Low-crosstalk data cable and method of manufacturing

Electricity: conductors and insulators – Conduits – cables or conductors – Insulated

Reexamination Certificate

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C174S1130AS

Reexamination Certificate

active

06310295

ABSTRACT:

FIELD OF THE INVENTION
This invention relates generally to a multi-conductor cable and method of manufacturing the same. In particular, the invention is directed to a data cable with a shielding member to separate conductors of a cable where the shielding member prevents cross-talk between the conductors.
BACKGROUND OF THE INVENTION
Multi-conductor cables are common for transferring multiple currents to and from electronic systems and devices. For example, multi-conductor cables are frequently used for audio, video and data transmission between components in communication networks, computer systems, and other similar bi-directional data transmission systems. In these types of multi-conductor cables, it is essential to reduce or prevent cross-talk due to the electromagnetic fields of current flowing in adjacent conductors. It is also important to properly insulate the conductors from each other and to provide an overall cable that is flexible, lightweight and free of moisture. Due to the potential length of this type of multi-conductor cable, it is desirable to produce a high quality cable which is easily manufactured at a low cost.
DESCRIPTION OF RELATIVE ART
It is well known in the art to provide floating or grounded metallic shielding in multi-conductor cables to prevent cross-talk between adjacent conductors or conductor pairs in a cable. For example, U.S. Pat. No. 3,911,200 discloses a cable assembly having an encapsulated shielding tape made of a laminate metal foil and plastic film bonded together. This shielding tape is folded into an L- shape to form a channel and then laminated to another piece of similarly shaped shielding tape to result in a multi-channel shielding tape, wherein a conductor resides in each channel. Furthermore, International Patent WO 98/48430 discloses a shielding core formed of a cross-talk reducing conductive material. The core is formed of conductive material and has multiple fins extruding in an outward direction from the core in order to isolate conductors in respective channels.
These prior art shielding techniques have problems in that they require complex pre-assembly or intricate formation of shielding members prior to cable construction. Therefore, it is desired to have a self adapting shielding member that can be formed at the same time the cable is pulled together in a cabling production device.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a low cost, low-crosstalk data cable that is easily manufactured using a self-adapting shielding tape. It is a further object of the invention to provide a method of manufacturing a low-crosstalk data cable that eliminates the need and expense of pre-formed or complicated formation of a shielding member by forming a channeled shielding member during the cable pulling process.
Therefore, there is provided a low-crosstalk data cable having a cable housing jacket made of flexible insulating material for housing a multi-channel shielding member and a plurality of conductors. A hollow multi-channel shielding member of the invention is formed during the cable pulling process from a single, flat, thin, self-adapting shielding tape. The multi-channel shielding member separates and prevents crosstalk between adjacent conductors. A grounded low-cross talk data cable is provided when a current drain wire is positioned down the center of the hollow multi-channel shielding member. Further, the low-crosstalk data cable may have a metallic outer shielding jacket positioned between the cable housing jacket and the combined conductors/multi-shielding member core. A second current drain wire may also be provided to enable grounding of the metallic outer shielding jacket.
These and other objects are achieved in accordance with a preferred embodiment of the invention as discussed below.


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