US4767891A — Mass terminable flat cable and cable assembly inc…

Claim 1

Independent Claim 194 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer.

Claim 2

Dependent Claim 194 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer.

Claim 3

Dependent Claim 22 words

A flat cable as set forth in claim 1 wherein in said second cable sections said conductors are arranged in twisted pairs.

Claim 4

Dependent Claim 23 words

A flat cable as set forth in claim 1 wherein the conductor jackets and the attachment layer are made of the same material.

Claim 5

Dependent Claim 19 words

A flat cable as set forth in claim 1 wherein the said attachment layer is formed of polyvinyl chloride.

Claim 6

Dependent Claim 19 words

A flat cable as set forth in claim 1 wherein said stabilization layer is made of a polyester film.

Claim 7

Dependent Claim 36 words

A flat cable as set forth in claim 1 wherein each of said first cable sections has a substantially flat side and an opposite undulating side with each undulation formed by one of the jacketed conductors.

Claim 8

Dependent Claim 24 words

A flat cable as set forth in claim 1 wherein said carrier film comprises an adhesive bonding said attachment layer to said stabilization layer.

Claim 9

Dependent Claim 248 words

A cable assembly for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable assembly comprising: a flat cable deformed from its flat, as-manufactured configuration into a non-flat configuration; and holding means disposed about the periphery of said cable holding said cable in said non-flat configuration whereby removal of the holding means allows said cable substantially to return to its flat configuration, said cable in its as-manufactured configuration comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer.

Claim 10

Dependent Claim 248 words

A cable assembly for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable assembly comprising: a flat cable deformed from its flat, as-manufactured configuration into a non-flat configuration; and holding means disposed about the periphery of said cable holding said cable in said non-flat configuration whereby removal of the holding means allows said cable substantially to return to its flat configuration, said cable in its as-manufactured configuration comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer.

Claim 11

Dependent Claim 16 words

A cable assembly as set forth in claim 8 wherein said non-flat configuration is substantially circular.

Claim 12

Dependent Claim 24 words

A cable assembly as set forth in claim 8 wherein the holding means comprises an outer jacket formed of an abrasion resistant thermoplastic material.

Claim 13

Dependent Claim 24 words

A cable assembly as set forth in claim 8 wherein said jacket has spaced indicia on its outside surface locating said first cable sections.

Claim 14

Dependent Claim 22 words

A cable assembly as set forth in claim 8 wherein said conductors are arranged in twisted pairs in said second cable sections.

Claim 15

Dependent Claim 15 words

A cable assembly as set forth in claim 8 further including a central strength member.

Claim 16

Dependent Claim 20 words

A cable assembly as set forth in claim 8 wherein said flat cable is spiralled to form said non-flat configuration.

Claim 17

Dependent Claim 20 words

A cable assembly as set forth in claim 8 wherein said flat cable is folded to form said non-flat configuration.

Claim 18

Dependent Claim 17 words

A cable assembly as set forth in claim 8 further comprising a metallic shield surrounding said cable.

Claim 19

Dependent Claim 15 words

A cable assembly as set forth in claim 16 wherein said shield is a foil.

Claim 20

Dependent Claim 15 words

A cable assembly as set forth in claim 16 wherein said shield is a braid.

Claim 21

Dependent Claim 20 words

A cable assembly as set forth in claim 16 wherein said shield comprises a foil layer and a braid layer.

Claim 22

Dependent Claim 257 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer, wherein said laminated carrier film is a first carrier film and is disposed on one side of said first cable section, each first cable section further comprising a second carrier film disposed on the other side of said first cable section, said second carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material.

Claim 23

Dependent Claim 257 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first cable section comprising a laminated carrier film holding said conductors, said carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material, and a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layer and the jacket material and displaying dimensional stability at the melting temperatures of the attachment layer and jacket material, the jackets of said conductors being fused to said attachment layer and said attachment layer being held by said stabilization layer, wherein said laminated carrier film is a first carrier film and is disposed on one side of said first cable section, each first cable section further comprising a second carrier film disposed on the other side of said first cable section, said second carrier film including an attachment layer of thermoplastic insulation having a melting temperature similar to that of the jacket material.

Claim 24

Dependent Claim 72 words

A flat cable as set forth in claim 20 wherein the attachment layer of said second carrier film and the attachment layer of said first carrier film are fused to each other between the conductors of each pair of adjacent conductors so that each side of each first cable section is undulating with each undulation formed by one of the jacketed conductors, the spacing between undulations matching the spacing between terminal elements.

Claim 25

Dependent Claim 40 words

A flat cable as set forth in claim 21 wherein said second carrier film further comprises a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of the attachment layers and the jacket material.

Claim 26

Dependent Claim 216 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship and have undulations on each side of the cable formed by said conductors matching the spacing of said terminal elements, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first section comprising a first film disposed on one side of the conductors and a second film disposed on the other side of said conductors, each film including an attachment layer with the attachment layers being fused together between each pair of adjacent conductors, at least one of said films comprising a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of said attachment layers and displaying dimensional stability at the melting temperatures of said attachment layers, the dimensional stabilization layer holding the attachment layer in said one film.

Claim 27

Dependent Claim 216 words

A flat cable for use with a mass termination connector having a plurality of regularly spaced terminal elements, said cable comprising: a plurality of discrete conductors extending throughout the length of said cable, each conductor having an insulative jacket made of a thermoplastic material; said cable having a plurality of spaced first cable sections in which said conductors are held in regularly spaced parallel relationship and have undulations on each side of the cable formed by said conductors matching the spacing of said terminal elements, said cable further having a plurality of spaced second cable sections in which said conductors are not held in regularly spaced parallel relationship, with adjacent first cable sections being spaced by a second cable section; each first section comprising a first film disposed on one side of the conductors and a second film disposed on the other side of said conductors, each film including an attachment layer with the attachment layers being fused together between each pair of adjacent conductors, at least one of said films comprising a dimensional stabilization layer made of an insulative material having a melting temperature higher than those of said attachment layers and displaying dimensional stability at the melting temperatures of said attachment layers, the dimensional stabilization layer holding the attachment layer in said one film.

Claim 28

Dependent Claim 39 words

A flat cable as set forth in claim 23 wherein the attachment layers in each first section have melting temperatures similar to that of the jacket material, said attachment layers also being fused to the jackets of said conductors.

Claim 29

Dependent Claim 29 words

A flat cable as set forth in claim 23 wherein each of said films in each first section comprises a said dimensional stabilization layer holding a corresponding attachment layer.

Claim 30

Dependent Claim 22 words

A flat cable as set forth in claim 23 wherein said conductors in said second cable sections are arranged in twisted pairs.

Claim 31

Dependent Claim 16 words

A cable assembly as set forth in claim 8 further including at least one central filler.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-08-30	1992-02-29	1992-08-30	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-08-30	1996-02-29	1996-08-30	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-08-30	2000-02-29	2000-08-30	$7700.00	Window Closed / Lapsed

Mass terminable flat cable and cable assembly incorporating the cable

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