| CPC H01B 7/1805 (2013.01) [B60R 16/023 (2013.01); H01B 11/10 (2013.01); H01B 13/06 (2013.01)] | 20 Claims |
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1. A cable comprising:
a plurality of parallel conductors arranged about a length of the cable;
a dielectric core comprising:
a plurality of parallel channels located at opposite sides of the dielectric core, each parallel channel being configured to secure a corresponding conductor; and
an alignment structure having a shape for the length of the cable;
a cable jacket that surrounds the parallel conductors and the dielectric core, the cable jacket being contoured to follow the shape of the alignment structure;
a shielding layer that surrounds the cable jacket; and
an outer jacket being contoured to the shielding layer and the alignment structure surrounded by the cable jacket.
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13. A method comprising:
obtaining a plurality of parallel conductors that provide a length of a cable;
forming a dielectric core for the length of the cable including forming:
a plurality of parallel channels located at opposite sides of the dielectric core and configured to secure a corresponding conductor; and
an alignment structure having a shape for the length of the cable;
pressing each of the parallel conductors into the parallel channels to secure the corresponding conductor in each of the parallel channels; and
insulating the dielectric core and the parallel conductors by disposing a cable jacket along the length of the cable that is contoured to follow the shape of the alignment structure,
wherein forming the dielectric core comprises shaping a dielectric surface of the dielectric core for forming a partial opening to each of the parallel channels defined by opposing retention structures configured to deflect away from the dielectric core to allow a partial deformation in the dielectric surface within that channel and thereby cause a retention force from the retention structures that secures the corresponding conductor within the partial opening to that channel, and
wherein pressing the parallel conductors into the parallel channels comprises pressing exposed portions of the parallel conductors with an insertion force to deflect the retention structures away from the dielectric core such that the retention structures apply the retention force that secures the corresponding conductor within the partial opening to that channel.
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18. A method comprising:
obtaining a plurality of parallel conductors that provide a length of a cable;
forming a dielectric core for the length of the cable including forming:
a plurality of parallel channels located at opposite sides of the dielectric core and configured to secure a corresponding conductor; and
an alignment structure having a shape for the length of the cable;
pressing each of the parallel conductors into the parallel channels to secure the corresponding conductor in each of the parallel channels;
insulating the dielectric core and the parallel conductors by disposing a cable jacket along the length of the cable that is contoured to follow the shape of the alignment structure; and
forming a connection with the parallel conductors by coupling an exposed portion of each of the parallel conductors within a portion of the cable jacket to respective contacts of a connector attached to that portion of the cable jacket.
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19. A method comprising:
obtaining a plurality of parallel conductors that provide a length of a cable;
forming a dielectric core for the length of the cable including forming:
a plurality of parallel channels located at opposite sides of the dielectric core and configured to secure a corresponding conductor; and
an alignment structure having a shape for the length of the cable;
pressing each of the parallel conductors into the parallel channels to secure the corresponding conductor in each of the parallel channels;
insulating the dielectric core and the parallel conductors by disposing a cable jacket along the length of the cable that is contoured to follow the shape of the alignment structure; and
at least one of:
preparing the cable for a connection by striping the cable jacket along a portion of the cable jacket or cutting through that portion of the cable jacket to reveal an exposed portion of the parallel conductors in that portion of the cable jacket prior to physically coupling respective contacts of a connector to the exposed portion of the parallel conductors; or
maintaining insulation provided by the cable jacket along another portion of the cable jacket and attaching another connector to the other portion of the cable jacket by crimping through the other portion of the cable jacket up to the dielectric surface of the dielectric core to electrically couple respective contacts of another connector to other exposed portions of the parallel conductors that remain insulated under the cable jacket at the other portion of the cable jacket.
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20. A method comprising:
obtaining a plurality of parallel conductors that provide a length of a cable;
forming a dielectric core for the length of the cable including forming:
a plurality of parallel channels located at opposite sides of the dielectric core and configured to secure a corresponding conductor; and
an alignment structure having a shape for the length of the cable;
pressing each of the parallel conductors into the parallel channels to secure the corresponding conductor in each of the parallel channels;
insulating the dielectric core and the parallel conductors by disposing a cable jacket along the length of the cable that is contoured to follow the shape of the alignment structure;
disposing a shielding layer around the cable jacket; and
disposing an outer jacket being contoured to the shielding layer and the alignment structure surrounded by the cable jacket.
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