Low inductance screened cable and method of manufacture

Abstract

Disclosed is a low inductance screened cable (100) including a first conductor (102) having a first cross-sectional area, a first insulation (104) surrounding the first 5 conductor, a second conductor (106) having a second cross-sectional area equal to the first cross-sectional area surrounding the first insulation, a second insulation (108) surrounding the second conductor, a copper tape screening (110) surrounding the second insulation, and an outer sheath (112) surrounding the copper tape screening The cable exhibits an inductance of less than or equal to 0.2 µH / m across a frequency 10 range of 100 Hz to 100 MHz. The conductors are made of high-conductivity copper complying with IS 8130 standards, while the insulations and outer sheath are made of UV-protected flame retardant low smoke (FRLS) compound with thicknesses optimized for low inductance requirements.

Description

LOW INDUCTANCE SCREENED CABLE AND METHOD OF MANUFACTURE FIELD OF DISCLOSURE

[0001] The present disclosure relates to electrical cables for power transmission systems, and more particularly to low inductance screened cable and method of manufacture.BACKGROUND

[0002] Power transmission systems play a crucial role in various industries, including telecommunications, industrial automation, and other power-sensitive environments. These systems often require cables capable of delivering stable and efficient power, especially in applications with fast-changing current demands.

[0003] Conventional power cables used in such systems often suffer from voltage drops caused by self-inductance, particularly under high-frequency switching conditions or during battery backup operations. This phenomenon can lead to compromised system reliability and performance. Additionally, traditional cables may be bulky, difficult to install, and less efficient in terms of power transmission over longer distances. The limitations of existing cable technologies become more apparent in applications such as Remote Radio Heads (RRH) in telecommunications, where compact design and consistent performance are essential.

[0004] Furthermore, electromagnetic interference (EMI) and cross-talk between cables in dense installations pose significant challenges in maintaining signal integrity and overall system efficiency. Existing solutions often fail to provide adequate shielding or require complex and expensive designs to mitigate these issues. The need for cables that can maintain low inductance across a wide frequency range while offering effective EMI protection has become increasingly important in modern power transmission applications.

[0005] Therefore, there exists a need for a technical solution that solves the aforementioned problems of conventional systems and methods for power transmission cables. Such a solution should address the issues of high inductance, voltage drops, EMI susceptibility, and installation challenges while providing a compact and efficient design suitable for various industrial applications.SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In an aspect of the present disclosure, a low inductance screened cable is disclosed. The cable includes a first conductor having a first cross-sectional area and comprising multiple conductor strands arranged in a bundled formation. A first insulation surrounds the first conductor and provides electrical isolation. A second conductor having a second cross-sectional area equal to the first cross-sectional area surrounds the first insulation, with the second conductor comprising multiple conductor strands arranged in a circular pattern. A second insulation surrounds the second conductor and provides additional electrical isolation and spacing. A copper tape screening surrounds the second insulation and provides electromagnetic shielding. An outer sheath surrounds the copper tape screening and provides environmental protection and mechanical strength. The cable exhibits an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz.

[0008] In some aspects of the present disclosure, the first conductor and the second conductor are made of high-conductivity copper complying with IS 8130 standards, ensuring optimal electrical performance and reliability.

[0009] In some aspects of the present disclosure, the first insulation and the second insulation are made of a flame retardant low smoke (FRLS) compound, providing enhanced safety characteristics and compliance with fire safety regulations.

[0010] In some aspects of the present disclosure, the FRLS compound is UV-protected, enhancing durability and performance in outdoor installations and environments with significant UV exposure.

[0011] In some aspects of the present disclosure, the outer sheath is made of a flexible, UV-resistant FRLS material, providing environmental protection while maintaining cable flexibility for installation and routing.

[0012] In some aspects of the present disclosure, the thickness of the first insulation, second insulation, and outer sheath are optimized to meet low inductance requirements while maintaining adequate dielectric strength and mechanical protection.

[0013] In some aspects of the present disclosure, the cable has a smaller cross-sectional area and reduced weight compared to conventional cables with equivalent performance, facilitating easier installation and reducing structural load requirements.

[0014] In some aspects of the present disclosure, the cable is configured for use in Remote Radio Head (RRH) systems, industrial automation, data centers, renewable energy systems, or power-sensitive environments requiring reliable performance and compact cable layouts.

[0015] In some aspects of the present disclosure, the cable may be tested for inductance at multiple specific frequencies including 100 Hz, 1000 Hz, 100 kHz, and 100 MHz to ensure consistent performance across its operational range.

[0016] In some aspects of the present disclosure, the cable may be customized with varying conductor sizes, insulation thicknesses, or shielding configurations to meet specific application requirements while maintaining the core low inductance characteristics.

[0017] In some aspects of the present disclosure, the copper tape screening may be applied with controlled thickness and tension to provide optimal electromagnetic shielding while maintaining cable flexibility.

[0018] In some aspects of the present disclosure, the cable may include additional features such as customizable outer sheath colors, enhanced temperature ratings, or specialized jacketing materials for specific environmental conditions.

[0019] In another aspect of the present disclosure, a method of manufacturing a low inductance screened cable is disclosed. The method includes forming a first conductor having a first cross-sectional area through processes such as wire drawing and strand bundling. The first conductor is surrounded with a first insulation using controlled extrusion processes. The first insulation is surrounded with a second conductor having a second cross-sectional area equal to the first cross-sectional area, ensuring balanced electromagnetic properties. The second conductor is surrounded with a second insulation using similar controlled extrusion processes. The second insulation is surrounded with a copper tape screening applied through wrapping or winding processes with controlled tension and coverage. The copper tape screening is surrounded with an outer sheath applied through extrusion processes with controlled temperature and pressure. The manufactured cable exhibits an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz.

[0020] In some aspects of the present disclosure, forming the first conductor and the second conductor includes using high-conductivity copper complying with IS 8130 standards and may involve precise control of wire drawing parameters and strand arrangement.

[0021] In some aspects of the present disclosure, surrounding the first conductor with the first insulation and surrounding the second conductor with the second insulation includes using a flame retardant low smoke (FRLS) compound with controlled extrusion parameters to achieve desired thickness and uniformity.

[0022] In some aspects of the present disclosure, the FRLS compound is UV-protected through the incorporation of UV-stabilizing additives during the compounding process.

[0023] In some aspects of the present disclosure, surrounding the copper tape screening with the outer sheath includes using a flexible, UV-resistant FRLS material withcontrolled extrusion parameters to achieve desired surface finish and dimensional accuracy.

[0024] In some aspects of the present disclosure, the method further includes optimizing the thickness of the first insulation, second insulation, and outer sheath through iterative testing and adjustment to meet low inductance requirements while maintaining other performance criteria.

[0025] In some aspects of the present disclosure, the method includes comprehensive testing procedures to verify that the manufactured cable exhibits the required inductance characteristics across the specified frequency range.

[0026] In some aspects of the present disclosure, the method may include additional quality control steps such as dimensional verification, insulation resistance testing, mechanical stress testing, and environmental conditioning tests.

[0027] In some aspects of the present disclosure, the manufactured cable has a smaller cross-sectional area and reduced weight compared to conventional cables with equivalent performance, and is configured for use in Remote Radio Head (RRH) systems, industrial automation, data centers, renewable energy systems, or powersensitive environments requiring reliable performance and compact cable layouts.

[0028] In some aspects of the present disclosure, the method may be adapted to produce cables with varying sizes, conductor configurations, or shielding levels to meet specific customer requirements or industry standards while maintaining the core low inductance properties.

[0029] The foregoing general description of the illustrative aspects and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0030] The following detailed description of the preferred aspects of the present disclosure will be better understood when read in conjunction with the appendeddrawings. The present disclosure is illustrated by way of example, and not limited by the accompanying figures, in which like references indicate similar elements.

[0031] FIG. 1 illustrates a cross-sectional view of a screened cable, according to aspects of the present disclosure; and

[0032] FIG. 2 illustrates a flowchart of a method for manufacturing a low inductance screened cable, according to aspects of the present disclosure.DETAILED DESCRIPTION

[0033] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0034] The present disclosure relates to a low inductance screened cable and method of manufacture. This innovative cable design addresses critical challenges in power transmission systems, particularly in applications requiring stable power delivery under fast-changing current demands. By incorporating advanced materials and a unique structural configuration, the cable achieves exceptionally low inductance across a wide frequency range, from 100 Hz to 100 MHz. This characteristic significantly reduces voltage drops and improves overall system reliability, making it particularly suitable for demanding applications where power quality and consistency are paramount.

[0035] The cable's construction features dual conductors with balanced electromagnetic properties, surrounded by high-performance insulation and shielding layers. This configuration not only minimizes self-inductance but also provides excellent protection against electromagnetic interference (EMI). The use of flame retardant low smoke (FRLS) compounds and UV-protected materials enhances the cable's durability and safety in various environments, from indoor installations to outdoor telecommunications infrastructure.

[0036] Key advantages of this low inductance screened cable include its compact size and reduced weight compared to conventional cables with equivalent performance. The cable's design allows for greater flexibility and ease of installation, making it particularly suitable for applications with space constraints or complex routing requirements. Furthermore, its consistent low inductance across a broad frequency spectrum ensures reliable performance in systems with varying load conditions or high-frequency switching operations, such as those found in modern power electronics and renewable energy systems.

[0037] This cable technology finds applications in diverse fields such as telecommunications infrastructure, industrial automation, data centers, renewable energy systems, and other power-sensitive environments. Its ability to maintain stable voltage levels and minimize power losses contributes to improved energy efficiency and system performance in critical applications. The cable's design also supports the growing trend toward higher power densities and more compact installations in modern electronic systems.

[0038] FIG. 1 illustrates a cross-sectional view of a screened cable 100. The screened cable 100 comprises multiple concentric layers arranged in a circular configuration, each layer serving a specific function in achieving the cable's low inductance and high-performance characteristics. At the center is a first conductor 102, which consists of multiple conductor strands arranged in a bundled formation. The first conductor 102 may be made of high-conductivity copper complying with IS 8130 standards, ensuring optimal electrical conductivity and mechanical properties. In some aspects of the present disclosure, the first conductor 102 may have a cross-sectional area optimized for specific application requirements, with the strand count and individual strand diameter selected to achieve the desired current-carrying capacity and flexibility characteristics.

[0039] Surrounding the first conductor 102 is a first insulation 104, which provides electrical isolation between the first conductor and subsequent layers. The firstinsulation 104 may be made of a flame retardant low smoke (FRLS) compound, providing enhanced safety characteristics and compliance with fire safety regulations. In some aspects of the present disclosure, the first insulation 104 may be UV-protected to enhance durability in outdoor environments and installations with significant UV exposure. The thickness of the first insulation 104 may be optimized to meet low inductance requirements while maintaining adequate dielectric strength and voltage withstand capability. The insulation material may be selected to provide excellent electrical properties across the operating frequency range while maintaining flexibility and processability during manufacturing.

[0040] A second conductor 106 encircles the first insulation 104 and is composed of multiple conductor strands arranged in a circular pattern around the insulated first conductor. The second conductor 106 may have a cross-sectional area equal to that of the first conductor 102, ensuring balanced electromagnetic properties and contributing to the cable's low inductance characteristics. In some aspects of the present disclosure, the second conductor 106 may be made of the same high-conductivity copper as the first conductor 102, complying with IS 8130 standards and ensuring consistent electrical and mechanical properties throughout the cable construction.

[0041] The second conductor 106 is enclosed by a second insulation 108, which provides electrical isolation and proper spacing between the conductors and subsequent layers. Similar to the first insulation 104, the second insulation 108 may be made of a flame retardant low smoke (FRLS) compound and may be UV-protected for enhanced environmental durability. The thickness of the second insulation 108 may be optimized to meet low inductance requirements while providing adequate protection and maintaining the desired cable geometry. The insulation material and thickness are selected to minimize the overall cable inductance while ensuring adequate electrical isolation and mechanical protection.

[0042] A copper tape screening 110 surrounds the second insulation 108, providing electromagnetic shielding and contributing to the cable's EMI protection capabilities.The copper tape screening 110 may be of appropriate thickness to effectively reduce electromagnetic interference (EMI) and cross-talk in environments with multiple cable runs or high levels of electromagnetic activity. In some aspects of the present disclosure, the copper tape screening 110 may be customized based on specific customer requirements for EMI protection levels, with the tape thickness, overlap, and application method optimized for the intended application environment.

[0043] The outermost layer consists of an outer sheath 112, which protects the internal components and provides mechanical strength to the cable assembly. The outer sheath 112 may be made of a flexible, UV-resistant FRLS material, providing environmental protection while maintaining cable flexibility for installation and routing. In some aspects of the present disclosure, the thickness and color of the outer sheath 112 may be customizable to meet specific application needs and customer preferences, with options for enhanced temperature ratings, chemical resistance, or specialized marking and identification features.

[0044] The arrangement of the components in screened cable 100 creates a low inductance cable design through careful optimization of geometry and materials. The first conductor 102 and second conductor 106 have identical cross-sectional areas, contributing to balanced electromagnetic properties and minimizing inductive effects. The copper tape screening 110 reduces electromagnetic interference and provides a return path for high-frequency currents, while the outer sheath 112 provides environmental protection and mechanical integrity. The first insulation 104 and second insulation 108 maintain proper spacing between the conductors and provide flameretardant properties while contributing to the overall low inductance design.

[0045] In operation, the screened cable 100 exhibits an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz. This low inductance characteristic is achieved through the optimized geometry and material selection of the cable components, including the balanced conductor configuration, optimized insulation thicknesses, and effective electromagnetic shielding. The balancedconductor configuration and the copper tape screening contribute to minimizing selfinductance and mutual inductance effects, while the overall cable geometry is optimized to maintain consistent impedance and minimize reactive components.

[0046] The screened cable 100 may be used in various applications requiring stable power delivery under fast-changing current demands. For example, the cable may be particularly suitable for use in Remote Radio Head (RRH) systems in telecommunications infrastructure, where the low inductance properties help minimize voltage drops and ensure consistent power delivery to sensitive RF equipment. In such applications, the cable's ability to maintain stable voltage levels under varying load conditions is crucial for maintaining signal quality and network performance.

[0047] Furthermore, the screened cable 100 may find applications in industrial automation settings where precise power control and minimal electromagnetic interference are critical for system operation. The cable's compact design and reduced weight compared to conventional cables with equivalent performance make it advantageous for installations with space constraints or where cable weight is a concern, such as in robotic systems, automated manufacturing equipment, or mobile industrial applications.

[0048] Additional applications may include data center power distribution systems, where the cable's low inductance characteristics help maintain power quality and reduce voltage fluctuations in high-density server installations. The cable may also be suitable for renewable energy systems, such as solar inverter connections or wind turbine power transmission, where consistent power delivery and EMI protection are important for system efficiency and grid compliance.

[0049] It should be noted that while FIG. 1 illustrates a specific configuration of the screened cable 100, various modifications may be made without departing from the scope of the present disclosure. For example, the number of conductor strands, insulation thicknesses, screening materials, or overall cable dimensions may beadjusted to meet specific performance requirements or manufacturing constraints while maintaining the core low inductance characteristics.

[0050] Although FIG. 1 illustrates that the screened cable 100 includes a single first conductor 102 and a single second conductor 106, it will be apparent to a person skilled in the art that the scope of the present disclosure is not limited to it. In various other aspects, the screened cable 100 may include multiple first conductors and multiple second conductors without deviating from the scope of the present disclosure. In such a scenario, each conductor is configured to perform one or more operations in a manner similar to the operations of the first conductor 102 and second conductor 106 as described herein, with appropriate scaling of cross-sectional areas and geometric relationships to maintain the balanced electromagnetic properties.

[0051] In some aspects of the present disclosure, the low inductance screened cable 100 may be tested for inductance at multiple frequencies to ensure consistent performance across its operational range. Specifically, the cable 100 may be tested to maintain an inductance of less than or equal to 0.2 pH / m at 100 Hz, 1000 Hz, 100 kHz, and 100 MHz. This comprehensive testing ensures that the cable 100 maintains its low inductance characteristics across a wide spectrum of frequencies, making it suitable for various applications with different power transmission requirements and frequency characteristics.

[0052] The low inductance screened cable 100 may be customized to meet specific application needs while maintaining its core performance characteristics. For example, the number of wires and wire sizes in the conductors 102 and 106 may be adjusted while maintaining the overall cross-sectional area and balanced electromagnetic properties. This flexibility allows for optimization of the cable's performance for different current carrying capacities and installation requirements, enabling the cable to be tailored for specific applications ranging from low-power telecommunications equipment to high-power industrial systems.

[0053] One of the key advantages of the low inductance screened cable 100 is its compact design and reduced weight compared to conventional cables with equivalent performance. For instance, in a practical application such as a Remote Radio Head (RRH) system with a power consumption of 160 W over a 100-meter cable run, a standard cable might require a 2-core 25 mm2configuration. In contrast, the low inductance screened cable 100 may achieve equivalent performance with a 2-core 10 mm2design, offering a significantly lighter and more efficient solution while maintaining the same power delivery capability and voltage regulation performance.

[0054] The cable's improved performance may also extend to other applications where size and weight are critical factors. In aerospace applications, the reduced weight can contribute to fuel efficiency and payload capacity, while in mobile telecommunications installations, the compact design facilitates easier installation and reduces structural requirements for mounting systems.

[0055] It should be noted that while specific dimensions and configurations have been described, these are for illustrative purposes only and should not be considered limiting. The actual dimensions, number of wires, and wire sizes may vary based on specific application requirements and manufacturing constraints, without deviating from the scope of the present disclosure. The cable design principles may be scaled to accommodate different power levels, voltage ratings, and environmental requirements while maintaining the fundamental low inductance characteristics.

[0056] Furthermore, although specific materials and standards (such as IS 8130 for copper conductors) have been mentioned, it will be apparent to a person skilled in the art that alternative materials and standards may be used without departing from the scope of the present disclosure, provided they meet the required electrical and mechanical properties for achieving the low inductance characteristics of the cable. Alternative conductor materials, insulation compounds, or shielding materials may be employed based on specific application requirements, cost considerations, or availability constraints.

[0057] FIG. 2 illustrates a flowchart of a method 200 for manufacturing a low inductance screened cable 100. The method 200 represents a comprehensive manufacturing process that ensures consistent production of cables meeting the specified low inductance requirements. The method 200 begins with step 202, where a first conductor 102 having a first cross-sectional area is formed. The first conductor 102 may be formed using high-conductivity copper complying with IS 8130 standards, with the formation process involving precise control of material properties and geometric parameters. In some aspects of the present disclosure, the formation of the first conductor 102 may involve drawing copper wire to the desired diameter and bundling multiple strands to achieve the required cross-sectional area, with careful attention to strand lay, tension control, and overall conductor geometry.

[0058] In step 204, the first conductor 102 is surrounded with first insulation 104 through a controlled extrusion process. This step may involve extruding a flame retardant low smoke (FRLS) compound around the first conductor 102, with precise control of extrusion temperature, pressure, and line speed to achieve the desired insulation thickness and uniformity. The thickness of the first insulation 104 may be carefully controlled to meet low inductance requirements while providing adequate electrical isolation and maintaining consistent cable geometry. In some aspects of the present disclosure, the FRLS compound may be UV-protected through the incorporation of UV-stabilizing additives, enhancing the cable's durability in outdoor installations and environments with significant UV exposure.

[0059] Step 206 involves surrounding the first insulation 104 with a second conductor 106, which requires precise control of conductor placement and geometry. The second conductor 106 may have a second cross-sectional area equal to the first cross-sectional area of the first conductor 102, with this equality in cross-sectional areas contributing to the balanced electromagnetic properties of the cable. The second conductor 106 may be formed and applied using techniques similar to those used for the first conductor102, ensuring consistency in material properties and geometry while maintaining the proper relationship between the two conductors.

[0060] The method 200 continues with step 208, where the second conductor 106 is surrounded with the second insulation 108 through another controlled extrusion process. Similar to the first insulation 104, the second insulation 108 may be made of a flame retardant low smoke (FRLS) compound and may be UV-protected for enhanced environmental durability. The extrusion process for applying the second insulation 108 may be carefully controlled to achieve the desired thickness and uniformity, with parameters optimized to maintain the cable's low inductance characteristics while providing adequate electrical and mechanical protection.

[0061] The process flows to step 210, where the second insulation 108 is surrounded with copper tape screening 110. The copper tape screening 110 may be applied using a wrapping or winding process, ensuring complete coverage around the second insulation 108 while maintaining proper tension and overlap. The thickness and tension of the copper tape application may be optimized to provide effective electromagnetic shielding while maintaining flexibility of the cable and avoiding damage to underlying layers. The screening application process may include quality control measures to ensure consistent coverage and proper adhesion.

[0062] In step 212, the copper tape screening 110 is surrounded with an outer sheath 112 through a final extrusion process. The outer sheath 112 may be made of a flexible, UV-resistant FRLS material, with the application involving an extrusion process that includes careful control of temperature and pressure to achieve the desired thickness and surface finish. In some aspects of the present disclosure, the color of the outer sheath 112 may be customized according to customer specifications or industry standards, with options for specialized marking, identification features, or enhanced environmental protection.

[0063] The method 200 then proceeds to decision step 214, where the cable is tested to determine if it exhibits inductance less than or equal to 0.2 pH / m across a frequencyrange of 100 Hz to 100 MHz. This testing may involve specialized equipment capable of measuring inductance across the specified frequency range with high accuracy and repeatability. The cable may be tested in various lengths and under different environmental conditions to ensure consistent performance across the expected range of operating conditions. The testing process may include multiple measurement points along the cable length to verify uniformity and may involve both laboratory testing and field verification procedures.

[0064] If the inductance requirement is met (Yes path from decision step 214), the process moves to completion step 216, where cable manufacturing is complete. At this stage, the cable may undergo additional quality control checks, such as dimensional verification, insulation resistance testing, mechanical stress tests, or environmental conditioning tests to ensure overall product quality and reliability. The completed cable may be subjected to final inspection procedures, packaging requirements, and documentation processes before shipment to customers.

[0065] If the inductance requirement is not met (No path from decision step 214), the process moves to adjustment step 218, where cable components are adjusted, and the process returns to step 202 to repeat the manufacturing sequence. Adjustments may include modifying conductor sizes, insulation thicknesses, screening application techniques, or other manufacturing parameters to achieve the desired inductance characteristics. The adjustment process may involve analysis of the test results to identify specific areas for improvement and may include consultation with design engineers to optimize the cable configuration.

[0066] It should be noted that while the method 200 describes a specific sequence of steps, variations in the order or nature of these steps may be made without departing from the scope of the present disclosure. For example, additional steps for quality control, intermediate testing, or specialized treatments may be incorporated into the manufacturing process as needed to meet specific customer requirements or industry standards. The manufacturing process may also include environmental controls,material handling procedures, and documentation requirements to ensure consistent product quality and traceability.

[0067] The method 200 results in the production of a low inductance screened cable 100 with an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz. This low inductance characteristic is achieved through the careful selection of materials, precise control of component geometries, and optimized manufacturing processes that ensure consistent performance across production runs. The manufacturing method incorporates quality control measures at each step to verify that the final product meets all specified requirements.

[0068] In some aspects of the present disclosure, the method 200 may be adapted to produce cables with varying sizes, conductor configurations, or shielding levels to meet specific customer requirements or industry standards. The flexibility of the manufacturing process allows for customization while maintaining the core low inductance properties of the cable, enabling production of cables tailored for specific applications ranging from telecommunications infrastructure to industrial automation systems.

[0069] The manufacturing method may also incorporate advanced process control systems, automated quality monitoring, and statistical process control techniques to ensure consistent product quality and minimize variation between production runs. These systems may include real-time monitoring of critical parameters, automated adjustment of process conditions, and comprehensive documentation of manufacturing history for each cable produced.

[0070] As used herein, the term "low inductance" refers to an inductance value of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz. This definition ensures that the cable maintains its low inductance characteristics across a wide range of operating frequencies, making it suitable for various applications with different power transmission requirements and frequency characteristics. The lowinductance specification is maintained through careful design of cable geometry, material selection, and manufacturing processes.

[0071] The low inductance screened cable 100 and its manufacturing method 200 as described herein may be adapted or modified in various ways to suit different applications or to incorporate future technological advancements in materials or manufacturing processes, while still maintaining the core principle of achieving low inductance across a wide frequency range. These adaptations may include alternative conductor materials, advanced insulation compounds, improved shielding techniques, or enhanced environmental protection features.

[0072] Thus, the cable 100 and the method 200 provide several significant technical advantages that address the limitations of conventional cable designs. The cable exhibits exceptionally low inductance of <0.2 pH / m across a wide frequency range from 100 Hz to 100 MHz, ensuring stable power delivery and minimizing voltage drops in fast-changing current demand applications. This characteristic is particularly beneficial in applications involving high-frequency switching, variable loads, or sensitive electronic equipment that requires stable power supply conditions.

[0073] Its dual balanced conductor design with identical cross-sectional areas contributes to superior electromagnetic properties and reduced inductive effects, providing more consistent impedance characteristics and improved power transmission efficiency. The incorporation of high-performance FRLS insulation and UV-protected materials enhances durability and safety in various environments, from indoor installations to outdoor telecommunications infrastructure exposed to harsh environmental conditions.

[0074] The copper tape screening 110 offers excellent EMI protection, crucial for maintaining signal integrity in dense cable installations and electromagnetically noisy environments. This shielding capability helps prevent interference between adjacent cables and protects sensitive equipment from external electromagnetic disturbances, contributing to overall system reliability and performance.

[0075] Furthermore, the cable's compact and lightweight design, compared to conventional cables with equivalent performance, facilitates easier installation and routing, particularly beneficial in space-constrained applications such as Remote Radio Head (RRH) systems and industrial automation settings. The reduced size and weight also contribute to lower installation costs, reduced structural requirements, and improved system aesthetics.

[0076] Lastly, the manufacturing method allows for customization of conductor sizes, insulation thicknesses, and shielding levels while maintaining core low inductance properties, enabling adaptability to diverse application requirements. This flexibility supports the development of application-specific cable solutions while maintaining the fundamental performance advantages of the low inductance design.

[0077] The cable technology described herein represents a significant advancement in power transmission cable design, offering improved performance, reduced size and weight, enhanced environmental durability, and manufacturing flexibility. These advantages make the cable particularly suitable for modern applications requiring high-performance power transmission in compact, reliable, and cost-effective solutions.

[0078] Aspects of the present disclosure are discussed here with reference to flowchart illustrations and block diagrams that depict methods, systems, and apparatus in accordance with various aspects of the present disclosure. Each block within these flowcharts and diagrams, as well as combinations of these blocks, can be executed by computer-readable program instructions. The various logical blocks, modules, circuits, and algorithm steps described in connection with the disclosed aspects may be implemented through electronic hardware, software, or a combination of both. To emphasize the interchangeability of hardware and software, the various components, blocks, modules, circuits, and steps are described generally in terms of their functionality. The decision to implement such functionality in hardware or software is dependent on the specific application and design constraints imposed on the overall system. Person having ordinary skill in the art can implement the describedfunctionality in different ways depending on the particular application, without deviating from the scope of the present disclosure.

[0079] The flowcharts and block diagrams presented in the figures depict the architecture, functionality, and operation of potential implementations of systems, methods, and apparatus according to different aspects of the present disclosure. Each block in the flowcharts or diagrams may represent an engine, segment, or portion of instructions comprising one or more executable instructions to perform the specified logical function(s). In some alternative implementations, the order of functions within the blocks may differ from what is depicted. For instance, two blocks shown in sequence may be executed concurrently or in reverse order, depending on the required functionality. Each block, and combinations of blocks, can also be implemented using special-purpose hardware-based systems that perform the specified functions or tasks, or through a combination of specialized hardware and software instructions.

[0080] Although the preferred aspects have been detailed here, it should be apparent to those skilled in the relevant field that various modifications, additions, and substitutions can be made without departing from the scope of the disclosure. These variations are thus considered to be within the scope of the disclosure as defined in the following claims.

[0081] Features or functionalities described in certain example aspects may be combined and re-combined in or with other example aspects. Additionally, different aspects and elements of the disclosed example aspects may be similarly combined and re-combined. Further, some example aspects, individually or collectively, may form components of a larger system where other processes may take precedence or modify their application. Moreover, certain steps may be required before, after, or concurrently with the example aspects disclosed herein. It should be noted that any and all methods and processes disclosed herein can be performed in whole or in part by one or more entities or actors in any manner.

[0082] Although terms like "first," "second," etc., are used to describe various elements, components, regions, layers, and sections, these terms should not necessarily be interpreted as limiting. They are used solely to distinguish one element, component, region, layer, or section from another. For example, a "first" element discussed here could be referred to as a "second" element without departing from the teachings of the present disclosure.

[0083] The terminology used here is intended to describe specific example aspects and should not be considered as limiting the disclosure. The singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "includes," "comprising," and "including," as used herein, indicate the presence of stated features, steps, elements, or components, but do not exclude the presence or addition of other features, steps, elements, or components.

[0084] As used herein, the term "or" is intended to be inclusive, meaning that "X employs A or B" would be satisfied by X employing A, B, or both A and B. Unless specified otherwise or clearly understood from the context, this inclusive meaning applies to the term "or."

[0085] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the relevant art. Terms should be interpreted consistently with their common usage in the context of the relevant art and should not be construed in an idealized or overly formal sense unless expressly defined here.

[0086] The terms "about" and "substantially," as used herein, refer to a variation of plus or minus 10% from the nominal value. This variation is always included in any given measure.

[0087] In cases where other disclosures are incorporated by reference and there is a conflict with the present disclosure, the present disclosure takes precedence to theextent of the conflict, or to provide a broader disclosure or definition of terms. If two disclosures conflict, the later-dated disclosure will take precedence.

[0088] The use of examples or exemplary language (such as "for example") is intended to illustrate aspects of the invention and should not be seen as limiting the scope unless otherwise claimed. No language in the specification should be interpreted as implying that any non-claimed element is essential to the practice of the invention.

[0089] While many alterations and modifications of the present invention will likely become apparent to those skilled in the art after reading this description, the specific aspects shown and described by way of illustration are not intended to be limiting in any way.

[0090] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

WE CLAIM:

1. A low inductance screened cable (100), comprising:a first conductor (102) having a first cross-sectional area;a first insulation (104) surrounding the first conductor (102);a second conductor (106) having a second cross-sectional area equal to the first cross-sectional area, the second conductor (106) surrounding the first insulation (104);a second insulation (108) surrounding the second conductor (106);a copper tape screening (110) surrounding the second insulation (108); and an outer sheath (112) surrounding the copper tape screening (110), wherein the cable (100) exhibits an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz.

2. The low inductance screened cable (100) of claim 1, wherein the first conductor (102) and the second conductor (106) are made of high-conductivity copper complying with IS 8130 standards.

3. The low inductance screened cable (100) of claim 2, wherein the first insulation (104) and the second insulation (108) are made of a flame retardant low smoke (FRLS) compound that is UV-protected.

4. The low inductance screened cable (100) of claim 3, wherein the outer sheath (112) is made of a flexible, UV-resistant FRLS material.

5. The low inductance screened cable (100) of claim 1, wherein the first conductor (102) comprises multiple conductor strands arranged in a bundled formation and thesecond conductor (106) comprises multiple conductor strands arranged in a circular pattern around the first insulation (104).

6. The low inductance screened cable (100) of claim 1, wherein the thickness of the first insulation (104), second insulation (108), and outer sheath (112) are optimized to meet low inductance requirements while the cable (100) has a smaller cross-sectional area and reduced weight compared to conventional cables with equivalent performance.

7. The low inductance screened cable (100) of claim 1, wherein the cable (100) is configured for use in Remote Radio Head (RRH) systems, industrial automation, data centers, renewable energy systems, or power-sensitive environments requiring reliable performance and compact cable layouts.

8. A method (200) of manufacturing a low inductance screened cable (100), the method comprising:forming a first conductor (102) having a first cross-sectional area; surrounding the first conductor (102) with a first insulation (104); surrounding the first insulation (104) with a second conductor (106) having a second cross-sectional area equal to the first cross-sectional area;surrounding the second conductor (106) with a second insulation (108); surrounding the second insulation (108) with a copper tape screening (110); and surrounding the copper tape screening (110) with an outer sheath (112), wherein the manufactured cable (100) exhibits an inductance of less than or equal to 0.2 pH / m across a frequency range of 100 Hz to 100 MHz.

9. The method (200) as claimed in claim 8, wherein forming the first conductor (102) and the second conductor (106) comprises using high-conductivity copper complying with IS 8130 standards, and wherein surrounding the first conductor (102) with the firstinsulation (104) and surrounding the second conductor (106) with the second insulation (108) comprises using a UV-protected flame retardant low smoke (FRLS) compound.

10. The method (200) as claimed in claim 8, wherein surrounding the copper tape screening (110) with the outer sheath (112) comprises using a flexible, UV-resistant FRLS material, and further comprising optimizing the thickness of the first insulation (104), second insulation (108), and outer sheath (112) to meet low inductance requirements.

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