US4663098A — Method of manufacturing high performance flat cab…

Claim 1

Independent Claim 120 words

A method of fabricating a flat electrical cable for transmitting high frequency signals comprising the steps of: feeding a plurality of conductor subassemblies through a progressive die means, each subassembly containing a pair of separately insulated conductive wires having a surrounding insulating web to hold the separately insulated conductors spaced apart and parallel one with respect to another; forming an electrically conductive shield around each subassembly by positioning the conductor subassembly in shielding material and folding free ends of the shielding material in overlapping engagement with the subassembly to form a shielded conductor subassembly; arranging the two shielded conductor subassemblies side-by-side with the overlapped ends of the shielding material facing one another; and extruding an insulator around the shielded subassemblies.

Claim 2

Independent Claim 120 words

A method of fabricating a flat electrical cable for transmitting high frequency signals comprising the steps of: feeding a plurality of conductor subassemblies through a progressive die means, each subassembly containing a pair of separately insulated conductive wires having a surrounding insulating web to hold the separately insulated conductors spaced apart and parallel one with respect to another; forming an electrically conductive shield around each subassembly by positioning the conductor subassembly in shielding material and folding free ends of the shielding material in overlapping engagement with the subassembly to form a shielded conductor subassembly; arranging the two shielded conductor subassemblies side-by-side with the overlapped ends of the shielding material facing one another; and extruding an insulator around the shielded subassemblies.

Claim 3

Dependent Claim 32 words

The method as set forth in claim 1 and further including the step of: holding the subassemblies spaced from each other and in parallel alignment as they pass through the extrusion press.

Claim 4

Dependent Claim 39 words

The method as set forth in claim 1 and further including the step of: holding the subassemblies spaced from each other and in an essentially horizontal plane with the wires of the subassemblies also in an essentially horizontal plane.

Claim 5

Independent Claim 138 words

A method of fabricating a low profile cable for transmitting high frequency electrical signals comprising the steps of: drawing insulated conductors through a first extrusion press to define two conductor subassemblies containing insulated conductive wires with a surrounding and extruded insulating web therearound to hold the separately insulated conductors spaced apart and parallel with respect to one another; forming an electrically conductive shield around each subassembly by positioning the conductor assembly in U-shaped shielding material and folding free ends of the shielding material in overlapping engagement with the subassembly to form a shielded conductor subassembly; arranging the two shielded conductor subassemblies side-by-side with the overlapped free ends of the shielding material facing one another; and feeding the shielded conductor subassemblies into a second extrusion press thereby extruding an insulator therearound during their movement through the second extrusion press.

Claim 6

Independent Claim 138 words

A method of fabricating a low profile cable for transmitting high frequency electrical signals comprising the steps of: drawing insulated conductors through a first extrusion press to define two conductor subassemblies containing insulated conductive wires with a surrounding and extruded insulating web therearound to hold the separately insulated conductors spaced apart and parallel with respect to one another; forming an electrically conductive shield around each subassembly by positioning the conductor assembly in U-shaped shielding material and folding free ends of the shielding material in overlapping engagement with the subassembly to form a shielded conductor subassembly; arranging the two shielded conductor subassemblies side-by-side with the overlapped free ends of the shielding material facing one another; and feeding the shielded conductor subassemblies into a second extrusion press thereby extruding an insulator therearound during their movement through the second extrusion press.

Claim 7

Independent Claim 132 words

A method of fabricating a low profile cable for transmitting high frequency electrical signals comprising the steps of: feeding two conductor subassemblies into a progressive die means, each subassembly containing a pair of insulated conductive wires embedded in an insulative web such that each pair of conductors are in a spaced apart and parallel relationship with respect to one another; forming, by means of said progressive die means, an electrically conductive shield around each subassembly by bending flat foil into an essentially U-shaped configuration by pulling the flat foil through an aperture in a forming block means; sequentially rolling the ends of the U-shaped foil into contact with each other to surround the subassembly by pulling the U-shaped foil through a series of sequential rollers; and extruding insulation around both conductor subassemblies.

Claim 8

Independent Claim 132 words

A method of fabricating a low profile cable for transmitting high frequency electrical signals comprising the steps of: feeding two conductor subassemblies into a progressive die means, each subassembly containing a pair of insulated conductive wires embedded in an insulative web such that each pair of conductors are in a spaced apart and parallel relationship with respect to one another; forming, by means of said progressive die means, an electrically conductive shield around each subassembly by bending flat foil into an essentially U-shaped configuration by pulling the flat foil through an aperture in a forming block means; sequentially rolling the ends of the U-shaped foil into contact with each other to surround the subassembly by pulling the U-shaped foil through a series of sequential rollers; and extruding insulation around both conductor subassemblies.

Claim 9

Dependent Claim 33 words

The method as set forth in claim 5 wherein each subassembly is supported on a separate supply reel and the shield material is supported in flat foil form an additional supply reel means.

Claim 10

Dependent Claim 25 words

The method as set forth in claim 5 wherein the finished cable is drawn through the extrusion press by a power driven take up reel.

Claim 11

Dependent Claim 37 words

The method as set forth in claim 5 and further including the step of: forming each shield from a flat foil configuration, to an essentially cylindrical configuration surrounding the subassemblies, prior to passage through the extrusion press.

Claim 12

Dependent Claim 26 words

The method as set forth in claim 5 and further including the step of feeding a subassembly to the foil before its passage through the forming-block.

Claim 13

Dependent Claim 37 words

The method as set forth in claim 9 wherein the bending is accomplished by pulling the flat foil through a V-shaped aperture in a primary forming-block and then through a U-shaped aperture in a secondary forming block.

Claim 14

Dependent Claim 52 words

The method as set forth in claim 9 wherein the U-shaped foil supports a subassembly prior to movement into the sequential rollers with the curved portion of the U-shaped foil and subassembly located facing downwardly and with the ends of the U-shaped foil and a flat surface of the subassembly facing upwardly.

Claim 15

Dependent Claim 62 words

The method as set forth in claim 11 wherein the sequential rollers include first rollers to contact and bend one upstanding leg of the U-shaped foil into contact with the flat face of the subassembly and the second rollers then bend the second upstanding leg into contact with the first upstanding leg of the U-shapes foil to thereby completely surround the subassembly.

Claim 16

Dependent Claim 33 words

The method as set forth in claim 12 and further including the step of: rotating the subassembly and shield fed from the sequential rollers about 90 degrees before feeding it to the extruder.

Claim 17

Dependent Claim 30 words

The method as set forth in claim 13 wherein the path of travel of the subassembly and foil is essentially a straight line from the forming-blocks to beyond the extruder.

Claim 18

Dependent Claim 27 words

The method as set forth in claim 12 and further including the step of applying a lubricant to the foil prior to its passage to the forming-blocks.

Claim 19

Independent Claim 124 words

A method of fabricating a low profile electrical transmission cable, comprising the steps of: feeding two conductor subassemblies into a progressive die means, each conductor subassembly comprising a pair of conductors embedded in an insulating body, fixedly spaced in a plane and parallel with respect to each other, the body having a flat surface extending transverse to the plane of the conductors; forming, with said progressive die means, an axially continuous conductive foil shield around each conductor subassembly by overlapping the ends of the foil shield along the body flat surface; arranging the two shielded conductor subassemblies side-by-side with the overlapping ends of the foil shield facing one another; and extruding insulation around the exterior of the foil shield encapsulating both shielded conductor subassemblies.

Claim 20

Independent Claim 124 words

A method of fabricating a low profile electrical transmission cable, comprising the steps of: feeding two conductor subassemblies into a progressive die means, each conductor subassembly comprising a pair of conductors embedded in an insulating body, fixedly spaced in a plane and parallel with respect to each other, the body having a flat surface extending transverse to the plane of the conductors; forming, with said progressive die means, an axially continuous conductive foil shield around each conductor subassembly by overlapping the ends of the foil shield along the body flat surface; arranging the two shielded conductor subassemblies side-by-side with the overlapping ends of the foil shield facing one another; and extruding insulation around the exterior of the foil shield encapsulating both shielded conductor subassemblies.

Claim 21

Dependent Claim 24 words

The method as set forth in claim 16 wherein a plurality of foil shields are simultaneously separately formed around a plurality of conductor subassemblies.

Claim 22

Dependent Claim 28 words

The method as set forth in claim 17 wherein the separate conductor subassemblies are oriented with the conductor planes relatively parallel as the foil shields are formed therearound.

Claim 23

Dependent Claim 41 words

The method as set forth in claim 18 wherein the conductor subassemblies are reoriented to dispose all of the conductors in the same plane after the foil shields are formed therearound and prior to extrusion of insulation around the foil shields.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1990-05-04	1990-11-03	1991-05-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1994-05-04	1994-11-03	1995-05-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1998-05-04	1998-11-03	1999-05-05	$7700.00	Window Closed / Lapsed

Method of manufacturing high performance flat cable

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