Technical Field

The present disclosure relates generally to flat electrical cables.

Background

Electrical cables for transmission of electrical signals are well known. One common type of electrical cable is a coaxial cable. Coaxial cables generally include an electrically conductive wire surrounded by an insulator. The wire and insulator are surrounded by a shield, and the wire, insulator, and shield are surrounded by a jacket. Another common type of electrical cable is a shielded electrical cable comprising one or more insulated signal conductors surrounded by a shielding layer formed, for example, by a metal foil. To facilitate electrical connection of the shielding layer, a further un- insulated conductor is sometimes provided between the shielding layer and the insulation of the signal conductor or conductors. Both these common types of electrical cable normally require the use of specifically designed connectors for termination and are often not suitable for the use of mass-termination techniques, i.e., the simultaneous connection of a plurality of conductors to individual contact elements, such as, e.g., electrical contacts of an electrical connector or contact elements on a printed circuit board.

Summary

The disclosure generally relates to shielded electrical cables that form a shielded ribbon cable. In particular, individual conductor sets of electrical cables are shielded and affixed to at least one carrier film to form a shielded ribbon cable. In one aspect, the present disclosure provides a shielded ribbon cable that includes a plurality of conductor sets extending along a length of a first carrier film and being spaced apart from each other along a width of the first carrier film. Each of the plurality of conductor sets includes: at least two insulated conductors; and an electrically conductive shield surrounding the at least two insulated conductors, wherein each of the plurality of conductor sets is affixed to a first major surface of the first carrier film.

In another aspect, the present disclosure provides a shielded ribbon cable that includes a first carrier film and a second carrier film facing the first carrier film, the first and the second carrier films extending along a length of the shielded ribbon cable. The shielded ribbon cable further includes a plurality of conductor sets extending between the first and the second carrier films along the length of the shielded ribbon cable and spaced apart from each other along a width of the shielded ribbon cable. Each of the plurality of conductor sets includes: at least two insulated conductors; and an electrically conductive shield surrounding the at least two insulated conductors. The first and the second carrier films are pinched together between adjacent conductor sets such that each conductor set is separated from an adjacent conductor set.

In yet another aspect, the present disclosure provides a shielded ribbon cable that includes a plurality of conductor sets extending along a length of the shielded ribbon cable and spaced apart from each other along a width of the shielded ribbon cable. Each of the plurality of conductor sets includes: at least two insulated conductors; an electrically conductive shield surrounding the at least two insulated conductors; and a jacket surrounding each of the electrically conductive shields, wherein the jacket extends between adjacent conductor sets in a pinched region, such that each conductor set is separated from an adjacent conductor set.

The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The figures and the detailed description below more particularly exemplify illustrative embodiments.

Brief Description of the Drawings

Throughout the specification reference is made to the appended drawings, where like reference numerals designate like elements, and wherein:

FIG. 1 shows a perspective view of a twinaxial cable;

FIG. 2 shows a perspective view of a twinaxial cable;

FIGS. 3A-3C shows cross-sectional schematic views of shielded ribbon cables;

FIG. 4 shows a cross-sectional schematic view of a shielded ribbon cable; and

FIG. 5 shows a cross-sectional schematic view of a shielded ribbon cable.

The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

Detailed Description

As the number and speed of interconnected devices increases, electrical cables that carry signals between such devices need to be smaller and capable of carrying higher speed signals without unacceptable interference or crosstalk. Shielding is used in some electrical cables to reduce interactions between signals carried by neighboring conductors such as, for example, electrical cables described in co-pending U.S. Patent Application No. 61/378877 filed on August 31, 2010, entitled "Connector Arrangements for Electrical Cables" (Attorney Docket No.

66887US002), the entire disclosure of which is included herein. The described cables have a generally flat configuration, and include conductor sets that extend along a length of the cable, as well as electrical shielding films disposed on opposite sides of the cable. Pinched portions of the shielding films between adjacent conductor sets help to electrically isolate the conductor sets from each other. Many of the cables also include drain (i.e., drain and/or ground) wires that electrically connect to the shields, and extend along the length of the cable. The cable configurations described herein can help to simplify the conductor sets and drain wires, reduce the size of the cable connection sites, and/or provide opportunities for mass termination of the cable.

The present application provides several alternative enhancements to the generally flat electrical cables (e.g., ribbon cables) described above. The present application generally provides shielded ribbon cables, where a plurality of conductor sets can be disposed separated from each other on at least one carrier, to form the shielded ribbon cable. In some cases, the shielded ribbon cables include pinched portions that isolate adjacent conductor sets from each other. In one particular embodiment, the shielded ribbon cables include features that can facilitate bending and movement of the cable.

Each end of the shielded ribbon cable can be readily attached (i.e., terminated) to a printed circuit board (PCB) or paddle card. The shielded ribbon cables are not limited to pair-wise grouping of insulated wires, but the groups can be one, two, three or more insulated wires.

Additionally, optional drain and/or ground wires can be included in any desired location within the shielded ribbon cable.

FIG. 1 shows a perspective view of a twinaxial cable 100, according to one aspect of the disclosure. Twinaxial cable 100 has an optional electrically insulative jacket 160 surrounding a conductive shield 140 that is helically wrapped around a conductor set 105 and at least one optional ground/drain wire 130. The at least one optional ground/drain wire 130 is in electrical contact with the conductive shield 140, and can be positioned anywhere within the conductive shield 140. In one particular embodiment shown in FIG. 1, two optional ground/drain wires 130 can be positioned nested within the conductor set 105, although any desired number of ground/drain wires 130 can be positioned anywhere within conductive shield 140. Conductor set 105 includes a first central conductor 1 10 surrounded by a first insulator 1 15, and a second central conductor 120 surrounded by a second insulator 125. In some cases, an adhesive material can be disposed between the first and second insulators 1 15, 125, and the conductive shield 140. FIG. 2 shows a perspective view of a twinaxial cable 200, according to one aspect of the disclosure. Each of the elements 205-260 shown in FIG. 2 correspond to like -numbered elements 105-160 shown in FIG. 1, which have been described previously. For example, optional electrically insulative jacket 160 described with reference to FIG. 1 corresponds to optional electrically insulative jacket 260 shown in FIG. 2, and so on. Twinaxial cable 200 has a first conductive shield 240 that is longitudinally wrapped around a conductor set 205 and at least one optional ground/drain wire 230 such that an overlap joint 245 is disposed parallel to a length direction 201 of the twinaxial cable 200. A second conductive shield 250 is helically wrapped around the first conductive shield 240, and an optional electrically insulative jacket 260 surrounds the second conductive shield 250. The at least one optional ground/drain wire 230 is in electrical contact with at least one of the first conductive shield 240 and the second conductive shield 250, and may be in contact with both of them. The at least one optional ground/drain wire 230 and can be positioned anywhere within the first and/or second conductive shield 240, 250. In one particular embodiment shown in FIG. 2, two optional ground/drain wires 230 can be positioned nested within the conductor set 205, although any desired number of ground/drain wires 230 can be positioned anywhere within first and/or second conductive shield 240, 250. Conductor set 205 includes a first central conductor 210 surrounded by a first insulator 215, and a second central conductor 220 surrounded by a second insulator 225.

In some cases, the longitudinal folding may mitigate the signal attenuation due to resonance by avoiding the periodicity of the shield gaps caused by helically wrapping the shield, however the overwrapping to prevent shield separation increases the shield stiffness, as described, for example, in co-pending U.S. Patent Application No. 61/378877 filed on August 31, 2010, entitled "Connector Arrangements for Electrical Cables" (Attorney Docket No. 66887US002).

In one particular embodiment, at least one of the conductor set 105, 205 includes two insulated conductors as shown in FIGS. 1 and 2 (i.e., a "twinaxial" cable); however, in some cases, any number of insulated conductors can be included in the conductor set, for example, 1, 2, 3, 4, or even 5 or more insulated conductors can be included in the conductor set. In some cases, uninsulated conductors can be included in the conductor set, for example, any number of optional grounding and/or drain wires 130, 230, can be disposed adjacent to the conductor set in several locations.

The conductors and/or ground wires may comprise any suitable conductive material and may have a variety of cross sectional shapes and sizes. For example, in cross section, the conductors and/or ground or drain wires may be circular, oval, rectangular or any other shape. One or more conductors and/or ground or drain wires in a cable may have one shape and/or size that differs from other one or more conductors and/or ground wires in the cable. The conductors and/or ground or drain wires may be solid or stranded wires. All of the conductors and/or ground or drain wires in a cable may be stranded, all may be solid, or some may be stranded and some solid. Stranded conductors and/or ground or drain wires may take on different sizes and/or shapes. The connectors and/or ground or drain wires may be coated or plated with various metals and/or metallic materials, including gold, silver, tin, and/or other materials.

The material used to insulate the conductors of the conductor sets may be any suitable material that achieves the desired electrical properties of the cable. In some cases, the insulation used may be a foamed insulation which includes air to reduce the dielectric constant and the overall thickness of the cable.

One or more of the conductive shields 140, 240, 250, may be conductive shielding films that may include a conductive layer and a non-conductive polymeric layer. The shielding films may have a thickness in the range of 0.01 mm to 0.05 mm and the overall thickness of the cable may be less than 2 mm or less than 1 mm. In some cases, one or both of the conductive shielding films may include multiple conductor layers separated by multiple non-conductive polymeric layers such as those described in, for example, U.S. Patent Application No. US2010/0300744 (Romanko et al.), the entire disclosure of which is included herein. The conductive layer may include any suitable conductive material, including but not limited to copper, silver, aluminum, gold, and alloys thereof.

The non-conductive polymeric layer may include any suitable polymeric material, including but not limited to polyester, polyimide, polyamide-imide, polytetrafluoroethylene, polypropylene, polyethylene, polyphenylene sulfide, polyethylene naphthalate, polycarbonate, silicone rubber, ethylene propylene diene rubber, polyurethane, acrylates, silicones, natural rubber, epoxies, and synthetic rubber adhesive. The non-conductive polymeric layer may include one or more additives and/or fillers to provide properties suitable for the intended application. In another aspect, at least one of the shielding films may include a laminating adhesive layer disposed between the conductive layer and the non-conductive polymeric layer. For shielding films that have a conductive layer disposed on a non-conductive layer, or that otherwise have one major exterior surface that is electrically conductive and an opposite major exterior surface that is substantially non-conductive, the shielding film may be incorporated into the shielded cable in several different orientations as desired. In some cases, for example, the conductive surface may face the conductor sets of insulated wires and ground wires, and in some cases the non-conductive surface may face those components. In cases where two shielding films are used, the films may be oriented such that their conductive surfaces face each other and each face the conductor sets and ground wires, or they may be oriented such that their non- conductive surfaces face each other and each face the conductor sets and ground wires, or they may be oriented such that the conductive surface of one shielding film faces the conductor sets and ground wires, while the non-conductive surface of the other shielding film faces conductor sets and ground wires from the other side of the cable.

In some cases, at least one of the shielding films may include a stand-alone conductive film, such as a compliant or flexible metal foil. The construction of the shielding films may be selected based on a number of design parameters suitable for the intended application, such as, e.g., flexibility, electrical performance, and configuration of the shielded electrical cable (such as, e.g., presence and location of ground conductors). In some cases, the shielding films have an integrally formed construction. In some cases, the shielding films may have a thickness in the range of 0.01 mm to 0.05 mm. The shielding films desirably provide isolation and shielding, and allow for a more automated and lower cost cable manufacturing process. In addition, the shielding films can help prevent a phenomenon known as "signal suck-out" or resonance, whereby high signal attenuation occurs at a particular frequency range. This phenomenon can occur in conventional shielded electrical cables where a conductive shield is wrapped around a conductor set.

FIG. 3 A shows a cross-sectional schematic view of a shielded ribbon cable 300 according to one aspect of the disclosure. Each of the elements 300a-360a and 300b-360b shown in FIG. 3A correspond to like-numbered elements 100- 160 shown in FIG. 1 , which have been described previously. For example, optional electrically insulative jacket 160 described with reference to FIG. 1 corresponds to optional electrically insulative jacket 360a and 360b, shown in FIG. 3, and so on.

In FIG. 3 A, shielded ribbon cable 300 includes a first twinaxial cable 300a and a second twinaxial cable 300b spaced apart from each other by a separation "D" along a width of a first carrier film 375. First carrier film 375 and first and second twinaxial cables 300a, 300b, also extend along a length that is perpendicular to the cross-sectional view shown in FIG. 3A. The first twinaxial cable 300a includes an optional electrically insulative jacket 360a surrounding a conductive shield 340a that is wrapped around a conductor set 305a and at least one optional ground/drain wire 330a. The at least one optional ground/drain wire 330a is in electrical contact with the conductive shield 340a, and can be positioned as described elsewhere. Conductor set 305a includes a first central conductor 310a surrounded by a first insulator 315a and a second central conductor 320a surrounded by a second insulator 325a. In a similar fashion, the second twinaxial cable 300b includes an optional electrically insulative jacket 360b surrounding a conductive shield 340b that is wrapped around a conductor set 305b and at least one optional ground/drain wire 330b. The at least one optional ground/drain wire 330b is in electrical contact with the conductive shield 340b, and can be positioned as described elsewhere. Conductor set 305b includes a first central conductor 310b surrounded by a first insulator 315b and a second central conductor 320b surrounded by a second insulator 325b. At least one of the conductive shields 340a, 340b can be a helically wrapped conductive shield, a longitudinally wrapped conductive shield, or any combination of helically wrapped conductive shields and longitudinally wrapped conductive shields, as described elsewhere.

Each of the first twinaxial cable 300a and the second twinaxial cable 300b can be disposed spaced apart from each other by any separation "D", such as in immediate contact (i.e., touching each other), or spaced by any desired distance, as described elsewhere. The first twinaxial cable 300a and the second twinaxial cable 300b, respectively, can be affixed to a first major surface 377 of the first carrier film 375 in a first affixed region 370a and a second affixed region 370b by any suitable technique including, for example, using an adhesive including solvent-based adhesives; thermally curable adhesives; radiation curable adhesives; hot-melt adhesives; thermally bonding including melting at the interface using ultrasonic or thermal energy; or any combination thereof.

If present (as shown), the optional electrically insulative jackets 360a, 360b of the first twinaxial cable 300a and the second twinaxial cable 300b, respectively, can be affixed to a first major surface 377 of the first carrier film 375 in the first affixed region 370a and the second affixed region 370b by any of the same techniques listed above. In some cases, each of the optional electrically insulative jackets 360a, 360b, and the first carrier film 375 can be formed at the same time and out of the same material, so that the material is continuous throughout each.

In one particular embodiment, the carrier films may include any suitable polymeric material, including but not limited to polyester, polyimide, polyamide-imide,

polytetrafluoroethylene, polypropylene, polyethylene, polyphenylene sulfide, polyethylene naphthalate, polycarbonate, silicone rubber, ethylene propylene diene rubber, polyurethane, acrylates, silicones, natural rubber, epoxies, and synthetic rubbers. The carrier film may also include one or more additives and/or fillers to provide properties suitable for the intended application, as known to one of skill in the art. In one particular embodiment, the carrier film may be an electrically conductive film, such as the electrically conductive films that are suitable for the shielding layers.

FIG. 3B shows a cross-sectional schematic view of a shielded ribbon cable 301 according to one aspect of the disclosure. Each of the elements 300a-360a and 300b-360b shown in FIG. 3B correspond to like-numbered elements 100- 160 shown in FIG. 1 , which have been described previously. For example, optional electrically insulative jacket 160 described with reference to FIG. 1 corresponds to optional electrically insulative jacket 360a and 360b, shown in FIG. 3B, and so on.

In FIG. 3B, shielded ribbon cable 301 includes a first twinaxial cable 300a and a second twinaxial cable 300b spaced apart from each other by a separation "D" along a width of a first carrier film 375. In this particular embodiment, the separation "D" is sufficient to permit the insertion of at least an additional twinaxial cable (not shown) between the first twinaxial cable 300a and the second twinaxial cable 300b. First carrier film 375 and first and second twinaxial cables 300a, 300b, also extend along a length that is perpendicular to the cross-sectional view shown in FIG. 3B. The first twinaxial cable 300a includes an optional electrically insulative jacket 360a surrounding a conductive shield 340a that is wrapped around a conductor set 305a and at least one optional ground/drain wire 330a. The at least one optional ground/drain wire 330a is in electrical contact with the conductive shield 340a, and can be positioned as described elsewhere. Conductor set 305a includes a first central conductor 310a surrounded by a first insulator 315a and a second central conductor 320a surrounded by a second insulator 325a.

In a similar fashion, the second twinaxial cable 300b includes an optional electrically insulative jacket 360b surrounding a conductive shield 340b that is wrapped around a conductor set 305b and at least one optional ground/drain wire 330b. The at least one optional ground/drain wire 330b is in electrical contact with the conductive shield 340b, and can be positioned as described elsewhere. Conductor set 305b includes a first central conductor 310b surrounded by a first insulator 315b and a second central conductor 320b surrounded by a second insulator 325b. At least one of the conductive shields 340a, 340b can be a helically wrapped conductive shield, a longitudinally wrapped conductive shield, or any combination of helically wrapped conductive shields and longitudinally wrapped conductive shields, as described elsewhere.

The first twinaxial cable 300a and the second twinaxial cable 300b, respectively, can be affixed to a first major surface 377 of the first carrier film 375 in a first affixed region 370a and a second affixed region 370b by any suitable technique including, for example, using an adhesive including solvent-based adhesives; thermally curable adhesives; radiation curable adhesives; hot- melt adhesives; thermally bonding including melting at the interface using ultrasonic or thermal energy; or any combination thereof.

If present (as shown), the optional electrically insulative jackets 360a, 360b of the first twinaxial cable 300a and the second twinaxial cable 300b, respectively, can be affixed to the first major surface 377 of the first carrier film 375 in the first affixed region 370a and the second affixed region 370b by any of the same techniques listed above. In some cases, each of the optional electrically insulative jackets 360a, 360b, and the first carrier film 375 can be formed at the same time and out of the same material, so that the material is continuous throughout each.

FIG. 3C shows a cross-sectional schematic view of a nested shielded ribbon cable 302 according to one aspect of the disclosure. Each of the elements 300a-360a and 300b-360b shown in FIG. 3C correspond to like-numbered elements 100-160 shown in FIG. 1, which have been described previously. For example, optional electrically insulative jacket 160 described with reference to FIG. 1 corresponds to optional electrically insulative jacket 360a and 360b, shown in FIG. 3C, and so on. Nested shielded ribbon cable 302 can provide for a compact technique to accommodate high-density cable connections, for example, those described in co-pending U.S. Patent Application No. 61/494055 filed on June 7, 2011, entitled "Nested Shielded Ribbon Cables" (Attorney Docket No. 67426US002).

In FIG. 3C, the shielded ribbon cable 301 as described in FIG. 3B includes an insertion of a third twinaxial cable 300c between the first twinaxial cable 300a and the second twinaxial cable 300b. The third twinaxial cable 300c is affixed to a second major surface 378 of a second carrier film 376 in a third affixed region 370C. The first carrier film 375 and the second carrier film 376 can be the same material, or they can be different materials, and each of the first and second carrier films 375, 376, can extend in both the width and length directions as far as desired, and can also include as many twinaxial cables as desired.

FIG. 4 shows a cross-sectional schematic view of a shielded ribbon cable 400 according to one aspect of the disclosure. Each of the elements 400a-460a and 400b-460b shown in FIG. 4 correspond to like-numbered elements 100- 160 shown in FIG. 1 , which have been described previously. For example, optional electrically insulative jacket 160 described with reference to FIG. 1 corresponds to optional electrically insulative jacket 460a and 460b, shown in FIG. 4, and so on.

In FIG. 4, shielded ribbon cable 400 includes a first twinaxial cable 400a and a second twinaxial cable 400b spaced apart from each other by a separation "D" along a width of a first carrier film 475 and a second carrier film 476. In one particular embodiment, first carrier film 475 and second carrier film 476 can be parallel to and facing each other as shown in FIG. 4. First and second carrier films 475, 476, and first and second twinaxial cables 400a, 400b, also extend along a length that is perpendicular to the cross-sectional view shown in FIG. 4. The first twinaxial cable 400a includes an optional electrically insulative jacket 460a surrounding a conductive shield 440a that is wrapped around a conductor set 405a and at least one optional ground/drain wire 430a. The at least one optional ground/drain wire 430a is in electrical contact with the conductive shield 440a, and can be positioned as described elsewhere. Conductor set 405a includes a first central conductor 410a surrounded by a first insulator 415a and a second central conductor 420a surrounded by a second insulator 425a.

In a similar fashion, the second twinaxial cable 400b includes an optional electrically insulative jacket 460b surrounding a conductive shield 440b that is wrapped around a conductor set 405b and at least one optional ground/drain wire 430b. The at least one optional ground/drain wire 430b is in electrical contact with the conductive shield 440b, and can be positioned as described elsewhere. Conductor set 405b includes a first central conductor 410b surrounded by a first insulator 415b and a second central conductor 420b surrounded by a second insulator 425b. At least one of the conductive shields 440a, 440b can be a helically wrapped conductive shield, a longitudinally wrapped conductive shield, or any combination of helically wrapped conductive shields and longitudinally wrapped conductive shields, as described elsewhere.

The first twinaxial cable 400a and the second twinaxial cable 400b, respectively, can be affixed to a first major surface 477 of the first carrier film 475 in a first affixed region 470a and a second affixed region 470b. The first twinaxial cable 400a and the second twinaxial cable 400b, respectively, can also be affixed to a second major surface 478 of the second carrier film 476 in a third affixed region 471a and a fourth affixed region 471b. The first twinaxial cable 400a and the second twinaxial cable 400b can be affixed thereto by any suitable technique including, for example, using an adhesive including solvent-based adhesives; thermally curable adhesives; radiation curable adhesives; hot-melt adhesives; thermally bonding including melting at the interface using ultrasonic or thermal energy; or any combination thereof.

If present (as shown), the optional electrically insulative jackets 460a, 460b of the first twinaxial cable 400a and the second twinaxial cable 400b, respectively, can be affixed to the first major surface 477 of the first carrier film 475 in a first affixed region 470a and the second affixed region 470b by any of the same techniques listed above. In some cases, each of the optional electrically insulative jackets 460a, 460b, and the first and second carrier films 475, 476, can be formed at the same time and out of the same material, so that the material is continuous throughout each.

FIG. 5 shows a cross-sectional schematic view of a shielded ribbon cable 500 according to one aspect of the disclosure. Each of the elements 500a-540a and 500b-540b shown in FIG. 5 correspond to like-numbered elements 100-140 shown in FIG. 1, which have been described previously. For example, conductive shield 140 described with reference to FIG. 1 corresponds to conductive shield 540a and 540b, shown in FIG. 5, and so on. In FIG. 5, a first carrier film 575 and a second carrier film 576 are pinched together in a pinched region 580, such that the optional electrically insulative jackets (e.g., elements numbered 160, 260a, 260b, 360a, 360b, 360c, 460a, 460b in FIGS. 1-4) are formed from the first and second carrier films 575, 576. Shielded ribbon cable 500 includes a first twinaxial cable 500a and a second twinaxial cable 500b spaced apart from each other by a separation "D" formed by a pinched region 580, along a width of a first carrier film 575 and a second carrier film 576. First and second carrier films 575, 576, and first and second twinaxial cables 500a, 500b, also extend along a length that is perpendicular to the cross-sectional view shown in FIG. 5. The first twinaxial cable 500a includes a conductive shield 540a that is wrapped around a conductor set 505a and at least optional one ground/drain wire 530a. The at least one optional ground/drain wire 530a is in electrical contact with the conductive shield 540a, and can be positioned as described elsewhere. Conductor set 505a includes a first central conductor 510a surrounded by a first insulator 515a and a second central conductor 520a surrounded by a second insulator 525a.

In a similar fashion, the second twinaxial cable 500b includes a conductive shield 540b that is wrapped around a conductor set 505b and at least one ground/drain wire 530b. The at least one ground/drain wire 530b is in electrical contact with the conductive shield 540b and can be positioned as described elsewhere. Conductor set 505b includes a first central conductor 510b surrounded by a first insulator 515b and a second central conductor 520b surrounded by a second insulator 525b. At least one of the conductive shields 540a, 540b can be a helically wrapped conductive shield, a longitudinally wrapped conductive shield, or any combination of helically wrapped conductive shields and longitudinally wrapped conductive shields, as described elsewhere.

In one particular embodiment (not shown) an optional electrically insulative jacket can surround each of the conductive shields 540a, 540b of the first twinaxial cable 400a and the second twinaxial cable 400b, respectively, as shown and described in FIGS. 1-4, and the first and second carrier films 575, 576 can surround the optional electrically insulative jackets and form the pinched regions 580. In one particular embodiment shown in FIG. 5, the optional electrically insulative jackets are instead formed directly from the first and second carrier films 575,576 that form pinched regions 580. The first and second carrier films 575, 576 can be affixed in the pinched regions 580 by any suitable technique including, for example, using an adhesive including solvent-based adhesives; thermally curable adhesives; radiation curable adhesives; hot-melt adhesives; thermally bonding including melting at the interface using ultrasonic or thermal energy; or any combination thereof. Although in the embodiments illustrated in FIGS. 3A-5, each conductor set has either one or two insulated conductors, in other embodiments, some of the conductor sets may include only one insulated conductor, or may include more than two insulated conductors. This flexibility in arrangements of conductor sets and insulated conductors allows the disclosed shielded ribbon cables to be configured in ways that are suitable for a wide variety of intended applications. For example, the conductor sets and insulated conductors may be configured to form: a multiple twinaxial cable, i.e., multiple conductor sets each having two insulated conductors; a multiple coaxial cable, i.e., multiple conductor sets each having only one insulated conductor; or combinations thereof.

In some embodiments, the above described shielded ribbon cables may further include additional non-insulated conductors that can be used to provide a common electrical contact (such as a ground) to each of the insulated conductor sets, for example, a conductor placed in electrical contact with and outer layer of a shielded conductor. In some cases, for example as shown in FIG. 4, a non-insulated conductor (not shown) can be placed in the region denoted by the separation "D", such that electrical contact can be made with each of the first and second conductive shields 440a, 440b. In cases where each of the first and second conductive shields 440a, 440b are fabricated from multilayer conductive films such that the outer conductive layer is electrically insulated from the inner conductive layer, as described elsewhere, this non-insulated conductor can provide additional advantages to preservation of satisfactory signals.

As discussed elsewhere herein, adhesive material may be used in the cable construction to bond one or two shielding films to one, some, or all of the conductor sets of the cable, and/or adhesive material may be used to bond conductive shields to the carrier films, or to bond optional electrically insulative jackets to the carrier films, and/or to bond two carrier films together at pinched regions of the cable. A layer of adhesive material may be disposed on at least one shielding film, and in cases where two shielding films are used, a layer of adhesive material may be disposed on both shielding films. In the latter cases, the adhesive used on one shielding film is preferably the same as, but may if desired be different from, the adhesive used on the other shielding film. A given adhesive layer may include an electrically insulative adhesive, and may provide an insulative bond between two shielding films. Furthermore, a given adhesive layer may provide an insulative bond between at least one of shielding films and insulated conductors of one, some, or all of the conductor sets, and between at least one of shielding films and one, some, or all of the ground conductors (if any). Alternatively, a given adhesive layer may include an electrically conductive adhesive, and may provide a conductive bond between two shielding films. Furthermore, a given adhesive layer may provide a conductive bond between at least one of shielding films and one, some, or all of the ground conductors (if any). Suitable conductive adhesives include conductive particles to provide the flow of electrical current. The conductive particles can be any of the types of particles currently used, such as spheres, flakes, rods, cubes, amorphous, or other particle shapes. They may be solid or substantially solid particles such as carbon black, carbon fibers, nickel spheres, nickel coated copper spheres, metal-coated oxides, metal-coated polymer fibers, or other similar conductive particles. These conductive particles can be made from electrically insulating materials that are plated or coated with a conductive material such as silver, aluminum, nickel, or indium tin-oxide. The metal-coated insulating material can be substantially hollow particles such as hollow glass spheres, or may comprise solid materials such as glass beads or metal oxides. The conductive particles may be on the order of several tens of microns to nanometer sized materials such as carbon nanotubes. Suitable conductive adhesives may also include a conductive polymeric matrix.

When used in a given cable construction, an adhesive layer is preferably substantially conformable in shape relative to other elements of the cable, and conformable with regard to bending motions of the cable. In some cases, a given adhesive layer may be substantially continuous, e.g., extending along substantially the entire length and width of a given major surface of a given shielding film. In some cases, the adhesive layer may include be substantially discontinuous. For example, the adhesive layer may be present only in some portions along the length or width of a given shielding film. A discontinuous adhesive layer may for example include a plurality of longitudinal adhesive stripes that are disposed, e.g., between the pinched portions of the shielding films on both sides of each conductor set and between the shielding films beside the ground conductors (if any). A given adhesive material may be or include at least one of a pressure sensitive adhesive, a hot melt adhesive, a thermoset adhesive, and a curable adhesive. An adhesive layer may be configured to provide a bond between shielding films that is substantially stronger than a bond between one or more insulated conductor and the shielding films. This may be achieved, e.g., by appropriate selection of the adhesive formulation. An advantage of this adhesive configuration is to allow the shielding films to be readily strippable from the insulation of insulated conductors. In other cases, an adhesive layer may be configured to provide a bond between shielding films and a bond between one or more insulated conductor and the shielding films that are substantially equally strong. An advantage of this adhesive configuration is that the insulated conductors are anchored between the shielding films. When a shielded electrical cable having this construction is bent, this allows for little relative movement and therefore reduces the likelihood of buckling of the shielding films. Suitable bond strengths may be chosen based on the intended application. In some cases, a conformable adhesive layer may be used that has a thickness of less than about 0.13 mm. In exemplary embodiments, the adhesive layer has a thickness of less than about 0.05 mm.

A given adhesive layer may conform to achieve desired mechanical and electrical performance characteristics of the shielded electrical cable. For example, the adhesive layer may conform to be thinner between the shielding films in areas between conductor sets, which increases at least the lateral flexibility of the shielded cable. This may allow the shielded cable to be placed more easily into a curvilinear outer jacket. In some cases, an adhesive layer may conform to be thicker in areas immediately adjacent the conductor sets and substantially conform to the conductor sets. This may increase the mechanical strength and enable forming a curvilinear shape of shielding films in these areas, which may increase the durability of the shielded cable, for example, during flexing of the cable. In addition, this may help to maintain the position and spacing of the insulated conductors relative to the shielding films along the length of the shielded cable, which may result in more uniform impedance and superior signal integrity of the shielded cable.

A given adhesive layer may conform to effectively be partially or completely removed between the carrier films in areas between conductor sets. In some cases, an adhesive layer may conform to effectively be partially or completely removed between at least one of the shielding films and the ground conductors. As a result, the ground conductors may electrically contact at least one of shielding films in these areas, which may increase the electrical performance of the cable. Even in cases where a thin layer of adhesive remains between at least one of shielding films and a given ground conductor, asperities on the ground conductor may break through the thin adhesive layer to establish electrical contact as intended.

Following are a list of embodiments of the present disclosure.

Item 1 is a shielded ribbon cable comprising a plurality of conductor sets extending along a length of a first carrier film and being spaced apart from each other along a width of the first carrier film, each of the plurality of conductor sets comprising: at least two insulated conductors; and an electrically conductive shield surrounding the at least two insulated conductors, wherein each of the plurality of conductor sets is affixed to a first major surface of the first carrier film.

Item 2 is the shielded ribbon cable of item 1, further comprising at least one drain wire parallel to the at least two insulated conductors, wherein the electrically conductive shield is in electrical contact with the at least one drain wire.

Item 3 is the shielded ribbon cable of item 1 or item 2, wherein the electrically conductive shield comprises a metallic film. Item 4 is the shielded ribbon cable of item 1 to item 3, wherein the electrically conductive shield comprises an electrically conductive multilayer film.

Item 5 is the shielded ribbon cable of item 4, wherein the electrically conductive multilayer film comprises an insulator disposed between at least two electrically conductive layers.

Item 6 is the shielded ribbon cable of item 2 to item 5, wherein the at least one drain wire is in contact with a first conductive layer of the electrically conductive shield, and at least one ground wire is in contact with a second conductive layer of the electrically conductive shield.

Item 7 is the shielded ribbon cable of item 1 to item 6, wherein the electrically conductive shield is wrapped helically around the at least two insulated conductors.

Item 8 is the shielded ribbon cable of item 1 to item 7, wherein the electrically conductive shield is wrapped around the length of the conductor sets such that the electrically conductive shield forms an overlapped region parallel to the length of the first carrier film.

Item 9 is the shielded ribbon cable of item 1 to item 8, further comprising a second carrier film disposed parallel to and facing the first carrier film, such that each electrically insulative jacket is affixed to a second major surface of the second carrier film.

Item 10 is the shielded ribbon cable of item 9, wherein the first and the second carrier films are pinched together between adjacent conductor sets such that each conductor set is separated from an adjacent conductor set.

Item 1 1 is the shielded ribbon cable of item 1 to item 10, wherein the first carrier film is an electrically non-conductive carrier film.

Item 12 is the shielded ribbon cable of item 1 to item 1 1, wherein the first carrier film is an electrically conductive carrier film in contact with an electrical ground.

Item 13 is the shielded ribbon cable of item 1 to item 12, further comprising an electrically insulating jacket surrounding the electrically conductive shield.

Item 14 is a shielded ribbon cable, comprising: a first carrier film and a second carrier film facing the first carrier film, the first and the second carrier films extending along a length of the shielded ribbon cable; a plurality of conductor sets extending between the first and the second carrier films along the length of the shielded ribbon cable and spaced apart from each other along a width of the shielded ribbon cable, each of the plurality of conductor sets comprising: at least two insulated conductors; and an electrically conductive shield surrounding the at least two insulated conductors; wherein the first and the second carrier films are pinched together between adjacent conductor sets such that each conductor set is separated from an adjacent conductor set. Item 15 is the shielded ribbon cable of item 14, further comprising at least one drain wire parallel to the at least two insulated conductors, wherein the electrically conductive shield is in electrical contact with the at least one drain wire.

Item 16 is the shielded ribbon cable of item 14 or item 15, wherein the electrically conductive shield comprises a metallic film.

Item 17 is the shielded ribbon cable of item 14 to item 16, wherein the electrically conductive shield comprises an electrically conductive multilayer film.

Item 18 is the shielded ribbon cable of item 16 or item 17, wherein the electrically conductive multilayer film comprises an insulator disposed between at least two electrically conductive layers.

Item 19 is the shielded ribbon cable of item 15 to item 18, wherein the at least one drain wire is in contact with a first conductive layer of the electrically conductive shield, and at least one ground wire is in contact with a second conductive layer of the electrically conductive shield.

Item 20 is the shielded ribbon cable of item 14 to item 19, wherein the electrically conductive shield is wrapped helically around the at least two insulated conductors.

Item 21 is the shielded ribbon cable of item 14 to item 20, wherein the electrically conductive shield is wrapped around the length of the conductor set such that the electrically conductive shield forms an overlapped region parallel to the length of the shielded ribbon cable.

Item 22 is the shielded ribbon cable of item 14 to item 21, wherein at least one of the first and the second carrier films is an electrically non-conductive carrier film.

Item 23 is the shielded ribbon cable of item 14 to item 22, wherein at least one of the first and the second carrier films is an electrically conductive carrier film in contact with an electrical ground.

Item 24 is a shielded ribbon cable, comprising: a plurality of conductor sets extending along a length of the shielded ribbon cable and spaced apart from each other along a width of the shielded ribbon cable, each of the plurality of conductor sets comprising: at least two insulated conductors; an electrically conductive shield surrounding the at least two insulated conductors; and a jacket surrounding each of the electrically conductive shields, wherein the jacket extends between adjacent conductor sets in a pinched region, such that each conductor set is separated from an adjacent conductor set.

Item 25 is the shielded ribbon cable of item 24, further comprising at least one drain wire parallel to the at least two insulated conductors, wherein the electrically conductive shield is in electrical contact with the at least one drain wire. Item 26 is the shielded ribbon cable of item 24 or item 25, wherein the jacket comprises a first and a second carrier film affixed together at the pinched region.

Item 27 is the shielded ribbon cable of item 26, wherein affixed together comprises adhered together with an adhesive layer or fused together without the adhesive layer.

Item 28 is the shielded ribbon cable of item 24 to item 27, wherein the electrically conductive shield comprises a metallic film.

Item 29 is the shielded ribbon cable of item 24 to item 28, wherein the electrically conductive shield comprises an electrically conductive multilayer film.

Item 30 is the shielded ribbon cable of item 29, wherein the electrically conductive multilayer film comprises an insulator disposed between at least two electrically conductive layers.

Item 31 is the shielded ribbon cable of item 25 to item 30, wherein the at least one drain wire is in contact with a first conductive layer of the electrically conductive shield, and at least one ground wire is in contact with a second conductive layer of the electrically conductive shield.

Item 32 is the shielded ribbon cable of item 24 to item 31, wherein the electrically conductive shield is wrapped helically around the at least two insulated conductors.

Item 33 is the shielded ribbon cable of item 24 to item 32, wherein the electrically conductive shield is wrapped around the length of the conductor set such that the electrically conductive shield forms an overlapped region parallel to the length of the shielded ribbon cable.

Item 34 is the shielded ribbon cable of item 24 to item 33, wherein at least one of the first and the second carrier films is an electrically non-conductive carrier film.

Item 35 is the shielded ribbon cable of item 24 to item 34, wherein at least one of the first and the second carrier films is an electrically conductive carrier film in contact with an electrical ground.

Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.