Unitary woven jacket and electrical transmission cable and method for production

Claim 1

A jacketed woven transmission cable comprising: a woven electrical transmission cable including a number of warp conductor elements for transmitting electrical signals interwoven with a cable weft element; a tubular woven cover about said woven electrical transmission cable in an open tubular configuration which includes cover warp elements interwoven with a cover weft yarn element around said woven cable; said woven cover and woven transmission cable being connected together by weaving said cable and cover together at predetermined picks of one of said weft elements to provide a unitary construction; a non-jacketed section at each end of said cable wherein said cover warp and said cover weft elements are woven in a closed flat weave structure which closes said tubular configuration of said woven cover at the beginning of said non-jacketed sections; and said warp conductor elements being woven through said flat closed weave structure of said woven cover at said non-jacketed sections lying on either side of said flat weave structure in a separated unbound configuration so that said conductor elements may be terminated and said woven cover is closed, where said warp conductor elements are terminated.

Claim 5

A method of producing individual woven jacketed electrical transmission cables comprising: weaving a continuous length cable structure which includes a plurality of said jacketed cable sections and a plurality of non-jacketed cable sections; weaving said jacketed cable sections by weaving a woven cable having a number of warp conductors for transmitting electrical signals together with a weft element, simultaneously weaving a tubulr woven cover in an open tubular configuration by weaving cover warp and cover weft elements around said woven cable, and interweaving said woven cable and woven cover at selected points of weaving to provide a one-piece construction; weaving said non-jacketed cable sections by reducing the weaving of said woven cover from an open tubular weave to a closed flat weave and breaking out said warp conductors through said woven cover and floating said warp conductors on either side of said flat weave in a separated unwoven configuration in said non-jacketed cable section; and severing said cable structure across selected sections of said cable structure to produce the individual woven jacketed transmission cables.

Claim 6

A method of producing individual woven jacketed electrical transmission cables comprising: weaving a continuous length cable structure which includes a plurality of said jacketed cable sections and a plurality of non-jacketed cable sections; weaving said jacketed cable sections by weaving a woven cable having a number of warp conductors for transmitting electrical signals together with a weft element, simultaneously weaving a tubulr woven cover in an open tubular configuration by weaving cover warp and cover weft elements around said woven cable, and interweaving said woven cable and woven cover at selected points of weaving to provide a one-piece construction; weaving said non-jacketed cable sections by reducing the weaving of said woven cover from an open tubular weave to a closed flat weave and breaking out said warp conductors through said woven cover and floating said warp conductors on either side of said flat weave in a separated unwoven configuration in said non-jacketed cable section; and severing said cable structure across selected sections of said cable structure to produce the individual woven jacketed transmission cables.

Claim 12

A method of producing individual unitary woven jacketed electrical transmission cables comprising: weaving a continuous length of cable structure which includes a plurality of said individual jacketed cable sections and a plurality of non-jacketed cable sections; weaving said jacketed cable sections to include a woven cable in which a number of cable warp conductors for transmitting electrical signals are interwoven with a cable weft element, weaving a woven cover about said woven cable by interweaving a plurality of cover warp elements and a cover weft element, and connecting said woven cable and woven cover by interweaving said woven cable and woven cover at selected points of weaving; weaving said non-jacketed cable sections by weaving said cover weft and warp elements in a closed flat weave structure, and weaving said cable warp conductors outwardly through said flat weave structure so that said warp conductors are floated unbound on either side of said flat closed cover structure; weaving a plurality of cut-line sections in said continuous length cable structure in which said cable warp conductors are bound in the weave; and severing said continuous length cable structure across said cut-line sections producing a number of individual woven jacketed transmission cables.

Claim 13

A method of producing individual unitary woven jacketed electrical transmission cables comprising: weaving a continuous length of cable structure which includes a plurality of said individual jacketed cable sections and a plurality of non-jacketed cable sections; weaving said jacketed cable sections to include a woven cable in which a number of cable warp conductors for transmitting electrical signals are interwoven with a cable weft element, weaving a woven cover about said woven cable by interweaving a plurality of cover warp elements and a cover weft element, and connecting said woven cable and woven cover by interweaving said woven cable and woven cover at selected points of weaving; weaving said non-jacketed cable sections by weaving said cover weft and warp elements in a closed flat weave structure, and weaving said cable warp conductors outwardly through said flat weave structure so that said warp conductors are floated unbound on either side of said flat closed cover structure; weaving a plurality of cut-line sections in said continuous length cable structure in which said cable warp conductors are bound in the weave; and severing said continuous length cable structure across said cut-line sections producing a number of individual woven jacketed transmission cables.

Claim 19

A method of constructing a unitary jacketed woven electrical transmission cable of the type which includes a woven cover and an inner woven electrical transmission cable having a plurality of warp elements including a number of elongated electrical conductors extending in a warp direction of the cable comprising: weaving said transmission cable warp elements and a first weft yarn element together to form said inner woven electrical transmission cable; simultaneously weaving a plurality of cover warp elements including warp yarns and a second weft yarn element to form said outer woven cover about said inner woven transmission cable while said transmission cable is being woven; interweaving one of said weft yarn elements with one of said warp elements so that said inner woven electrical transmission cable and said outer woven cover are simultaneously woven and attached together as one-piece; and weaving a plurality of longitudinal non-jacketed sections at terminal ends of said cable in which said woven cover is reduced from a tubular weave to a close flat weave and said elongated electrical conductors are broken out of said woven cover and floated freely on each side of said close flat weave of said woven cover.

Claim 20

A method of constructing a unitary jacketed woven electrical transmission cable of the type which includes a woven cover and an inner woven electrical transmission cable having a plurality of warp elements including a number of elongated electrical conductors extending in a warp direction of the cable comprising: weaving said transmission cable warp elements and a first weft yarn element together to form said inner woven electrical transmission cable; simultaneously weaving a plurality of cover warp elements including warp yarns and a second weft yarn element to form said outer woven cover about said inner woven transmission cable while said transmission cable is being woven; interweaving one of said weft yarn elements with one of said warp elements so that said inner woven electrical transmission cable and said outer woven cover are simultaneously woven and attached together as one-piece; and weaving a plurality of longitudinal non-jacketed sections at terminal ends of said cable in which said woven cover is reduced from a tubular weave to a close flat weave and said elongated electrical conductors are broken out of said woven cover and floated freely on each side of said close flat weave of said woven cover.

Claim 26

A method of producing individual woven jacketed electrical transmission cables comprising: weaving a continuous length cable structure which includes a plurality of said individual jacketed cable sections, a plurality of non-jacketed cable sections, and a plurality of auxiliary cut-line cable sections; weaving said jacketed sections by weaving a woven cable which includes a number of warp conductors for transmitting electrical signals bound with a weft element, simultaneously weaving a tubular woven cover including cover warp and weft elements in an open tubular configuration around said woven cable, and interweaving said woven cable and woven cover at selected points of weaving to provide a one-piece construction; weaving said non-jacketed cable section by reducing the weaving of said woven cover from an open tubular weave to a closed flat weave and breaking-out said warp electrical conductors through said woven cover and floating said warp conductors on either side of said flat weave in a separated unwoven configuration; weaving said auxiliary cut-line sections by weaving said warp conductors in a bound configuration; weaving said jacketed cable sections, non-jacketed cable sections, and cut-line cable sections in the following order; (i) weaving a cut-line cable section, (ii) weaving a non-jacketed cable section, (iii) weaving a jacketed cable section; (iv) weaving a non-jacketed cable section, (v) weaving a cut-line cable section, and repeating steps (ii) through (v) along the length of said continuous cable structure generally for each individual jacketed cable being produced; and severing said continuous length cable structure across said cut-line sections to produce individual jacketed electrical transmission cables.

Claim 27

A method of producing individual woven jacketed electrical transmission cables comprising: weaving a continuous length cable structure which includes a plurality of said individual jacketed cable sections, a plurality of non-jacketed cable sections, and a plurality of auxiliary cut-line cable sections; weaving said jacketed sections by weaving a woven cable which includes a number of warp conductors for transmitting electrical signals bound with a weft element, simultaneously weaving a tubular woven cover including cover warp and weft elements in an open tubular configuration around said woven cable, and interweaving said woven cable and woven cover at selected points of weaving to provide a one-piece construction; weaving said non-jacketed cable section by reducing the weaving of said woven cover from an open tubular weave to a closed flat weave and breaking-out said warp electrical conductors through said woven cover and floating said warp conductors on either side of said flat weave in a separated unwoven configuration; weaving said auxiliary cut-line sections by weaving said warp conductors in a bound configuration; weaving said jacketed cable sections, non-jacketed cable sections, and cut-line cable sections in the following order; (i) weaving a cut-line cable section, (ii) weaving a non-jacketed cable section, (iii) weaving a jacketed cable section; (iv) weaving a non-jacketed cable section, (v) weaving a cut-line cable section, and repeating steps (ii) through (v) along the length of said continuous cable structure generally for each individual jacketed cable being produced; and severing said continuous length cable structure across said cut-line sections to produce individual jacketed electrical transmission cables.