conductor set 10 between the central conductors 32a, 32b of the opposing endmost insulated conductors 30a, 30b of the two or more insulated conductors 30 of the conductor set 10 and along the length (i.e., along the z-axis) of the conductor set 10.

[0063] At least one of the first and second outermost surfaces 40a, 40b is intentionally and substantially uniformly wrinkled along the width and the length of the outermost surface 40a, 40b. In some embodiments, at least one of the top and bottom second shielding film portions 50a, 50b is intentionally and substantially uniformly wrinkled along the width and the length of the second shielding film portion 50a, 50b.

[0064] In some embodiments, the substantially uniformly wrinkled the at least one of the first and second outermost surfaces 40a, 40b has a varying height along the at least the length of the outer shield 20. In some embodiments, the substantially uniformly wrinkled the at least one of the first and second outermost surfaces 40a, 40b has the varying height having a RMS of greater than about 5 microns. In some embodiments, the substantially uniformly wrinkled the at least one of the first and second outermost surfaces 40a, 40b has the varying height having the RMS of greater than about 6 microns, greater than about 7 microns, greater than about 8 microns, greater than about 9 microns, or greater than about 10 microns. In some embodiments, the substantially uniformly wrinkled the at least one of the first and second outermost surfaces 40a, 40b may have the varying height having the RMS of about 10.82 microns.

[0065] In some embodiments, the substantially uniformly wrinkled the at least one of the top or bottom second shielding film portions 50a, 50b has a varying height having an RMS of greater than about 5 microns. In some embodiments, the substantially uniformly wrinkled the at least one of the top and bottom second shielding film portions 50a, 50b has the varying height having the RMS of greater than about 6 microns, greater than about 7 microns, greater than about 8 microns, greater than about 9 microns, or greater than about 10 microns. In some embodiments, the substantially uniformly wrinkled the at least one of the top or bottom second shielding film portions 50a, 50b may have the varying height having the RMS of about 10.82 microns.

[0066] FIG. 3 A shows a schematic sectional perspective view of one of the conductor sets 10, according to an embodiment of the present disclosure. FIG. 3B shows a schematic sectional view of the second shielding film 31, according to an embodiment of the present disclosure.

[0067] Referring to FIGS. 3A and 3B, in some embodiments, for each of the conductor sets 10, the second shielding film 31 includes electrically conductive top and bottom second shielding films 31a, 31b disposed on opposite corresponding first and second sides 10a, 10b of the conductor set 10. The top and bottom second shielding films 31a, 31b include cover portions 35a, 35b and pinched portions 36a, 36b. Specifically, the top second shielding film 3 la includes the cover portion 35a and the pinched portion 36a and the bottom second shielding film 31b includes the cover portion 35b and the pinched portion 36b. The top and bottom second shielding films 3 la, 3 lb include the cover portions 35a, 35b and the pinched portions 36a, 36b arranged such that, in a transverse cross-section, the cover portions 35a, 35b of the top and bottom second shielding films 3 la, 3 lb, in combination, substantially surround the conductor set 10, and the pinched portions 36a, 36b of the top and bottom second shielding films 31a, 31b in combination form pinched portions of the conductor set 10 on each lateral side of the conductor set 10. Specifically, in the transverse cross-section, the cover portion 35a of the top second shielding film 31a and the cover portion 35b of the bottom second shielding film 3 lb, in combination, substantially surround the conductor set 10, and the pinched portion 36a of the top second shielding film 3 la and the pinched portion 36b of the bottom second shielding film 3 lb, in combination, form the pinched portions of the conductor set 10 on each lateral side of the conductor set 10.

[0068] Each of the pinched portions 36a, 36b includes an edge 37a, 37b extending along the length of the cable 300. In some embodiments, the edge 37a, 37b of each of the conductor sets 10 is not sealed along the length of the cable 300. In some embodiments, the edges 37a, 37b of the corresponding pinched portions 36a, 36b of each of the conductor sets 10 are not sealed along the length of the cable 300.

[0069] In some embodiments, the cover portions 35a, 35b of the top and bottom shielding films 31a, 31b of each conductor set 10, in combination, substantially surround the conductor set 10 by encompassing at least 70% of a periphery of the conductor set 10. In some embodiments, the cover portions 35a, 35b of the top and bottom shielding films 31, 3 lb of each conductor set 10 in combination substantially may surround the conductor set 10 by encompassing at least 80%, at least 90%, or at least 95% of the periphery of the conductor set 10.

[0070] In some embodiments, each of the conductor sets 10 includes an adhesive 90 bonding the electrically conductive second shielding film 31 to the two or more insulated conductors of the conductor set 10. For example, the adhesive 90 may bond the top and bottom second shielding films 31a, 31b to the two or more insulated conductors 30 of the conductor set 10. In other words, the adhesive 90 may bond the cover portions 35a, 35b to the two or more insulated conductors 30 of the conductor set 10. The adhesive 90 may include any adhesive as per desired application attributes.

[0071] In some embodiments, the electrically conductive second shielding film 31 of each of the substantially planar conductor sets 10 includes a second metal layer 38 and a third substrate layer 39. In some embodiments, the second metal layer 38 is disposed over the third substrate layer 39. In some embodiments, the top and bottom second shielding films 31a, 31b include respective top and bottom second metal layers 38a, 38b and respective third substrate layers 39a, 39b. Specifically, in some embodiments, the top second shielding film 31a includes the top second metal layer 38a and the third substrate layer 39a and the bottom second shielding film 31b includes the bottom second metal layer 38b and the third substrate layer 39b.

[0072] FIG. 4 illustrates a flow chart of a method 400 of making the cable 300, according to an embodiment of the present disclosure. The method 400 will be described with reference to FIGS. 1A- 3. FIGS. 5 A and 5B are schematic views depicting a process of bending a cable bundle 110. The method 400 will be described with additional reference to FIGS. 5 A and 5B.

[0073] At step 402, the method 400 includes providing the plurality of conductor sets 10 extending longitudinally along substantially the same first direction (i.e., substantially along the z-axis). Each of the conductor sets 10 includes the plurality of insulated conductors 30. Each of the insulated conductors 30 includes the electrically conductive central conductor 32 surrounded by the electrically insulative material 33.

[0074] At step 404, the method 400 includes substantially surrounding each of the conductor sets 10 with, and bonding the conductor set 10 to, the one or more internal layers 31 along the length of the conductor set 10. In some embodiments, the conductor sets 10 are bonded to the one or more internal layers 31 via the adhesive 90.

[0075] At step 406, the method 400 includes forming the cable bundle 110 (shown in FIGS. 5A and 5B) by substantially surrounding the conductor sets 10 and the one or more internal layers 31 of the conductor sets 10 with the one or more external layers 20 along the lengths of the conductor sets 10 such that each of the conductor sets 10 is substantially free to slide back and forth within the one or more external layers 20 along the first direction.

[0076] At step 408, the method 400 includes forming the cable 300 by intentionally and substantially uniformly wrinkling at least the first major side 20a, 20b of the one or more external layers 20 of the cable bundle 110 along the length of the one or more external layers 20. In other words, the method 400 includes forming the cable 300 by intentionally and substantially uniformly wrinkling at least one of the first major sides 20a, 20b of the one or more external layers 20 of the cable bundle 110 along the length of the one or more external layers 20.

[0077] In some embodiments, the method 400 further includes intentionally and substantially uniformly wrinkling at least the first major side 31c, 3 Id of the one or more internal layers 31 of each of the conductor sets 10 along the length of the one or more internal layers 31. In other words, the method 400 further includes intentionally and substantially uniformly wrinkling at least one of the first major sides 31c, 3 Id of the one or more internal layers 31 of each of the conductor sets 10 along the length of the one or more internal layers 31. In some embodiments, the method 400 includes intentionally and substantially uniformly wrinkling both the first major sides 31c, 3 Id of the one or more internal layers 31 of each of the conductor sets 10 along the length of the one or more internal layers 31.

[0078] In some embodiments, the at least the first major side 20a, 20b of the one or more external layers 20 of the cable bundle 110 is intentionally and uniformly wrinkled along the length of the one or more external layers 20 by bending the cable bundle 110 over a shaft 120 (shown in FIGS. 5A and 5B) centered on a shaft rotation axis 121 (shown in FIGS. 5A and 5B) to form a bend angle al (shown in FIG. 5A).

[0079] In some embodiments, the bend angle al is at least about 10 degrees and at most about 70 degrees. In some embodiments, the bend angle al is at least about 20 degrees and at most about 60 degrees.

[0080] In some embodiments, the shaft 120 has an outer diameter of less than about 50 millimeters (mm). In some embodiments, the shaft 120 has the outer diameter of less than about 45 mm, less than about 40 mm, less than about 35 mm, less than about 30 mm, or less than about 25 mm. In some embodiments, the shaft 120 may be allowed to rotate freely on ball bearings (not shown).

[0081] The intentional substantially and uniform wrinkling of the outer shield 20 may provide additional flexibility to the cable 300 to bend. This may prevent any loss of signal which may otherwise be caused by any rupture or breakage of the cable 300 due to low flexibility. Further, the intentional substantially and uniform wrinkling may not negatively affect an electrical performance of the cable 300.

[0082] FIGS. 6 A and 6B show exemplary photographs of portions of a comparative cable and a wrinkled cable, respectively. The wrinkled cable is similar to the cable 300. The comparative cable is also substantially similar to the cable 300, however, the comparative cable is not wrinkled. FIG. 7 illustrates an exemplary graph 700 depicting variations in the heights of a comparative cable (e.g., the comparative cable shown in FIG. 6A) and a wrinkled cable (e.g., the wrinkled cable shown in FIG. 6B) along the lengths (i.e., substantially along the z-axis) of the respective portions of the of the comparative cable and the wrinkled cable. The length of the portion is shown as distance and expressed in millimeters (mm) in the abscissa. The height is expressed in micrometers (pm) in the ordinate.

[0083] Specifically, the graph 700 includes a curve 702 depicting the variation in the height of the wrinkled cable when the at least one of the first and second outermost surfaces 40a, 40b (shown in FIG. 2) is intentionally and substantially uniformly wrinkled along the length of the outermost surfaces 40a, 40b. Further, the graph 700 includes a curve 704 depicting the variation in the height of the comparative cable (i.e., not wrinkled).

[0084] As is apparent from the curves 702, 704, the variation in the height of the wrinkled cable (e.g., as shown in FIG. 6B) is greater than that of the comparative cable (e.g., as shown in FIG. 6A). Accordingly, the wrinkled cable may be more flexible as compared to the comparative cable.

[0085] Table 1 lists exemplary values for different parameters of the comparative cable and the wrinkled cable. Specifically, Table 1 includes RMS values of the variation in the height, ranges of the variation in heights, ratios of the RMS values to the ranges, averages of the absolute values of the variation in the heights Avg(Abs), averages (Avg) of the variations in the height, ratios of the RMS values to absolute values of the averages Abs(Avg), ratios of the RMS to the average values of the absolute values Avg(Abs), and ratios of the Avg(Abs) to the Avg(Abs) for the comparative cable and the wrinkled cable.

[0086] Table 1

[0087] The at least one of the first and second outermost surfaces 40a, 40b of the wrinkled cable has the varying height having the RMS of about 10.82 microns. Therefore, when the at least one of the first and second outermost surfaces 40a, 40b of the cable 300 is substantially uniformly wrinkled, the at least one of the first and second outermost surfaces 40a, 40b has the varying height having the RMS of greater than about 5 microns.

[0088] FIG. 8 illustrates a graph 800 depicting variations of in heights of first, second, third, and fourth comparative cables and corresponding first, second, third, and fourth wrinkled cables (e.g., the cable 300) along the lengths of the corresponding cables after the intentional substantially and uniform wrinkling. The length is shown as distance and expressed in millimeters (mm) in the abscissa. The height is expressed in micrometers (pm) in the ordinate.

[0089] The graph 800 includes curves 802, 804, 806, and 808 depicting the variations in the heights of the respective first, second, third, and fourth comparative cables along their lengths. Specifically, the curve 802 depicts the variation in the height of the first comparative cable along its length, the curve 804 depicts the variation in the height of the second comparative cable along its length, the curve 806 depicts the variation in the height of the third comparative cable along its length, and the curve 808 depicts the variation in the height of the fourth comparative cable along its length.

[0090] The graph 800 further includes curves 812, 814, 816, and 818 depicting the variations in the heights of the respective first, second, third, and fourth wrinkled cables when their outer shield 20 (shown in FIG.l) is intentionally and substantially uniformly wrinkled along the length of the outer shield 20. Specifically, the curve 812 depicts the variation in the height of the first wrinkled cable along its length, the curve 814 depicts the variation in the height of the second wrinkled cable along its length, the curve 816 depicts the variation in the height of the third wrinkled cable along its length, and the curve 818 depicts the variation in the height of the fourth wrinkled cable along its length.

[0091] As is apparent from the curves 802, 804, 806, 808, 812, 814, 816, and 818, the variation in the heights of the first, second, third, and fourth wrinkled cables is greater than that of the respective first, second, third, and fourth comparative cables. Accordingly, the first, second, third, and fourth wrinkled cables may be more flexible (for e.g., at bends) as compared to the first, second, third, and fourth comparative cables.

[0092] Table 2 lists exemplary values for different parameters of the first, second, third, and fourth comparative cables and the first, second, third, and fourth wrinkled cables. Specifically, Table 2 includes RMS values of the variation in the heights, ranges of the variation in the heights, ratios of the RMS values to the ranges, standard deviations Std of the variation in the heights, an average Avg(Std(Comp)) of the standard deviation of the first, second, third, and fourth comparative cables and an average Avg(Std(Wrin)) of the standard deviations of the first, second, third, and fourth wrinkled cables.

[0093] Table 2

[0094]

[0095] Therefore, on an average, the outer shield 20 of each of the first, second, third, and fourth wrinkled cables has the varying height having the RMS of greater than about 50 microns. Therefore, when the outer shield 20 is substantially uniformly wrinkled, the outer shield 20 has the varying height having the RMS of greater than about 50 microns.

[0096] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0097] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

CLAIMS1. A shielded electrical cable comprising a plurality of separate individual substantially planar conductor sets extending along a length of the cable and, in combination, substantially surrounded by a same electrically conductive multilayer first shielding film comprising at least an electrically insulative first substrate layer and an electrically conductive first metal layer, each of the substantially planar conductor sets comprising two or more insulated conductors extending along the length of the cable and arranged side-by-side along a width of the conductor set and substantially surrounded by an electrically conductive second shielding film, each of the two or more insulated conductors of the conductor set comprising an electrically conductive central conductor surrounded by an electrically insulative material, wherein, each of the substantially planar conductor sets comprises opposing first and second outermost surfaces extending across the width of the conductor set between the central conductors of opposing endmost insulated conductors of the two or more insulated conductors of the conductor set and along the length of conductor set, at least one of the first and second outermost surfaces intentionally and substantially uniformly wrinkled along the width and the length of the outermost surface.

2. The shielded electrical of claim 1, wherein the substantially uniformly wrinkled the at least one of the first and second outermost surfaces has a varying height having a root mean square (RMS) of greater than about 5 microns.

3. The shielded electrical of claim 1, wherein the second shielding film of each of the substantially planar conductor sets comprises opposing top and bottom second shielding film portions extending across the width of the conductor set between the central conductors of opposing endmost insulated conductors of the two or more insulated conductors of the conductor set and along the length of conductor set, at least one of the top and bottom second shielding film portions intentionally and substantially uniformly wrinkled along the width and the length of the second shielding film portion.

4. The shielded electrical of claim 3, wherein the substantially uniformly wrinkled the at least one of the top and bottom second shielding film portions has a varying height having a root mean square (RMS) of greater than about 5 microns.

5. A shielded electrical cable comprising a plurality of conductor sets extending along a length of the cable and substantially surrounded, in one-to-one correspondence, by a plurality of electrically conductive inner shields, the conductor sets and the inner shields, in combination, substantially surrounded by an electrically conductive outer shield, each of the conductor sets comprising two or more insulated conductors extending along the length of the cable, each of the two or more insulated conductors comprising an electrically conductive central conductor surrounded by an electricallyinsulative material, the outer shield intentionally and substantially uniformly wrinkled along at least the length of the outer shield.

6. The shielded electrical cable of claim 5, wherein the substantially uniformly wrinkled outer shield has a varying height along the at least the length of the outer shield, the varying height having a root mean square (RMS) of greater than about 50 microns.

7. The shielded electrical cable of claim 6, wherein each of the conductor sets is substantially planar lying in a corresponding plane, and wherein the conductor sets are so arranged inside the outer shield so that the planes corresponding to the conductor sets are substantially parallel with each other.

8. A method of making a cable, comprising: providing a plurality of conductor sets extending longitudinally along substantially a same first direction, each of the conductor sets comprising a plurality of insulated conductors, each of the insulated conductors comprising an electrically conductive central conductor surrounded by an electrically insulative material; substantially surrounding each of the conductor sets with, and bonding the conductor set to, one or more internal layers along the length of the conductor set; forming a cable bundle by substantially surrounding the conductor sets and the one or more internal layers of the conductor sets with one or more external layers along the lengths of the conductor sets such that each of the conductor sets is substantially free to slide back and forth within the one or more external layers along the first direction; and forming the cable by intentionally and substantially uniformly wrinkling at least a first major side of the one or more external layers of the cable bundle along the length of the one or more external layers.

9. The method of making a cable according to claim 8, further comprising intentionally and substantially uniformly wrinkling at least a first major side of the one or more internal layers of each of the conductor sets along the length of the one or more internal layers.

10. The method of making the cable according to claim 8, wherein the at least the first major side of the one or more external layers of the cable bundle is intentionally and substantially uniformly wrinkled along the length of the one or more external layers by bending the cable bundle over a shaft centered on a shaft rotation axis to form a bend angle, and moving the cable bundle back and forth over the shaft along the length of the cable bundle from substantially a first longitudinal end of the cable bundle to an opposite second longitudinal end of the cable bundle while substantially maintaining the bend angle and while the shaft rotates about the shaft rotation axis.

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