(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2011/0147039 A1
`(43) Pub. Date:
`Jun. 23, 2011
`Smith et al.
`
`US 2011 0147039A1
`
`(54)
`
`COMMUNICATION CABLE COMPRISING
`ELECTRICALLY DISCONTINUOUS SHIELD
`HAVING NONMETALLIC APPEARANCE
`
`(75)
`
`Inventors:
`
`(73)
`
`Assignee:
`
`Delton C. Smith, Kennesaw, GA
`(US); James S. Tyler, Woodstock,
`GA (US); Christopher McNutt,
`Woodstock, GA (US); Paul E.
`Neveux, JR., Atlanta, GA (US)
`Superior Essex Communications
`LP
`
`(21)
`(22)
`
`(63)
`
`Appl. No.:
`
`13/039,918
`
`Filed:
`
`Mar. 3, 2011
`
`Related U.S. Application Data
`Continuation of application No. 12/313,910, filed on
`Nov. 25, 2008, now Pat. No. 7,923,632, which is a
`
`continuation-in-part of application No. 1 1/502,777,
`filed on Aug. 11, 2006, now abandoned.
`
`Publication Classification
`
`(51) Int. Cl.
`(2006.01)
`HOB II/06
`(52) U.S. Cl. .................................................... 174/102 R
`
`ABSTRACT
`(57)
`A tape can comprise a dielectric film that has a pattern of
`electrically conductive areas adhering thereto. The conduc
`tive areas can be electrically isolated from one another. The
`tape can utilize means to obscure the metallic finish and can
`contain indicators to deter installers from grounding the tape
`at either end. The tape can be wrapped around one or more
`conductors, such as wires that transmit data, to provide elec
`trical or electromagnetic shielding for the conductors. The
`resulting cable can have a shield that is electrically discon
`tinuous between opposite ends of the cable.
`
`
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`Patent Application Publication
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`Jun. 23, 2011 Sheet 1 of 5
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`US 2011/O147039 A1
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`Patent Application Publication
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`Jun. 23,2011 Sheet 1 of 5
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`Patent Application
`Publication
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`Jun. 23, 2011 Sheet 2 of 5
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`US 2011/O147039 A1
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`Patent Application Publication
`
`Jun. 23, 2011 Sheet 3 of 5
`
`US 2011/O147039 A1
`
`Start Manufacture Cable with Segmented Tape Process
`
`Flat-sheet extruder produces roll of film of dielectric material, such as plastic,
`polymeric material, or polyester
`
`Material handling system transports roll of dielectric film to a metallization
`machine
`
`300
`
`305
`
`310
`
`315
`Metallization machine unwinds roll of dielectric film; applies intermittent strips or
`patches of a Conductive material, such as aluminum or copper, as the dielectric
`film is unwound; and winds the resulting film onto a take-up reel
`
`32O
`Material handling system transports roll of film with conductive patches to slitting
`machine
`
`Operator enters diameter of cable(s) (or of cable cores) into sitting controller
`- 330
`Controller moves slitting knives of the sitting machine to widths corresponding
`to circumferences of the cables
`
`325
`
`Slitting machine unwinds the roll of film with conductive patches, slits the film
`into slender, intermittently conductive segments or segmented tapes, and winds
`each resulting tape onto a separate roll or spool
`
`
`
`335
`
`Fig. 3A
`
`

`

`Patent Application Publication
`
`Jun. 23, 2011 Sheet 4 of 5
`
`US 2011/014.7039 A1
`
`Material handling system transports roll of segmented tape of appropriate width
`to cabling system and loads roll onto feed spindle
`
`340
`
`345
`
`Material handling system loads one, or two, or more reels of twisted pairs of
`conductors into feed area of cabling system
`
`350
`Cabling system unwinds roll of segmented tape and one or more reels of twisted
`pairs of conductors. The cabling system's feeding mechanisms position the
`twisted pairs of conductors adjacent the tape as each is unwound, e.g. so that
`the conductors are on top of the flat surface of the tape.
`
`355
`
`A curling mechanism of the cabling system curis the segmented tape over the
`conductor pairs as they move synchronously or continuously downstream in the
`production line. Thus, the segmented tape is wrapped lengthwise around the
`Conductors.
`
`
`
`
`
`Extruder of cabling system extrudes jacket over the segmented tape and the
`conductor pairs. Thus, the cabling system produces a cable with the conductors
`and the shielding film in the core of the cable, wherein the segmented tape
`provides a segmented shield for the conductors.
`
`360
`
`Take-up reel at downstream end of cabling system accumulates finished cable
`
`365
`
`Fig. 3B
`
`

`

`Patent Application Publication
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`Jun. 23, 2011 Sheet 5 of 5
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`US 2011/O147039 A1
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`Patent Application Publication
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`Jun. 23,2011 Sheet 5 of 5
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`

`US 2011/O 147039 A1
`
`Jun. 23, 2011
`
`COMMUNICATION CABLE COMPRISING
`ELECTRICALLY DISCONTINUOUS SHIELD
`HAVING NONMETALLIC APPEARANCE
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`0001. This application is a continuation of and claims
`priority to U.S. patent application Ser. No. 12/313,910,
`entitled “Communication Cable Comprising Electrically
`Discontinuous Shield Having Nonmetallic Appearance'.
`filed on Nov. 25, 2008, which is a continuation in part of and
`claims priority to U.S. patent application Ser. No. 1 1/502,
`777, entitled “Method And Apparatus For Fabricating Noise
`Mitigating Cable' and filed on Aug. 11, 2006 in the name of
`Delton C. Smith et al. The entire contents of U.S. patent
`application Ser. Nos. 12/313,910 and 1 1/502,777 are hereby
`incorporated herein by reference.
`
`FIELD OF THE TECHNOLOGY
`0002 The present invention relates to manufacturing a
`communication cable that is shielded from electromagnetic
`radiation and more specifically to applying isolated patches
`of conductive material to a dielectric film, providing the film
`with a nonmetallic appearance, and wrapping the resulting
`material around wires of the cable.
`
`BACKGROUND
`0003. As the desire for enhanced communication band
`width escalates, transmission media need to convey informa
`tion at higher speeds while maintaining signal fidelity and
`avoiding crosstalk. However, effects such as noise, interfer
`ence, crosstalk, alien crosstalk, and alien elfext crosstalk can
`strengthen with increased data rates, thereby degrading signal
`quality or integrity. For example, when two cables are dis
`posed adjacent one another, data transmission in one cable
`can induce signal problems in the other cable via crosstalk
`interference.
`0004 One approach to addressing crosstalk in a commu
`nication cable is to circumferentially encase the cable in a
`continuous shield, such as a flexible metallic tube or a foil that
`coaxially surrounds the cable's conductors. However, shield
`ing based on convention technology can be expensive to
`manufacture and/or cumbersome to install in the field. In
`particular, complications can arise when a cable is encased by
`a shield that is electrically continuous between the two ends
`of the cable.
`0005. In a typical application, each cable end is connected
`to a terminal device Such as an electrical transmitter, receiver,
`or transceiver. The continuous shield can inadvertently carry
`Voltage along the cable, for example from one terminal device
`at one end of the cable towards the other terminal device at the
`other end of the cable. If a person contacts the shielding, the
`person may receive a shock if the shielding is not properly
`grounded. Accordingly, continuous cable shields are typi
`cally grounded at both ends of the cable to reduce shock
`hazards and loop currents that can interfere with transmitted
`signals.
`0006 Such a continuous shield can also set up standing
`waves of electromagnetic energy based on signals received
`from nearby energy sources. In this scenario, the shield's
`standing wave can radiate electromagnetic energy, somewhat
`like an antenna, that may interfere with wireless communi
`cation devices or other sensitive equipment operating nearby.
`
`0007 Accordingly, to address these representative defi
`ciencies in the art, what is needed is an improved capability
`for shielding conductors that may carry high-speed commu
`nication signals. Another need exists for a method and appa
`ratus for efficiently manufacturing communication cables
`that are resistant to noise. Yet another need exists for a cable
`construction that effectively Suppresses crosstalk and/or other
`interference without providing an electrically conductive
`path between ends of the cable. A further need exists for
`imparting a discontinuous shield with a nonmetallic appear
`ance or an indication that the shield functions without
`grounding. A capability addressing one or more of these
`needs would support increasing bandwidth without unduly
`increasing cost or installation complexity.
`
`SUMMARY
`0008. The present invention supports fabricating, manu
`facturing, or making shielded cables that may be used to
`communicate data or other information.
`0009. In one aspect of the present invention, a section of
`dielectric film can have a pattern of electrically conductive
`areas or patches attached thereto, wherein the conductive
`areas are electrically isolated from one another. The section of
`dielectric film can comprise a tape, a ribbon, or a narrow Strip
`of dielectric material. Such as polyester, polypropylene or
`Some other non-conducting polymer. The conductive areas
`can comprise aluminum, copper, metallic material, or some
`other form of material that readily conducts electricity. The
`conductive areas can be printed, fused, transferred, bonded,
`vapor deposited, imprinted, coated, or otherwise attached to
`the dielectric film. In other words, a tape can comprise a
`flexible dielectric material having conductive patches
`attached thereto, and physical separation between the con
`ductive patches can electrically isolate the patches from one
`another. The tape can provide visual information for differ
`entiating the tape from a continuous, metallic tape that would
`ordinarily be grounded in installation. For example, the tape
`can comprise a colorant or other agent on the conductive
`patches and/or on the dielectric film to obscure any metallic
`finish or metallic appearance of the patches. As another
`example, the tape can comprise a plurality of strips of opaque
`dielectric film that enclose the conductive patches. As another
`example, the tape can comprise a message or notification in
`one or more locations along the tape informing a user that the
`cable can be deployed without electrically grounding the
`tape.
`0010. The tape can be wrapped around one or more con
`ductors, such as wires that transmit data, to provide electrical
`or electromagnetic shielding for the conductors. The tape can
`also be wrapped around the cable itself, alone or enveloped by
`another jacket. The tape and/or the resulting shield can be
`electrically discontinuous between opposite ends of the
`cable. Thus, incremental sections or segments of conductive
`shielding can circumscribe the cable at incremental locations
`along the cable. While electricity can flow freely in each
`individual section of shielding, the shield discontinuities can
`inhibit electricity from flowing in the shielding material along
`the full or axial length of the cable.
`0011
`For another aspect of the invention, a communica
`tion cable can be implemented by a combination of an outer
`jacket, a tape, and first and second individually insulated
`electrical conductors. The outer jacket defines an interior
`volume that extends lengthwise between a first end and a
`second end of the cable. The tape is disposed in the interior
`
`

`

`US 2011/O 147039 A1
`
`Jun. 23, 2011
`
`Volume and extends lengthwise to define at least two cham
`bers within the interior volume. The tape typically comprises
`(i) electrically conductive patches that are operable to shield
`against interference and (ii) indicia differentiating the tape
`from an electrically continuous tape. An electrically conduc
`tive patch positioned on the tape at the first end of the cable is
`isolated electrically from an electrically conductive patch
`positioned on the tape at the second end of the cable. The first
`individually insulated electrical conductors are disposed in a
`first chamber and extend substantially between the first end
`and the second end. The second individually insulated elec
`trical conductors are disposed in a second of the chambers and
`extend substantially between the first end and the second end.
`0012. A communication cable also can be formed by the
`combination of an outer jacket, twisted pairs of individually
`insulated electrical conductors and a tape. The outer jacket
`defines an interior volume that extends lengthwise between a
`first end and a second end of the cable. The twisted pairs of
`individually insulated electrical conductors are disposed in
`the interior volume. The tape disposed is in the interior Vol
`ume and separates a first twisted pair from a second twisted
`pair. The tape typically comprises (i) electrically conductive
`patches that are operable to shield against interference,
`wherein an electrically conductive patch at the first end is
`isolated electrically from an electrically conductive patch at
`the second end, and (ii) indicia differentiating the tape from
`an electrically continuous tape. The indicia is useful for
`enabling an installer of the communication cable to readily
`identify the tape from an electrically continuous tape.
`0013. A communication cable also can be formed by the
`combination of individually insulated electrical conductors
`useful for transmitting communication signals between a first
`end and a second end of the cable, an elongated object that
`extends between the first end and the second end of the cable,
`and an outer jacket that covers the electrical conductors and
`the elongated object. The elongated object typically com
`prises (i) a Substrate comprising electrical insulation, (ii)
`patches comprising electrically conductive material, and (iii)
`indicia differentiating the elongated object from an electri
`cally continuous elongated object. The patches of the elon
`gated object can be attached to the Substrate and are operable
`to shield at least one of the individually insulated electrical
`conductors from interference. A patch positioned on the elon
`gated tape at the first end of the cable is electrically isolated
`from a patch positioned on the elongated tape at the second
`end of the cable.
`0014 For yet another aspect of the invention, a communi
`cation cable can beformed by the combination of individually
`insulated electrical conductors for transmitting communica
`tion signals between a first end and a second end of the cable,
`a flexible member running alongside the individually insu
`lated electrical conductors and extending between the cable
`ends, and an outerjacket that covers the individually insulated
`electrical conductors and the flexible member. The flexible
`member typically comprises (i) patches, comprising electri
`cally conductive material, and (ii) indicia differentiating the
`flexible member from an electrically continuous flexible
`member to cable installer. The patches are operable to shield
`at least two of the individually insulated electrical conductors
`from interference. A patch positioned on the flexible member
`at the first end of the communication cable is electrically
`isolated from a patch positioned on the flexible member at the
`second end of the communication cable.
`
`0015 The discussion of shielding conductors presented in
`this Summary is for illustrative purposes only. Various aspects
`of the present invention may be more clearly understood and
`appreciated from a review of the following detailed descrip
`tion of the disclosed embodiments and by reference to the
`drawings and the claims that follow. Moreover, other aspects,
`systems, methods, features, advantages, and objects of the
`present invention will become apparent to one with skill in the
`art upon examination of the following drawings and detailed
`description. It is intended that all Such aspects, systems, meth
`ods, features, advantages, and objects are to be included
`within this description, are to be within the scope of the
`present invention, and are to be protected by the accompany
`ing claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0016 FIG. 1 is a cross sectional view of an exemplary
`communication cable that comprises a segmented shield in
`accordance with an embodiment of the present invention.
`(0017 FIGS. 2A and 2B are, respectively, overhead and
`cross sectional views of an exemplary segmented tape that
`comprises a pattern of conductive patches attached to a
`dielectric film substrate inaccordance with an embodiment of
`the present invention.
`0018 FIG. 2C is an illustration of an exemplary technique
`for wrapping a segmented tape lengthwise around a pair of
`conductors in accordance with an embodiment of the present
`invention.
`(0019 FIGS. 3A and 3B, collectively FIG. 3, are a flow
`chart depicting an exemplary process for manufacturing
`shielded cable in accordance with an embodiment of the
`present invention.
`0020 FIGS. 4A and 4B are, respectively, overhead and
`cross sectional views of exemplary segmented tapes that
`comprise patterns of conductive patches attached to a dielec
`tric film Substrate and technology for differentiating the seg
`mented tape from a continuous, metallic tape in accordance
`with an embodiment of the present invention.
`0021 Many aspects of the invention can be better under
`stood with reference to the above drawings. The elements and
`features shown in the drawings are not to scale, emphasis
`instead being placed upon clearly illustrating the principles of
`exemplary embodiments of the present invention. Moreover,
`certain dimension may be exaggerated to help visually con
`Vey Such principles. In the drawings, reference numerals des
`ignate like or corresponding, but not necessarily identical,
`elements throughout the several views.
`
`DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`0022. The present invention supports manufacturing or
`fabricating a noise-mitigating communication cable, wherein
`at least one break or discontinuity in the shielding along the
`cable electrically isolates the shielding at one end of the cable
`from the shielding at the other end of the cable. As an alter
`native to forming a continuous or contiguous conductive path,
`the tape can be segmented or can comprise intermittently
`conductive patches or areas.
`0023. A method and apparatus for making cables compris
`ing a segmented tape will now be described more fully here
`inafter with reference to FIGS. 1-4, which describe represen
`tative embodiments of the present invention. In an exemplary
`embodiment, the segmented tape can be characterized as
`
`

`

`US 2011/O 147039 A1
`
`Jun. 23, 2011
`
`shielding tape or as tape with segments or patches of conduc
`tive material. FIG. 1 provides an end-on view of a cable with
`segmented tape. FIGS. 2A and 2B show a tape that can be
`used for fabricating a cable with segmented tape. FIG. 2C
`depicts wrapping segmented tape around or over conductors.
`FIG. 3 offers a process for making cable with segmented
`shielding. FIGS. 4A and 4B (collectively FIG. 4) show tapes
`with an obscured metallic finish that can be used for fabricat
`ing a cable with segmented tape.
`0024. The invention can be embodied in many different
`forms and should not be construed as limited to the embodi
`ments set forth herein; rather, these embodiments are pro
`vided so that this disclosure will be thorough and complete,
`and will fully convey the scope of the invention to those
`having ordinary skill in the art. Furthermore, all “examples’
`or “exemplary embodiments’ given herein are intended to be
`non-limiting, and among others Supported by representations
`of the present invention.
`0025 Turning now to FIG. 1, this figure illustrates a cross
`sectional view of a communication cable 100 that comprises
`a segmented shield 125 according to an exemplary embodi
`ment of the present invention.
`0026. The core 110 of the cable 100 contains four pairs of
`conductors 105, four being an exemplary rather than limiting
`number. Each pair 105 can be a twisted pair that carries data
`at 10Gbps, for example. The pairs 105 can each have the same
`twist rate (twists-per-meter or twists-per-foot) or may be
`twisted at different rates.
`0027. The core 110 can be hollow as illustrated or alter
`natively can comprise a gelatinous, Solid, or foam material,
`for example in the interstitial spaces between the individual
`conductors 105. In one exemplary embodiment, one or more
`members can separate each of the conductor pairs 105 from
`the other conductor pairs 105. For example, the core 110 can
`contain an extruded or pultruded separator that extends along
`the cable 110 and that provides a dedicated cavity or channel
`for each of the four conductor pairs 105. Viewed end-on or in
`cross section, the separator could have a cross-shaped geom
`etry or an X-shaped geometry.
`0028 Such an internal separator can increase physical
`separation between each conductor pair 105 and can help
`maintain a random orientation of each pair 105 relative to the
`other pairs 105 when the cable 100 is field deployed.
`0029. A segmented tape 125 surrounds and shields the
`four conductor pairs 105. As discussed in further detail below,
`the segmented tape 125 comprises a substrate film 150 with
`patches 175 of conductive material attached thereto. As illus
`trated, the segmented tape 125 extends longitudinally along
`the length of the cable 100, essentially running parallel with
`and wrapping over the conductors 105.
`0030. In an alternative embodiment, the segmented tape
`125 can wind helically or spirally around the conductor pairs
`105. More generally, the segmented tape 125 can circumfer
`entially cover, house, encase, or enclose the conductor pairs
`105. Thus, the segmented tape 125 can circumscribe the
`conductors 105, to extend around or over the conductors 105.
`Although FIG. 1 depicts the segmented tape 125 as partially
`circumscribing the conductors 105, that illustrated geometry
`is merely one example. In many situations, improved block
`age of radiation will result from overlapping the segmented
`tape 125 around the conductors 105, so that the segmented
`tape fully circumscribes the conductors 105. Moreover, in
`certain embodiments, the side edges of the segmented tape
`125 can essentially butt up to one another around the core 110
`
`of the cable 100. Further, in certain embodiments, a signifi
`cant gap can separate these edges, so that the segmented tape
`125 does not fully circumscribe the core 110.
`0031. In one exemplary embodiment, one side edge of the
`segmented tape 125 is disposed over the other side edge of the
`tape 125. In other words, the edges can overlap one another,
`with one edge being slightly closer to the center of the core
`110 than the other edge.
`0032. An outerjacket 115 of polymer seals the cable 110
`from the environment and provides strength and structural
`support. The jacket 115 can be characterized as an outer
`heath, a jacket, a casing, or a shell. A small annular spacing
`120 may separate the jacket 115 from the segmented tape 125.
`0033. In one exemplary embodiment, the cable 100 or
`Some other similarly noise mitigated cable can meet a trans
`mission requirement for “10 G Base-T data corn cables. In
`one exemplary embodiment, the cable 100 or some other
`similarly noise mitigated cable can meet the requirements set
`forth for 10Gbps transmission in the industry specification
`known as TIA 568-B.2-10 and/or the industry specification
`known as ISO 11801. Accordingly, the noise mitigation that
`the segmented tape 125 provides can help one or more twisted
`pairs of conductors 105 transmit data at 10 Gbps or faster
`without unduly experiencing bit errors or other transmission
`impairments. As discussed in further detail below, an auto
`mated and scalable process can fabricate the cable 100 using
`the segmented tape 125.
`0034 Turning now to FIGS. 2A and 2B, these figures
`respectively illustrate overhead and cross sectional views of a
`segmented tape 125 that comprises a pattern of conductive
`patches 175 attached to a substrate film 150 according to an
`exemplary embodiment of the present invention. That is,
`FIGS. 2A and 2B depict an exemplary embodiment of the
`segmented tape 125 shown in FIG. 1 and discussed above.
`More specifically, FIG. 1 illustrates a cross sectional view of
`the cable 100 wherein the cross section cuts through one of
`the conductive patches 175, perpendicular to the major axis of
`the segmented tape 125.
`0035. The segmented tape 125 comprises a substrate film
`150 of flexible dielectric material that can be wound around
`and stored on a spool. That is, the illustrated section of seg
`mented tape 125 can be part of a spool of segmented tape 125.
`The film can comprise a polyester, polypropylene, polyeth
`ylene, polyimide, or some other polymer or dielectric mate
`rial that does not ordinarily conduct electricity. That is, the
`segmented tape 125 can comprise a thin Strip of pliable mate
`rial that has at least some capability for electrical insulation.
`In one exemplary embodiment, the pliable material can com
`prise a membrane or a deformable sheet. In one exemplary
`embodiment, the substrate is formed of the polyester material
`sold by E. I. DuPont de Nemours and Company under the
`registered trademark MYLAR.
`0036. The conductive patches 175 can comprise alumi
`num, copper, nickel, iron, or some metallic alloy or combi
`nation of materials that readily transmits electricity. The indi
`vidual patches 175 can be separated from one another so that
`each patch 175 is electrically isolated from the other patches
`175. That is, the respective physical separations between the
`patches 175 can impede the flow of electricity between adja
`cent patches 175.
`0037. The conductive patches 175 can span fully across
`the segmented tape 125, between the tape's long edges. As
`discussed in further detail below, the conductive patches 175
`can be attached to the substrate film 150 via gluing, bonding,
`
`

`

`US 2011/O 147039 A1
`
`Jun. 23, 2011
`
`adhesion, printing, painting, welding, coating, heated fusion,
`melting, or vapor deposition, to name a few examples.
`0038. In one exemplary embodiment, the conductive
`patches 175 can be over-coated with an electrically insulating
`film, Such as a polyester coating (not shown in FIGS. 2A and
`2B). In one exemplary embodiment, the conductive patches
`175 are sandwiched between two dielectric films, the sub
`strate film 150 and another electrically insulating film (shown
`in FIG. 4B and discussed below).
`0039. The segmented tape 125 can have a width that cor
`responds to the circumference of the core 110 of the cable
`100. The width can be slightly smaller than, essentially equal
`to, or larger than the core circumference, depending on
`whether the longitudinal edges of the segmented tape 125 are
`to be separated, butted together, or overlapping, with respect
`to one another in the cable 100.
`0040. In one exemplary embodiment, the substrate film
`150 has a thickness of about 1-5 mils (thousandths of an inch)
`or about 25-125 microns. Each conductive patch 175 can
`comprise a coating of aluminum having a thickness of about
`0.5 mils or about 13 microns. Each patch 175 can have a
`length of about 1.5 to 2 inches or about 4 to 5 centimeters.
`Other exemplary embodiments can have dimensions follow
`ing any of these ranges, or some other values as may be useful.
`The dimensions can be selected to provide electromagnetic
`shielding over a specific band of electromagnetic frequencies
`or above or below a designated frequency threshold, for
`example.
`0041 Turning now to FIG.2C, this figure illustrates wrap
`ping a segmented tape 125 lengthwise around a pair of con
`ductors 105 according to an exemplary embodiment of the
`present invention. Thus, FIG. 2C shows how the segmented
`tape 125 discussed above can be wrapped around or over one
`or more pairs of conductors 125 as an intermediate step in
`forming a cable 100 as depicted in FIG. 1 and discussed
`above. While FIG. 1 depicts four pairs of wrapped conductors
`105, FIG. 2C illustrates wrapping a single pair 105 as an aid
`to visualizing an exemplary assembly technique.
`0042. As illustrated in FIG.2C, the pair of conductors 105
`is disposed adjacent the segmented tape 125. The conductors
`105 extend essentially parallel with the major or longitudinal
`axis/dimension of the segmented tape 125. Thus, the conduc
`tors 105 can be viewed as being parallel to the surface or plane
`of the segmented tape 125. Alternatively, the conductors 105
`can be viewed as being over or under the segmented tape 125
`or being situated along the center axis of the segmented tape
`125. Moreover, the conductors 105 can be viewed as being
`essentially parallel to one or both edges of the segmented tape
`125.
`0043. The long edges of the segmented tape 125 are
`brought up over the conductors 105, thereby encasing the
`conductors 105 or wrapping the segmented tape 125 around
`or over the conductors 105. In an exemplary embodiment, the
`motion can be characterized as folding or curling the seg
`mented tape 125 over the conductors 105. As discussed
`above, the long edges of the segmented tape 125 can overlap
`one another following the illustrated motion.
`0044. In one exemplary embodiment, the conductive
`patches 175 face inward, towards the conductors 105. In
`another exemplary embodiment, the conductive patches 175
`face away from the conductors 105, towards the exterior of
`the cable 100.
`0045. In one exemplary embodiment, the segmented tape
`125 and the conductors 105 are continuously fed from reels,
`
`bins, containers, or other bulk storage facilities into a narrow
`ing chute or a funnel that curls the segmented tape 125 over
`the conductors 105.
`0046. In one exemplary embodiment, FIG. 2C describes
`operations in a Zone of a cabling machine, wherein segmented
`tape 125 fed from one reel (not illustrated) is brought into
`contact with conductors 105 feeding off of another reel. That
`is, the segmented tape 125 and the pair of conductors 105 can
`synchronously and/or continuously feed into a chute or a
`mechanism that brings the segmented tape 125 and the con
`ductors 105 together and that curls the segmented tape 125
`lengthwise around the conductors 105. So disposed, the seg
`mented tape 125 encircles or encases the conductors 105 in
`discontinuous, conductive patches.
`0047 Downstream from this mechanism (or as a compo
`nent of this mechanism), a nozzle or outlet port can extrude a
`polymeric jacket, skin, casing, or sheath 115 over the seg
`mented tape, thus providing the basic architecture depicted in
`FIG. 1 and discussed above.
`0048 Turning now to FIG. 3, this figure is a flowchart
`depicting a process 300 for manufacturing shielded cable 100
`according to an exemplary embodiment of the present inven
`tion. Process 300 can produce the cable 100 illustrated in FIG.
`1 using the segmented tape 125 and the conductors 105 as
`base materials.
`0049. At Step 305 an extruder produces a film of dielectric
`material. Such as polyester, which is wound onto a roll or a
`reel. At this stage, the film can be much wider than the cir
`cumference of any particular cable in which it may ultimately
`be used and might one to three meters across, for example. As
`discussed in further detail below, the extruded film will be
`processed to provide the substrate film 150 discussed above.
`0050. In one exemplary embodiment, the extruder can
`apply a colorant, an opacity promoter, or an obscuring agent
`to the dielectric material before it is wound onto a roll or a
`reel. Such additives can impart the segmented tape 125 with a
`visual appearance that a user can clearly distinguish from a
`continuous, metallic tape that the user would be inclined to
`attach to a grounding post or rod.
`0051. At Step 310, a material handling system transports
`the roll to a metallization machine or to a metallization sta
`tion. The material handling