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US20120312579A1 - Cable jacket with embedded shield and method for making the same - Google Patents

Cable jacket with embedded shield and method for making the same Download PDF

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Publication number
US20120312579A1
US20120312579A1 US13/157,492 US201113157492A US2012312579A1 US 20120312579 A1 US20120312579 A1 US 20120312579A1 US 201113157492 A US201113157492 A US 201113157492A US 2012312579 A1 US2012312579 A1 US 2012312579A1
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US
United States
Prior art keywords
jacket
cable
substrate material
shielding
substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/157,492
Inventor
Robert D. Kenny
David M. FAUSZ
II David P. Camp
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Cable Technologies Corp
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US13/157,492 priority Critical patent/US20120312579A1/en
Assigned to GENERAL CABLE TECHNOLOGIES CORPORATION reassignment GENERAL CABLE TECHNOLOGIES CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FAUSZ, DAVID M., CAMP, DAVID P., II, KENNY, ROBERT D.
Priority to MX2013014587A priority patent/MX344493B/en
Priority to PCT/US2012/036950 priority patent/WO2012170138A1/en
Priority to AU2012268739A priority patent/AU2012268739A1/en
Priority to EP12797541.5A priority patent/EP2718940A4/en
Priority to JP2014514463A priority patent/JP2014519690A/en
Priority to BR112013031641A priority patent/BR112013031641A2/en
Priority to KR1020137033396A priority patent/KR20140041559A/en
Priority to CA2837182A priority patent/CA2837182C/en
Priority to CA2992227A priority patent/CA2992227C/en
Publication of US20120312579A1 publication Critical patent/US20120312579A1/en
Priority to US13/948,828 priority patent/US9362027B2/en
Priority to CL2013003526A priority patent/CL2013003526A1/en
Priority to US15/152,265 priority patent/US9859040B2/en
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/002—Pair constructions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • H01B11/10—Screens specially adapted for reducing interference from external sources
    • H01B11/1008—Features relating to screening tape per se
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/18—Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/1834—Construction of the insulation between the conductors
    • H01B11/1856—Discontinuous insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/18—Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/1869—Construction of the layers on the outer side of the outer conductor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/18—Applying discontinuous insulation, e.g. discs, beads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0073—Shielding materials
    • H05K9/0098—Shielding materials for shielding electrical cables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0005—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3462—Cables

Definitions

  • the present invention relates to a jacket for a cable that includes an embedded shield and the method for making the jacket. More specifically, the jacket includes a shield that is a shielding tape with discontinuous conductive shielding segments. The shielding tape is embedded with the jacket by co-extruding the shielding tape with the jacket.
  • Conventional communications cables typically include a core of twisted pairs of insulated conductors that are enclosed in a protective jacket.
  • conventional cables often include at least one shielding layer disposed around the core of twisted pairs of conductors.
  • a non-conductive barrier layer between the shielding layer and the pairs must also be provided to insulate the core of pairs of the cable.
  • Such cables are often bulky because of the requirement of both a shielding layer and a barrier layer. Therefore, a need exists for a cable that protects against alien crosstalk and that is not bulky.
  • the present invention may provide a cable jacket that comprises first and second jacket layers each formed of a jacket material. At least one shielding tape may be embedded between the first and second jacket layers.
  • the shielding tape is formed of a substrate material and the substrate material has at least one conductive segment.
  • the substrate material and the jacket material are the same, although different materials may be utilized.
  • the substrate material includes a plurality of conductive segments disposed in a spaced discontinuous arrangement.
  • a plurality of shielding tapes are embedded between the first and second jacket layers.
  • the present invention may also provide a cable that comprises at least one twisted pair of insulated conductors and a jacket that encloses the twisted pair of insulated conductors.
  • the jacket is formed of a jacket material.
  • a shielding tape may be embedded in the jacket.
  • the shielding tape is formed of a substrate material that has at least one conductive segment.
  • the cable does not include a barrier layer.
  • the present invention may further provide a cable assembly that comprises a plurality of cables that are bundled together.
  • Each of the plurality of cables includes at least one twisted pair of insulated conductors, a jacket enclosing the at least one twisted pair of insulated conductors where the jacket is formed of a jacket material, and at least one shielding tape embedded in the jacket.
  • the at least one shielding tape is formed of a substrate material and the substrate material has at least one conductive segment, whereby the cable does not include a barrier layer enclosed by the jacket.
  • the present invention may also provide a method for making a cable jacket that comprises the steps of providing at least one shielding tape that has a substrate formed of a substrate material where the substrate includes at least one conductive segment; inserting the at least one shielding tape between first and second jacket layers of the cable jacket and each of the layers is formed of a jacket material; and co-extruding the shielding tape with the first and second jacket layers, wherein the substrate material of the shielding tape and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrate and the first and second jacket layers bond together.
  • FIG. 1 is a cross-sectional view of a cable having a jacket according to an exemplary embodiment of the invention, showing the jacket with a plurality of shields embedded therein;
  • FIG. 2 is a plan view of a shield of the cable jacket illustrated in FIG. 1 , showing the shield as a tape with a plurality of conductive segments;
  • FIG. 3 is a cross-sectional view of a cable assembly according to an embodiment of the invention, showing a plurality of the cables bundled together.
  • a jacket 100 for a cable C such as a communications cable
  • the jacket 100 of the present invention accomplishes the above by combining at least one discontinuous shield 200 with the jacket material.
  • the cable C includes the jacket 100 , one or more twisted pairs of insulated conductors 102 , and an optional separator 104 disposed between the pairs 102 to isolate the same.
  • the jacket 100 includes inner and outer layers 110 and 120 that, when combined with one or more of the shields 200 , form a single jacket.
  • the inner and outer layers 110 and 120 are extruded with the shields 200 , such that the layers and shields melt together to form the jacket.
  • the layers 110 and 120 and the shields 200 may be bonded to one another by any known method, such as adhesive and the like.
  • the inner and outer layers 110 and 120 may be formed of any known jacket material for communication cabling, such as PVC, HDPE, FEP, flame retardant PE, or the like. Because the one or more shields 200 are incorporated in the jacket 100 , a separate shielding layer surrounding the conductor pairs 102 is not required. Also, the inner layer 110 acts as a barrier between the one or more shields 200 , thereby eliminating the need for a separate barrier layer. The overall diameter of the cable is reduced because less jacket material is required for the jacket 100 and both the shielding and barrier layers have been eliminated.
  • the shield 200 may be a shielding layer or tape made up of a substrate 202 , as seen in FIG. 2 , that is preferably of the same type and chemical nature of the material of the jacket 100 .
  • the substrate of the shielding tape is also PVC. That allows the jacketing material to properly bond with the substrate material of the shielding tape 200 to form the single jacket 100 .
  • the shielding tape 200 may include a plurality of conductive segments 204 , such as aluminum, copper, ferrite, or any other conductive bricks.
  • the segments 204 may be applied to the surface of the substrate 202 by adhesive, heat pressing, laser ablation, vapor deposition, or by spraying conductive particles onto the substrate 202 to form the segments.
  • the conductive segments 204 can be sandwiched between two layers of the substrate 200 .
  • the conductive segments 204 are preferably spaced from each other, thereby forming a discontinuous shield, as seen in FIG. 2 .
  • the conductive segments 204 are shown as having a substantially rectangular shape, the segments 204 may have other shapes, such as square, trapezoidal, diamond, and the like. Additionally, the segments 204 may all be substantially the same size or may have various sizes.
  • the conductive segments 204 may also be placed in a random pattern along the substrate.
  • one or more of the shielding tapes 200 is inserted into the jacket 100 during the jacket extrusion process. Specifically, the shielding tape 200 is pulled through the actual die/crosshead or tooling for the jacket 100 in between the inner and outer layers 110 and 120 of the jacket. Thus, one or more shielding tapes 200 may be sandwiched by the inner and outer jacket layers 110 and 120 . During that co-extrusion process, the material of the jacket layers 110 and 120 is in a molten or near molten state. When the shielding tape or tapes 200 come into contact with the molten jacket material, bonding/melting of the shielding tape or tapes occurs within the jacket material. Alternatively, the two jacket layers may be preformed materials (not in a molten state) that are bonded together.
  • the material of the jacket 100 and its layers 110 and 120 are the same as the substrate 202 of the shielding tapes 200 , so that the materials readily mix and bond to each other. This creates a near seamless dispersing of the shielding tape 200 within the jacket 100 .
  • the jacket layers 110 and 120 may be formed of a different material than the substrate 202 of the shielding tapes 200 . In that case, the jacket layers 110 and 120 may be bonded to the substrates 202 of the shielding tapes by any know method, such as adhesive bonding, high pressure, or the like.
  • the outer jacket layer 120 may suffice as a barrier to hold the shielding tape 200 and the inner jacket layer 110 in place.
  • the conductive segments 204 are encased in the jacket 100 while also maintaining the original orientation of the segments on the shielding tape 200 . That orientation of the segments insures consistent electrical properties of the cable, such as return loss and attenuation.
  • the method of the present invention allows conductive shielding segments 204 to be inserted into the jacket 100 without negatively impacting the physical properties of the jacket, such as tensile strength and elongation. That is because the near continuous material of jacket 100 (incorporated with one or more shielding tapes 200 ) maintains its original tensile strength as well as elongation properties.
  • a plurality of the cables C may be bundled together.
  • An optional outer jacket 300 may be provided that encloses the bundle cables C.
  • Each cable C includes the jacket 100 , as described above.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Insulated Conductors (AREA)
  • Communication Cables (AREA)
  • Installation Of Indoor Wiring (AREA)
  • Manufacturing Of Electric Cables (AREA)

Abstract

A cable jacket that comprises first and second jacket layers each formed of a jacket material. At least one shielding tape is embedded between the first and second jacket layers. The shielding tape is formed of a substrate material and the substrate material has at least one conductive segment.

Description

    FIELD OF THE INVENTION
  • The present invention relates to a jacket for a cable that includes an embedded shield and the method for making the jacket. More specifically, the jacket includes a shield that is a shielding tape with discontinuous conductive shielding segments. The shielding tape is embedded with the jacket by co-extruding the shielding tape with the jacket.
    • BACKGROUND OF THE INVENTION
  • Conventional communications cables typically include a core of twisted pairs of insulated conductors that are enclosed in a protective jacket. To avoid crosstalk with other cables, often referred to as alien crosstalk, conventional cables often include at least one shielding layer disposed around the core of twisted pairs of conductors. A non-conductive barrier layer between the shielding layer and the pairs must also be provided to insulate the core of pairs of the cable.
  • Such cables, however, are often bulky because of the requirement of both a shielding layer and a barrier layer. Therefore, a need exists for a cable that protects against alien crosstalk and that is not bulky.
    • SUMMARY OF THE INVENTION
  • Accordingly, the present invention may provide a cable jacket that comprises first and second jacket layers each formed of a jacket material. At least one shielding tape may be embedded between the first and second jacket layers. The shielding tape is formed of a substrate material and the substrate material has at least one conductive segment. In a preferred embodiment, the substrate material and the jacket material are the same, although different materials may be utilized. In another embodiment, the substrate material includes a plurality of conductive segments disposed in a spaced discontinuous arrangement. In yet another embodiment, a plurality of shielding tapes are embedded between the first and second jacket layers.
  • The present invention may also provide a cable that comprises at least one twisted pair of insulated conductors and a jacket that encloses the twisted pair of insulated conductors. The jacket is formed of a jacket material. A shielding tape may be embedded in the jacket. The shielding tape is formed of a substrate material that has at least one conductive segment. The cable does not include a barrier layer.
  • The present invention may further provide a cable assembly that comprises a plurality of cables that are bundled together. Each of the plurality of cables includes at least one twisted pair of insulated conductors, a jacket enclosing the at least one twisted pair of insulated conductors where the jacket is formed of a jacket material, and at least one shielding tape embedded in the jacket. The at least one shielding tape is formed of a substrate material and the substrate material has at least one conductive segment, whereby the cable does not include a barrier layer enclosed by the jacket.
  • The present invention may also provide a method for making a cable jacket that comprises the steps of providing at least one shielding tape that has a substrate formed of a substrate material where the substrate includes at least one conductive segment; inserting the at least one shielding tape between first and second jacket layers of the cable jacket and each of the layers is formed of a jacket material; and co-extruding the shielding tape with the first and second jacket layers, wherein the substrate material of the shielding tape and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrate and the first and second jacket layers bond together.
  • Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
  • FIG. 1 is a cross-sectional view of a cable having a jacket according to an exemplary embodiment of the invention, showing the jacket with a plurality of shields embedded therein;
  • FIG. 2 is a plan view of a shield of the cable jacket illustrated in FIG. 1, showing the shield as a tape with a plurality of conductive segments; and
  • FIG. 3 is a cross-sectional view of a cable assembly according to an embodiment of the invention, showing a plurality of the cables bundled together.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • Referring to FIGS. 1 and 2, a jacket 100 for a cable C, such as a communications cable, according to an exemplary embodiment of the present invention minimizes noise coming from external cable sources, i.e. alien crosstalk, without the need for grounding the cable C. The jacket 100 of the present invention accomplishes the above by combining at least one discontinuous shield 200 with the jacket material.
  • As seen in FIG. 1, the cable C includes the jacket 100, one or more twisted pairs of insulated conductors 102, and an optional separator 104 disposed between the pairs 102 to isolate the same. The jacket 100 includes inner and outer layers 110 and 120 that, when combined with one or more of the shields 200, form a single jacket. Preferably, the inner and outer layers 110 and 120 are extruded with the shields 200, such that the layers and shields melt together to form the jacket. Alternatively, the layers 110 and 120 and the shields 200 may be bonded to one another by any known method, such as adhesive and the like. The inner and outer layers 110 and 120 may be formed of any known jacket material for communication cabling, such as PVC, HDPE, FEP, flame retardant PE, or the like. Because the one or more shields 200 are incorporated in the jacket 100, a separate shielding layer surrounding the conductor pairs 102 is not required. Also, the inner layer 110 acts as a barrier between the one or more shields 200, thereby eliminating the need for a separate barrier layer. The overall diameter of the cable is reduced because less jacket material is required for the jacket 100 and both the shielding and barrier layers have been eliminated.
  • The shield 200 may be a shielding layer or tape made up of a substrate 202, as seen in FIG. 2, that is preferably of the same type and chemical nature of the material of the jacket 100. For example, if the material of the jacket 100 is PVC, then the substrate of the shielding tape is also PVC. That allows the jacketing material to properly bond with the substrate material of the shielding tape 200 to form the single jacket 100.
  • The shielding tape 200 may include a plurality of conductive segments 204, such as aluminum, copper, ferrite, or any other conductive bricks. The segments 204 may be applied to the surface of the substrate 202 by adhesive, heat pressing, laser ablation, vapor deposition, or by spraying conductive particles onto the substrate 202 to form the segments. Alternatively, the conductive segments 204 can be sandwiched between two layers of the substrate 200. The conductive segments 204 are preferably spaced from each other, thereby forming a discontinuous shield, as seen in FIG. 2. Although the conductive segments 204 are shown as having a substantially rectangular shape, the segments 204 may have other shapes, such as square, trapezoidal, diamond, and the like. Additionally, the segments 204 may all be substantially the same size or may have various sizes. The conductive segments 204 may also be placed in a random pattern along the substrate.
  • According to an exemplary method of the present invention, one or more of the shielding tapes 200 is inserted into the jacket 100 during the jacket extrusion process. Specifically, the shielding tape 200 is pulled through the actual die/crosshead or tooling for the jacket 100 in between the inner and outer layers 110 and 120 of the jacket. Thus, one or more shielding tapes 200 may be sandwiched by the inner and outer jacket layers 110 and 120. During that co-extrusion process, the material of the jacket layers 110 and 120 is in a molten or near molten state. When the shielding tape or tapes 200 come into contact with the molten jacket material, bonding/melting of the shielding tape or tapes occurs within the jacket material. Alternatively, the two jacket layers may be preformed materials (not in a molten state) that are bonded together.
  • Preferably, the material of the jacket 100 and its layers 110 and 120 are the same as the substrate 202 of the shielding tapes 200, so that the materials readily mix and bond to each other. This creates a near seamless dispersing of the shielding tape 200 within the jacket 100. Alternatively, the jacket layers 110 and 120 may be formed of a different material than the substrate 202 of the shielding tapes 200. In that case, the jacket layers 110 and 120 may be bonded to the substrates 202 of the shielding tapes by any know method, such as adhesive bonding, high pressure, or the like. On the other hand, the outer jacket layer 120 may suffice as a barrier to hold the shielding tape 200 and the inner jacket layer 110 in place.
  • During the co-extrusion process, the conductive segments 204 are encased in the jacket 100 while also maintaining the original orientation of the segments on the shielding tape 200. That orientation of the segments insures consistent electrical properties of the cable, such as return loss and attenuation. Thus, the method of the present invention allows conductive shielding segments 204 to be inserted into the jacket 100 without negatively impacting the physical properties of the jacket, such as tensile strength and elongation. That is because the near continuous material of jacket 100 (incorporated with one or more shielding tapes 200) maintains its original tensile strength as well as elongation properties.
  • Referring to FIG. 3, a plurality of the cables C may be bundled together. An optional outer jacket 300 may be provided that encloses the bundle cables C. Each cable C includes the jacket 100, as described above.
  • While particular embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.

Claims (30)

1. A cable jacket, comprising:
first and second jacket layers each formed of a jacket material; and
at least one shielding tape embedded between said first and second jacket layers, said at least one shielding tape being formed of a substrate material, said substrate material having at least one conductive segment.
2. A cable jacket according to claim 1, wherein
said jacket material and said substrate material are the same material.
3. A cable jacket according to claim 1, wherein
said at least one conductive segment forms a substantially rectangular brick.
4. A cable jacket according to claim 1, wherein
said substrate material includes a plurality conductive segments that are disposed in a spaced discontinuous arrangement.
5. A cable jacket according to claim 4, wherein
each of said conductive segments is formed of one of aluminum, copper, or ferrite.
6. A cable jacket according to claim 4, wherein
said conductive segments are bonded to said substrate of said shielding tape by adhesive, heat pressing or laser ablation.
7. A cable jacket according to claim 4, wherein
said conductive segments are embedded in said substrate of said shielding tape.
8. A cable jacket according to claim 4, wherein
conductive particles are sprayed onto said substrate of said shielding tape to form said conductive segments.
9. A cable jacket according to claim 1, further comprising
a plurality of shielding tapes embedded between said first and second jacket layers, each of said shielding tapes having a substrate material, each substrate material having a plurality of conductive segments disposed in a spaced discontinuous arrangement, and said substrate material of said plurality of shielding tapes and said jacket material is the same.
10. A cable, comprising:
at least one twisted pair of insulated conductors;
a jacket enclosing said at least one twisted pair of insulated conductors, said jacket being formed of a jacket material; and
at least one shielding tape embedded in said jacket, said at least one shielding tape being formed of a substrate material, said substrate material having at least one conductive segment,
whereby the cable does not include a barrier layer enclosed by said jacket.
11. A cable according to claim 10, wherein
said jacket material and said substrate material are the same material.
12. A cable according to claim 10, wherein
said substrate material includes a plurality conductive segments that are disposed in a spaced discontinuous arrangement.
13. A cable according to claim 12, wherein
each of said conductive segments is formed of one of aluminum, copper, or ferrite.
14. A cable according to claim 10, further comprising
a plurality of shielding tapes embedded in said jacket, each of said shielding tapes having a substrate material, each substrate material having a plurality of conductive segments disposed in a spaced discontinuous arrangement, and said substrate material of said plurality of shielding tapes and said jacket material is the same.
15. A cable according to claim 10, further comprising
a plurality of twisted pairs of conductors enclosed by said jacket.
16. A cable according to claim 15, further comprising
a separator disposed between said plurality of twisted pairs of conductors.
17. A cable assembly, comprising:
a plurality of cables, said plurality of cables being bundled together, each of said plurality of cables including:
at least one twisted pair of insulated conductors,
a jacket enclosing said at least one twisted pair of insulated conductors, said jacket being formed of a jacket material, and
at least one shielding tape embedded in said jacket, said at least one shielding tape being formed of a substrate material, said substrate material having at least one conductive segment, whereby the cable does not include a barrier layer enclosed by said jacket.
18. A cable assembly according to claim 17, wherein
said jacket material and said substrate material are the same material.
19. A cable assembly according to claim 17, wherein
said substrate material includes a plurality conductive segments that are disposed in a spaced discontinuous arrangement.
20. A cable assembly according to claim 17, further comprising
a plurality of shielding tapes embedded in said jacket of each of said plurality of cables, each of said shielding tapes having a substrate material, each substrate material having a plurality of conductive segments disposed in a spaced discontinuous arrangement, and said substrate material of said plurality of shielding tapes and said jacket material is the same.
21. A cable assembly according to claim 17, further comprising
a plurality of twisted pairs of conductors enclosed by said jacket of each of said plurality of cables.
22. A cable assembly according to claim 21, further comprising
a separator disposed between said plurality of twisted pairs of conductors.
23. A cable assembly according to claim 21, further comprising
an outer jacket enclosing said plurality of cables.
24. A method for making a cable jacket, comprising the steps of:
providing at least one shielding tape having a substrate formed of a substrate material, said substrate including at least one conductive segment;
inserting the at least one shielding tape between first and second jacket layers of the cable jacket, each of said first and second jacket layers being formed of a jacket material; and
co-extruding the at least one shielding tape with the first and second jacket layers, wherein the substrate material of the at least one shielding tape and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrate and first and second jacket layers bond together.
25. A method according to claim 24, further comprising the step of
providing a plurality of shielding tapes, each shielding tape having a substrate formed of a substrate material, and each substrate including a plurality of conductive segments in a spaced discontinuous arrangement;
inserting the plurality of shielding tapes between the first and second jacket layers of the cable jacket; and
co-extruding the plurality of shielding tapes with the first and second jacket layers, wherein the substrate material of the shielding tapes and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrates and first and second jacket layers are bonded together.
26. A method according to claim 24, wherein
said substrate includes a plurality of conductive segments positioned in a spaced discontinuous arrangement.
27. A method according to claim 25, wherein
the position of the conductive segments is the same before and after the co-extrusion step.
28. A method according to claim 25, further comprising the step of
bonding said conductive segments to said shielding tape by adhesive, heat pressing, or laser ablation.
29. A method according to claim 25, further comprising the step of
spraying conductive particles onto said shielding tape to form said conductive segments.
30. A method according to claim 25, further comprising the step of
embedding said conductive particles in said shielding tape.
US13/157,492 2011-06-10 2011-06-10 Cable jacket with embedded shield and method for making the same Abandoned US20120312579A1 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
US13/157,492 US20120312579A1 (en) 2011-06-10 2011-06-10 Cable jacket with embedded shield and method for making the same
CA2992227A CA2992227C (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
BR112013031641A BR112013031641A2 (en) 2011-06-10 2012-05-08 shielded cable wrap and method for doing the same
CA2837182A CA2837182C (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
AU2012268739A AU2012268739A1 (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
EP12797541.5A EP2718940A4 (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
JP2014514463A JP2014519690A (en) 2011-06-10 2012-05-08 Cable covering with embedded shield and method of manufacturing the same
MX2013014587A MX344493B (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same.
KR1020137033396A KR20140041559A (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
PCT/US2012/036950 WO2012170138A1 (en) 2011-06-10 2012-05-08 Cable jacket with embedded shield and method for making the same
US13/948,828 US9362027B2 (en) 2011-06-10 2013-07-23 Method for making cable jacket with embedded shield
CL2013003526A CL2013003526A1 (en) 2011-06-10 2013-12-09 Cable cover comprising at least one layer formed of a cover material, said cover material that is insulating, and at least one conductive segment incorporated in said at least one layer; cable; cable assembly; method to make a cable cover.
US15/152,265 US9859040B2 (en) 2011-06-10 2016-05-11 Method for making cable jacket with embedded shield

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US13/948,828 Active 2031-11-20 US9362027B2 (en) 2011-06-10 2013-07-23 Method for making cable jacket with embedded shield
US15/152,265 Active US9859040B2 (en) 2011-06-10 2016-05-11 Method for making cable jacket with embedded shield

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US15/152,265 Active US9859040B2 (en) 2011-06-10 2016-05-11 Method for making cable jacket with embedded shield

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US (3) US20120312579A1 (en)
EP (1) EP2718940A4 (en)
JP (1) JP2014519690A (en)
KR (1) KR20140041559A (en)
AU (1) AU2012268739A1 (en)
BR (1) BR112013031641A2 (en)
CA (2) CA2992227C (en)
CL (1) CL2013003526A1 (en)
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CA2837182A1 (en) 2012-12-13
CA2992227C (en) 2019-01-22
MX344493B (en) 2016-12-16
WO2012170138A4 (en) 2013-02-21
BR112013031641A2 (en) 2016-12-06
MX2013014587A (en) 2014-09-25
EP2718940A1 (en) 2014-04-16
AU2012268739A1 (en) 2013-12-12
CA2837182C (en) 2018-03-06
CL2013003526A1 (en) 2014-08-08
EP2718940A4 (en) 2014-10-29
WO2012170138A1 (en) 2012-12-13
US9362027B2 (en) 2016-06-07
KR20140041559A (en) 2014-04-04
US9859040B2 (en) 2018-01-02
JP2014519690A (en) 2014-08-14
US20160254078A1 (en) 2016-09-01
CA2992227A1 (en) 2012-12-13
US20130306214A1 (en) 2013-11-21

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