Shielding tape with multiple foil layers

Patent metadata

Field	Value
Publication number	US-10424423-B2
Application number	US-201715644477-A
Country	US
Kind code	B2
Filing date	Jul 7, 2017
Priority date	Jul 16, 2009
Publication date	Sep 24, 2019
Grant date	Sep 24, 2019

Abstract

A coaxial cable of the present invention comprises a center conductor, a dielectric surrounding the center conductor, a shielding tape surrounding the dielectric, a braided metal surrounding the shielding tape, and an outer jacket surrounding the braided metal. The shielding tape comprises: (i) a first shielding layer bonded to a first separating layer; (ii) a second shielding layer bonded to the first separating layer and a second separating layer; and (iii) a third shielding layer bonded to the second separating layer. The present invention eliminates the potential problem of the outer shielding structures separating and interfering with connector attachment. Furthermore, the use of three or more shielding layers in the shielding tape of the present invention improves the flex life of the shield tape by covering micro-cracks in the metal layers with additional shielding layers, thus reducing signal egress or ingress. Accordingly, the present invention provides cost savings and/or an improvement in shielding performance.

First claim

What is claimed is:

1. A method of manufacturing a coaxial cable, the method comprising:
surrounding a center conductor with a dielectric; and
wrapping a shielding tape around the dielectric, wherein the shielding tape is formed by a method including—
subjecting a first surface of a first plastic sheet to a corona discharge to activate the first surface;
applying adhesive to at least one of the activated first surface of the first plastic sheet or a first surface of a first metal sheet;
laminating the first metal sheet to the first plastic sheet by pressing the first surface of the first metal sheet against the first surface of the first plastic sheet with the adhesive therebetween;
subjecting a second surface of the first plastic sheet to a corona discharge to activate the second surface;
applying adhesive to at least one of the activated second surface of the first plastic sheet or a first surface of a second metal sheet;
laminating the second metal sheet to the first plastic sheet by pressing the first surface of the second metal sheet against the second surface of the first plastic sheet with the adhesive therebetween;
subjecting a first surface of a second plastic sheet to a corona discharge to activate the first surface of the second plastic sheet;
applying adhesive to at least one of the activated first surface of the second plastic sheet or a first surface of a third metal sheet;
laminating the third metal sheet to the second plastic sheet by pressing the first surface of the third metal sheet against the first surface of the second plastic sheet with the adhesive therebetween;
subjecting a second surface of the second plastic sheet to a corona discharge to activate the second surface of the second plastic sheet;
applying adhesive to at least one of the activated second surface of the second plastic sheet or a second surface of the second metal sheet; and
laminating the second metal sheet to the second plastic sheet by pressing the second surface of the second metal sheet against the second surface of the second plastic sheet with the adhesive therebetween, wherein—
laminating the first and second metal sheets to the first plastic sheet forms a first lamination,
laminating the third metal sheet to the second plastic sheet forms a second lamination separate from the first lamination, and
laminating the second metal sheet to the second plastic sheet forms a third lamination including the first, second, and third metal sheets individually separated from each other by the first and second plastic sheets.

2. The method of claim 1
wherein the method of forming the shielding tape further includes—
heating the first lamination in an oven to cure at least one of the adhesive between the first plastic sheet and the first metal sheet or the adhesive between the first plastic sheet and the second metal sheet;
heating the second lamination in an oven to cure the adhesive between the second plastic sheet and the third metal sheet; and
heating the third lamination in an oven to cure the adhesive between the second plastic sheet and the second metal sheet.

3. The method of claim 2 wherein the first lamination is heated separately from the second lamination.

4. The method of claim 1 wherein subjecting the surfaces of the first and second plastic sheets to corona discharges includes etching the surfaces.

5. A method of manufacturing a coaxial cable, the method comprising:
surrounding a center conductor with a dielectric; and
wrapping a shielding tape around the dielectric, wherein the shielding tape is formed by a method including—
subjecting a first surface of a first plastic sheet to a corona discharge to activate the first surface;
applying adhesive to at least one of the activated first surface of the first plastic sheet or a first surface of a first metal sheet;
moving the first plastic sheet toward a laminating device;
moving the first metal sheet toward the laminating device, wherein
subjecting the first surface of the first plastic sheet to a corona discharge includes subjecting the first surface of the first plastic sheet to a corona discharge before the first sheet reaches the laminating device, and wherein applying adhesive to at least one of the first surface of the first plastic sheet or the first surface of the first metal sheet includes applying adhesive to the first surface of the first plastic sheet after the first plastic sheet has been subjected to the corona discharge and before the first plastic sheet reaches the laminating device;
laminating the first metal sheet to the first plastic sheet by pressing the first surface of the first metal sheet against the first surface of the first plastic sheet with the adhesive therebetween, wherein pressing the first surface of the first metal sheet against the first surface of the first plastic sheet includes pressing the first surface of the first metal sheet against the first surface of the first plastic sheet at the laminating device;
subjecting a second surface of the first plastic sheet to a corona discharge to activate the second surface;
applying adhesive to at least one of the activated second surface of the first plastic sheet or a first surface of a second metal sheet;
laminating the second metal sheet to the first plastic sheet by pressing the first surface of the second metal sheet against the second surface of the first plastic sheet with the adhesive therebetween;
subjecting a first surface of a second plastic sheet to a corona discharge to activate the first surface of the second plastic sheet;
applying adhesive to at least one of the activated first surface of the second plastic sheet or a first surface of a third metal sheet;
laminating the third metal sheet to the second plastic sheet by pressing the first surface of the third metal sheet against the first surface of the second plastic sheet with the adhesive therebetween;
subjecting a second surface of the second plastic sheet to a corona discharge to activate the second surface of the second plastic sheet;
applying adhesive to at least one of the activated second surface of the second plastic sheet or a second surface of the second metal sheet; and
laminating the second metal sheet to the second plastic sheet by pressing the second surface of the second metal sheet against the second surface of the second plastic sheet with the adhesive therebetween.

6. The method of claim 1 wherein the method of forming the shielding tape further includes laminating an adhesive sheet to one of the first or third metal sheets, and wherein wrapping the shielding tape around the dielectric includes pressing the adhesive sheet against the dielectric.

7. The method of claim 1 , further comprising:
wrapping a braided metal around the shielding tape; and
surrounding the braided metal with an outer jacket.

8. The method of claim 1 wherein at least one of the first and second plastic sheets include polyester, and wherein at least one of the first, second, and third metal sheets include aluminum.

9. The method of claim 1 wherein at least one of the first and second plastic sheets include polyester, and wherein at least one of the metal sheets includes copper and at least one of the remaining metal sheets includes aluminum.

10. A method of manufacturing a coaxial cable, the method comprising:
surrounding a center conductor with a dielectric; and
wrapping a shielding tape around the dielectric, wherein the shielding tape is formed by a method including—
subjecting a first surface of a first plastic sheet to a corona discharge to activate the first surface;
applying adhesive to at least one of the activated first surface of the first plastic sheet or a first surfa

Assignees

• Pct int inc

Inventors

• Visser Leonard James

Classifications

• Y10T29/49123

  Co-axial cable · CPC title

• H01B11/1826

  Co-axial cables with at least one longitudinal lapped tape-conductor · CPC title

• H01B11/1813 Primary

  Co-axial cables with at least one braided conductor · CPC title

• H01B11/1008

  Features relating to screening tape per se · CPC title

• H01B11/1016

  composed of a longitudinal lapped tape-conductor · CPC title