Adhesive bonding and miscellaneous chemical manufacture – Methods – Making electrical conductors of indefinite length
Reexamination Certificate
1999-09-17
2001-10-02
Ball, Michael W. (Department: 3729)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Making electrical conductors of indefinite length
C156S051000, C264S272110, C174S11000P
Reexamination Certificate
active
06296725
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to high frequency ribbon cables, and more particularly, to high frequency ribbon cables for twist capsule applications.
BACKGROUND OF THE INVENTION
There are applications in which signals need to be transmitted to a rotating member. Frequently, such signals can be transmitted using electrical slip rings. However, there are applications in which the high frequency of the signal and/or the attenuation of the signal is such that electrical slip rings are not usable. Many times in such applications the rotating member needs to rotate one or two revolutions in a clockwise and/or a counter clockwise direction although rotational travel of up to ten or more revolutions is sometimes required. In such applications, a twist capsule cable is preferred. A conventional twist capsule tape (for use at low frequencies) is constructed of flexible printed circuit material having copper runs laminated between polymer film. These tapes perform in a similar manner to cables of conventional electrical wire, which becomes ineffective as a signal transmission line as frequencies increase.
Sufficient length needs to be provided to allow the twist capsule cable to have enough length so that the twist capsule cable can be coiled, like a clock spring, and have sufficient length to travel to the extreme rotational positions of plus/minus two revolutions.
A need exists in the art to be able to make relatively low volume twist capsule cable for special applications.
SUMMARY OF THE INVENTION
It is, therefore, an object of the invention to provide a method and apparatus for manufacturing high frequency ribbon cable for twist capsule applications in which low volume production runs can be made efficiently and at low cost.
It is another object of the present invention to provide a twist capsule cable which is rugged in operation and economical to manufacture.
These and other objects of the present invention are achieved by providing a method for surrounding electrical cable, such as coax cable or twinax cable, with an elastomer to form a twist capsule cable. The cables are placed in a fixture and stretched to a desired tautness using rubber bands at opposite ends of each cable without allowing the cables to sag in the fixture. The cables are clamped into yokes at opposite ends of the fixture. An elastomer, such as silicone, is poured into the fixture and allowed to cure. The portion of the cables within the fixture are embedded into the elastomer after the elastomer cures. Additional length of twist capsule cable can be fabricated by performing a similar process on adjoining sections of cable. The elastomer is then coated with a polyxylylene or similar polymer such as Parylene™ to prevent the elastomer from rubbing on itself when coiled and when uncoiling. Advantageously, any number of cables can be embedded in the elastomer to form the twist capsule cable. Also advantageously, the present invention provides excellent attenuation at 1 GHz. Some channels operate between 10 MHz and 80 MHz. The cables are capable of carrying radio, Identify Friend and Foe (IFF), Ethernet and other signals.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings are to be regarded as illustrative in nature, and not as restrictive.
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Bowman Anthony Lee
Lawson Glenn
Trenor Tyrone
Ball Michael W.
Haran John T.
Litton Systems Inc.
Lowe Hauptman & Gilman & Berner LLP
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