Conjoined cables include two or more individual lines, such as cables or wires, combined into a single composite cable. For example, one type of conjoined cable is a messengered coaxial cable in which a coaxial cable is combined with a messenger support wire into a single composite cable. The messenger support wire provides support to the coaxial cable in situations where the coaxial cable aerially spans long distances, such as 75 feet or more. Another example conjoined cable is a standard RCA cable that includes a video line, a left audio line, and a right audio line combined into a single composite cable. Each line of the RCA cable is typically terminated on either end with an RCA plug.
In a typical conjoined cable, the two or more individual lines are generally connected via an outer jacket of the conjoined cable. For example, a single outer jacket can be extruded around two individual lines in a conjoined cable with only a relatively thin webbing of jacket material connecting the two individual lines to one another.
One difficulty with manufacturing a conjoined cable is achieving the proper tear resistance of the webbing. The tear resistance of the webbing is dictated by the type of material from which the webbing is formed, as well as the thickness of the webbing. For example, the webbing of a messengered coaxial cable should be wide enough that the coaxial cable will not inadvertently become separated from the messenger support wire, but not so wide that a cable technician is unable to easily tear a desired portion of the messenger support wire away from the coaxial cable to affix the messenger support wire to an anchor or bracket and to connect the coaxial cable to electronic equipment during equipment setup. In another example, the webbing of an RCA cable should be wide enough that none of the video, left audio, or right audio lines will become inadvertently separated from the other line(s) of the RCA cable, but not so wide that a user is unable to easily tear a desired portion of any line away from the other line(s) to insert the corresponding plug into a jack of audio or visual equipment during equipment setup. Forming the proper thickness of the webbing in a conjoined cable requires very careful process control, which can be expensive and time consuming.
Another difficulty with manufacturing a conjoined cable is dealing with the residual webbing remaining on each individual line of a conjoined cable after the individual lines have been torn apart at the webbing. For example, the residual webbing of a messengered coaxial cable can interfere with the termination of the coaxial cable. In particular, terminating the coaxial cable by attaching a connector to the coaxial cable generally requires that the outside jacket of the coaxial cable be round and smooth. Therefore, the residual webbing left over on the outside jacket may need to be cut or shaved off of the area to which the connector is to be attached. This cutting or shaving inherently risks cutting through the jacket and other internal layers of the coaxial cable, thus damaging the cable and degrading its performance. It addition, even without cutting all the way through the jacket, too much of the jacket may be shaved off of the connector area which can compromise the seal of the subsequently attached connector. Failing to remove excess residual webbing can likewise compromise the seal of the subsequently attached connector.
In general, example embodiments of the present invention relate to redundant webbing connecting two or more lines in a conjoined cable. The example redundant webbing disclosed herein has proper tear resistance such that the lines of the conjoined cable will not inadvertently become separated from one another but can easily be torn apart from one another by a technician during installation of the conjoined cable. The example redundant webbing disclosed herein enables proper tear resistance of the webbing to be achieved relatively easily. In addition, the example redundant webbing disclosed herein minimizes the amount of residual webbing remaining on each individual line of a conjoined cable after the individual lines have been torn apart at the webbing, which can facilitate termination of the individual lines of the conjoined cable.
In one example embodiment, a conjoined cable includes a first line, a second line, and an integral jacket. The integral jacket includes a first line sleeve surrounding the first line, a second line sleeve surrounding the second line, a first webbing connecting the first line sleeve to the second line sleeve, and a second webbing connecting the first line sleeve to the second line sleeve. The first and second line sleeves and the first and second webbings cooperate to define a passageway between the first and second lines.
In another example embodiment, a messengered coaxial cable includes a coaxial cable, a messenger support wire, and an integral jacket. The coaxial cable includes a center conductor configured to propagate a signal, a dielectric surrounding the center conductor, and an outer conductor surrounding the dielectric. The integral jacket includes a cable sleeve surrounding the coaxial cable, a wire sleeve surrounding the messenger support wire, a first webbing connecting the cable sleeve to the wire sleeve, and a second webbing connecting the cable sleeve to the wire sleeve. The cable sleeve, wire sleeve, and first and second webbings cooperate to define a passageway positioned between the coaxial cable and the messenger support wire.
In yet another example embodiment, an RCA cable includes first, second, and third lines and an integral jacket. The integral jacket includes a first line sleeve surrounding the first line, a second line sleeve surrounding the second line, a third line sleeve surrounding the third line, a first webbing connecting the first line sleeve to the second line sleeve, a second webbing connecting the first line sleeve to the second line sleeve, a third webbing connecting the second line sleeve to the third line sleeve, and a fourth webbing connecting the second line sleeve to the third line sleeve. The first and second line sleeves and the first and second webbings cooperate to define a first passageway between the first and second lines. The second and third line sleeves and the third and fourth webbings cooperate to define a second passageway between the third and fourth lines.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential characteristics of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Moreover, it is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
Aspects of example embodiments of the present invention will become apparent from the following detailed description of example embodiments given in conjunction with the accompanying drawings, in which:
Example embodiments of the present invention relate to redundant webbing connecting two or more cables or wires in a conjoined cable. In the following detailed description of some example embodiments, reference will now be made in detail to example embodiments of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Moreover, it is to be understood that the various embodiments of the invention, although different, are not necessarily mutually exclusive. For example, a particular feature, structure, or characteristic described in one embodiment may be included within other embodiments. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
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The center conductor 202 is positioned at the core of the example coaxial cable 200. The center conductor 202 is configured to carry a range of electrical current (amperes) as well as propagate an RF/electronic digital signal. In some example embodiments, the center conductor 202 is formed from solid copper, copper-clad aluminum (CCA), copper-clad steel (CCS), or silver-coated copper-clad steel (SCCCS), although other conductive materials are possible. For example, the center conductor 202 can be formed from any type of conductive metal or alloy. In addition, the center conductor 202 can be solid, hollow, stranded, corrugated, plated, or clad, for example.
The dielectric 204 surrounds the center conductor 202, and generally serves to support and insulate the center conductor 202 and the first conductive tape 206. Although not shown in the figures, a bonding agent, such as a polymer, can be employed to bond the dielectric 204 to the center conductor 202. In some example embodiments, the dielectric 204 can be, but is not limited to, taped, solid, or foamed polymer or fluoropolymer. For example, the dielectric 204 can be foamed polyethylene (PE).
The first conductive tape 206 surrounds the dielectric 204 and generally serves to minimize the ingress and egress of high frequency electromagnetic radiation to/from the center conductor 202. For example, in some applications, the first conductive tape 206 can shield against electromagnetic radiation with a frequency greater than or equal to about 50 MHz. The first conductive tape 206 is a laminate tape that can include, but is not limited to, the following layers: aluminum/polymer, bonding agent/aluminum/polymer, bonding agent/aluminum/polymer/aluminum, or aluminum/polymer/aluminum, for example. It is understood, however, that the discussion herein of tape is not limited to tape having any particular combinations of layers.
The first conductive braid 208 surrounds the first conductive tape 206. The first conductive braid 208 generally serves to minimize the ingress and egress of low frequency electromagnetic radiation to/from the center conductor 202. For example, in some applications, the first conductive braid 208 can shield against electromagnetic radiation with a frequency less than about 50 MHz. In addition, the first conductive braid 208 also serves to give structural support to, and thereby strengthen, the coaxial cable 200. The first conductive braid 208 can be formed from inter-woven, fine gauge aluminum or copper wires, such as 34 American wire gauge (AWG) wires, for example. It is understood, however, that the discussion herein of braid is not limited to braid formed from any particular type or size of wire.
The second conductive tape 210 surrounds the first conductive braid 208 and is identical in form and function to the first conductive tape 206. The second conductive braid 212 surrounds the second conductive tape 210 and is identical in form and function to the first conductive braid 208.
The messenger support wire 300 of the messengered coaxial cable 100 runs adjacent to and parallel to the coaxial cable 200. The messenger support wire 300 can be formed from any type of support material such as galvanized, carbon steel wire, for example. The messenger support wire 300 can provide support to the coaxial cable 200 in situations where the coaxial cable 200 aerially spans long distances, such as 75 feet or more.
The coaxial cable 200 and the messenger support wire 300 are surrounded by and connected together with an integral jacket 400. The jacket 400 surrounds the coaxial cable 200 and the messenger support wire 300, and generally serves to protect the internal components of the messengered coaxial cable 100 from external contaminants, such as dust, moisture, and oils, for example. In a typical embodiment, the jacket 400 also functions to limit the bending radius of the messengered coaxial cable 100 to prevent kinking, and functions to protect the messengered coaxial cable 100 (and its internal components) from being crushed or otherwise misshapen from an external force. The example jacket 400 can be formed from a variety of materials such as, but not limited to, polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), flame retardant polyvinyl chloride (flame retardant PVC), or some combination thereof.
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In some example embodiments, the passageways disclosed herein can be filled with a gas during cable formation. For example, a gas may be injected into the passageways, through a tip of the die for example, in order to prevent the passageways from collapsing while the corresponding integral jacket 400, 400′, or 400″ cools and hardens. This gas may be an inert gas such as helium, neon, argon, krypton, xenon, carbon dioxide, nitrogen, or some combination thereof. Alternatively, this cable formation step may be omitted altogether where the passageways are maintained using methods other than filling with a gas while the jacket 400, 400′, or 400″ is cooled and hardened.
Advantageously, each of the redundant webbing configurations 406, 406′, and 406″ is formed to have proper tear resistance such that the coaxial cable 200 and the messenger support wire 300 of the messengered coaxial cable 100 will not inadvertently become separated from one another, but can easily be torn apart from one another during installation of the messengered coaxial cable 100. The example redundant webbing configurations 406, 406′, and 406″ disclosed herein enable proper tear resistance of the webbing to be achieved relatively easily. In particular, the individual thicknesses of the redundant webbings can vary more than with single webbings. Thus, forming the individual thicknesses of the redundant webbings requires less careful process control than with single webbings, which can save expense and consume less time.
In addition, the example redundant webbing disclosed herein configurations 406, 406′, and 406″ reduce the amount of residual webbing remaining on the cable sleeve 402 of the coaxial cable 200 after the coaxial cable 200 has been torn apart at the webbing. This reduction in the amount of residual webbing can facilitate termination of the coaxial cable 200, with the connector 250 of
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The first, second, and third lines 600, 700, and 800 are surrounded by and connected together with the integral jacket 900. The jacket 900 surrounds the first, second, and third lines 600, 700, and 800, and generally serves to protect the internal components of the example RCA cable 500 from external contaminants, such as dust, moisture, and oils, for example. The jacket 900 also functions to limit the bending radius of the RCA cable 500 to prevent kinking, and functions to protect the RCA cable 500 (and its internal components) from being crushed or otherwise misshapen from an external force. The example jacket 900 can be formed from a variety of materials including any material or combination of materials listed above in connection with the jacket 400.
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Each of the redundant webbing configurations 908 and 910 is formed to have proper tear resistance such that the first, second, and third lines 600, 700, and 800 will not inadvertently become separated from one another, but can easily be torn apart from one another during installation of the RCA cable 500. The example redundant webbing configurations 908 and 910 disclosed herein enable proper tear resistance of the webbing to be achieved relatively easily. In particular, the individual thicknesses of the redundant webbings can vary more than with single webbings. Thus, forming the individual thicknesses of the redundant webbings requires less careful process control than with single webbings, which can save expense and consume less time.
Although the example embodiments are described in the context of a messengered coaxial cable and an RCA cable with three lines, it is understood that other conjoined cable configurations may likewise benefit from the redundant webbing disclosed herein. Further, various types of conjoined cable lines, such as coaxial cable, electrical lines, power lines, and fiber optic cable, may benefit from the redundant webbing disclosed herein. For example, any of the following conjoined cables can include redundant webbing: standard-shield messengered coaxial cable (where the outer conductor includes one braid layer and one tape layers) and tri-shield messengered cable (where the outer conductor includes one braid layer and two tape layers), dual coaxial cable (where two coaxial cables are combined into a single composite cable), coaxial/power cable (where a coaxial cable and an electrical power cable are combined into a single composite cable), coaxial/RCA cable (where a coaxial cable and an RCA cable are combined into a single composite cable), an RCA cable with only two lines (such as a right audio line and a left audio line) or more than three lines, or any combination thereof.
In addition, where a conjoined cable includes three or more lines combined into a single composite cable, one webbing configuration of the conjoined cable may be a non-redundant webbing configuration with only a single webbing, while one or more other webbing configurations of the conjoined cable may be redundant webbing configurations each having two or more webbings. Further, a single conjoined cable may include one redundant webbing configuration with a first number of redundant webbings and another redundant webbing configuration with a second different number of redundant webbings.
Also, although example embodiments are described in the context of conjoined cables with lines that run parallel to one another, it understood that conjoined cables with lines that twist around one another may likewise benefit from the redundant webbing disclosed herein. Further, although example embodiments are described in the context of conjoined cables with webbing that runs the entire length of the conjoined cables, it understood that conjoined cables with webbing that runs only periodically along the length of the conjoined cables may similarly benefit from the redundant webbing disclosed herein.
Further, although the tearing paths 413, 423, 437, 917, and 923 are disclosed in the Figures as being substantially tangential to the surrounding lines, it is understood that the respective webbings can instead be shaped such that they tend to tear along a path that is not tangential to the surrounding lines. Further, it is understood that the angle between the tearing paths 413, 423, 437, 917, and 923 and the surrounding lines may be uniform or may vary along the length of the respective conjoined cables. Also, although the tearing paths 423 and 437 are disclosed in
Also, although the passageways 412, 420, 422, 432, 434, 436, 916, and 922 are each disclosed in the Figures as having a substantially oval-shaped cross section, it is understood that any of these passageways can instead have a cross-section with a variety of other shapes such as triangular, square, rectangular, circular, or diamond-shaped. Further, it is understood that passageways with cross-sections having well-defined corners, such as squares or diamonds, may help contribute to a well-defined tearing path in the surrounding webbings. Accordingly, the disclosure of passageways defined between webbings herein is not limited to the example oval-shaped cross section disclosed in the Figures.
The example embodiments disclosed herein may be embodied in other specific forms. The example embodiments disclosed herein are to be considered in all respects only as illustrative and not restrictive.