Abstract: A coaxial cable may include an inner conductor, an outer conductor and a dielectric material layer therebetween. The inner conductor may include a tubular bimetallic layer and may have a pair of opposing longitudinal edge portions at a longitudinal seam. The tubular bimetallic layer may include an inner metal layer and an outer metal layer bonded thereto and coextensive therewith. In addition, the opposing longitudinal edge portions may be angled inwardly to define a pair of adjacent inwardly extending tabs.

Abstract: A coaxial cable may include an inner conductor, an outer conductor, and a dielectric material layer therebetween. The inner conductor may include a tubular bimetallic layer having a pair of opposing longitudinal edges at a longitudinal seam. The tubular bimetallic layer may include an inner metal layer and an outer metal layer bonded thereto with the inner metal layer having a lower melting point than the outer layer. At least one of the opposing longitudinal edges of the tubular bimetallic layer may be at least partially bevelled. In addition, the longitudinal seam may include a welded joint between at least portions of the opposing longitudinal edges.

Abstract: The present invention is a flexible low loss coaxial cable comprising a cylindrical plastic rod, an inner conductor surrounding the plastic rod, a dielectric layer surrounding the inner conductor, and a tubular metallic sheath closely surrounding the dielectric layer. The coaxial cable can further include a protective polymer jacket surrounding the sheath. The cylindrical plastic rod supports the inner conductor in bending and can be formed around a central structural member. The present invention also includes a method of making flexible coaxial cable.

Abstract: A flexible low loss coaxial cable comprises a cylindrical plastic rod, an inner conductor surrounding the plastic rod, a dielectric layer surrounding the inner conductor, and a tubular metallic sheath closely surrounding the dielectric layer. The coaxial cable can further include a protective polymer jacket surrounding the sheath. The cylindrical plastic rod supports the inner conductor in bending and can be formed around a central structural member. The present invention also includes a method of making flexible coaxial cable.

Abstract: The communications system transmits both communications signals and electrical power to a plurality of subscribers. The communications signals can include video, voice and data signals. The communications system includes a coaxial drop cable for transmitting both the communications signals and electrical power from a cable tap to at least one subscriber of the communications system. The coaxial drop cable includes an annular outer conductor surrounding the dielectric material and having a mechanically and electrically continuous, non-overlapping tubular metallic shield. The coaxial drop cable has predetermined signal transmission characteristics, including enhanced shielding properties, which are maintained while the coaxial drop cable is flexed due, at least in part, to an increase in the stiffness of the dielectric material relative to the outer conductor.

Abstract: A method of making a flexible coaxial cable is provided. The method comprises advancing a cable core comprising a conductor and an expanded foam dielectric surrounding the conductor along a predetermined path of travel, directing an elongate strip of copper onto the advancing cable core and bending the copper strip into a generally cylindrical form so as to loosely encircle the core. Opposing longitudinal edges of the thus formed copper strip are then moved into abutting relation and a longitudinal weld is formed joining the abutting edges to thereby form an electrically and mechanically continuous tubular copper sheath loosely surrounding the cable core. The cable core and the surrounding sheath are simultaneously advanced while the tubular sheath is deformed into an oval configuration loosely surrounding the core. The longitudinal weld of the advancing sheath is then directed against a scarfing blade and weld flash from the sheath is scarfed from the sheath.

Abstract: A flexible coaxial cable includes a core including at least one inner conductor and a foam polymer dielectric surrounding the inner conductor. The flexible coaxial cable also includes an electrically and mechanically continuous tubular copper sheath closely surrounding the core and adhesively bonded to the core. A protective outer jacket surrounds the tubular metallic sheath and is adhesively bonded to the tubular metallic sheath to increase the bending properties of the cable. The bond peel strength of the adhesive bond between the polymer jacket and the sheath is no more than 36 lb./in to provide a coaxial cable having excellent bending characteristics and which can be easily stripped to provide an electrical connection between the coaxial cable and other conductive elements. The present invention also includes a method of making flexible coaxial cable.

Abstract: A method of making a flexible coaxial cable is provided. The method comprises advancing a cable core comprising a conductor and an expanded foam dielectric surrounding the conductor along a predetermined path of travel, directing an elongate strip of copper onto the advancing cable core and bending the copper strip into a generally cylindrical form so as to loosely encircle the core. Opposing longitudinal edges of the thus formed copper strip are then moved into abutting relation and a longitudinal weld is formed joining the abutting edges to thereby form an electrically and mechanically continuous tubular copper sheath loosely surrounding the cable core. The cable core and the surrounding sheath are simultaneously advanced while the tubular sheath is deformed into an oval configuration loosely surrounding the core. The longitudinal weld of the advancing sheath is then directed against a scarfing blade and weld flash from the sheath is scarfed from the sheath.

Abstract: An apparatus for making cable including an elongate core and a surrounding longitudinally welded tube includes one or more pairs of opposing tube forming rolls which form a tape into a generally tubular shape surrounding the advancing core. A pair of tube forming rolls define exit tube forming rolls mounted to have an adjustable spacing therebetween. A first sensor generates an exit roll spacing signal which is one parameter that may be displayed to the operator or used to directly to control the spacing. Downstream from an induction welding coil, a pair of opposing weld rolls are mounted to have an adjustable spacing therebetween for permitting setting of a desired pressure between the heated opposing longitudinal edges of the advancing tape. A second sensor generates a weld roll spacing signal which may also be displayed or used to directly control the spacing within a desired range. An associated method is also disclosed.