Method of producing flat stranded magnetic conductor cable

Claim 1

In a method for the manufacture of a flat, rectangular cable comprised of two layers of compacted, helically wound coated conductors and an interposed strip of insulating sheet material, the steps comprising: (a) continuously supplying to a forming station a longitudinally advancing and rotating generally circular array of at least four coated conductors, and forming the conductors into a helical configuration of circular cross-section; (b) gradually transforming the cross-section of said array from circular to a flat elliptical configuration; (c) continuously feeding a strip of insulating sheet material longitudinally into the center of said array of conductors; (d) comprising said conductors tightly about said insulating strip to transform said elliptical structure into a cable of generally rectangular cross-section in which said conductors are densely packed to provide less than about 15 percent of void space in said cable and are disposed substantially in two layers with said strip interposed therebetween, said strip and the coating on said conductors providing electrical insulation between said layers as well as between the individual conductors; and (e) continuously withdrawing the cable so produced from said forming station.