Method of making a free floating sheathed cable

Claim 1

A method for manufacturing an electrical cable comprising the steps of: wrapping polytetrafluoroethylene foam tape around an inner conductor; sintering the polytetrafluoroethylene tape to form a first single piece insulating layer around the inner conductor; braiding strands of wire around the first insulating layer to form a shield; wrapping solid polytetrafluoroethylene tape around the shield; sintering the solid polytetrafluoroethylene tape to form a second insulating layer which is around the shield, wherein the inner conductor, shield and insulating layers form a coaxial cable; attaching a leader wire to an the coaxial cable; passing the leader wire through a sheath having an inner diameter in excess of the outer diameter of the coaxial cable and a length shorter than the length of the coaxial cable, so as to draw the coaxial cable into the sheath; removing the leader wire; electrically coupling each end of the inner conductor to a connector; and coupling each end of the sheath to a connector.

Claim 2

A method for manufacturing an electrical cable comprising the steps of: wrapping polytetrafluoroethylene foam tape around an inner conductor; sintering the polytetrafluoroethylene tape to form a first single piece insulating layer around the inner conductor; braiding strands of wire around the first insulating layer to form a shield; wrapping solid polytetrafluoroethylene tape around the shield; sintering the solid polytetrafluoroethylene tape to form a second insulating layer which is around the shield, wherein the inner conductor, shield and insulating layers form a coaxial cable; attaching a leader wire to an the coaxial cable; passing the leader wire through a sheath having an inner diameter in excess of the outer diameter of the coaxial cable and a length shorter than the length of the coaxial cable, so as to draw the coaxial cable into the sheath; removing the leader wire; electrically coupling each end of the inner conductor to a connector; and coupling each end of the sheath to a connector.

Claim 5

The method of providing a physically shielded audio cable which may be substantially bent or stressed without damage to the inner electrical conductors, comprising: providing a coaxial cable formed by sequentially spiral wrapping and sintering polytetrafluoroethylene foam tape around an inner electrical conductor and wrapping and sintering solid polytetrafluoroethylene tape around an outer electrical conductor to form respective foam and solid polytetrafluoroethylene layers; inserting a length of said coaxial cable through a sheath, the length of said coaxial cable being greater than the length of the sheath and the inner diameter of the sheath being substantially greater than the outer diameter of the solid teflon insulating layer of the coaxial cable; and providing electrical connectors at each end to form an assembly in which the length of the interior electrical conductor is greater than the sheath.

Claim 6

The method of providing a physically shielded audio cable which may be substantially bent or stressed without damage to the inner electrical conductors, comprising: providing a coaxial cable formed by sequentially spiral wrapping and sintering polytetrafluoroethylene foam tape around an inner electrical conductor and wrapping and sintering solid polytetrafluoroethylene tape around an outer electrical conductor to form respective foam and solid polytetrafluoroethylene layers; inserting a length of said coaxial cable through a sheath, the length of said coaxial cable being greater than the length of the sheath and the inner diameter of the sheath being substantially greater than the outer diameter of the solid teflon insulating layer of the coaxial cable; and providing electrical connectors at each end to form an assembly in which the length of the interior electrical conductor is greater than the sheath.