Fire-resistant coaxial cables are described as well as methods to manufacture them. The dielectric between the coax cable's central conductor and outer coaxial conductor ceramify under high heat, such as those specified by common fire test standards (e.g., 1850 F./1010 C. for two hours). The dielectric can be composed of ceramifiable silicone rubber, such as that having a polysiloxane matrix with inorganic flux and refractory particles. Because thick layers of uncured ceramifiable silicone rubber deform under their own weight when curing, multiple thinner layers are coated and serially cured in order to build up the required thickness. A sacrificial sheath mold is used to hold each layer of uncured ceramifiable silicone rubber in place around the central conductor while curing. The outer conductor can be a metal foil, metal braid, and/or corrugated metal. Another layer of extruded ceramifiable silicone dielectric or an outer wrap of ceramic fiber yarn surrounds the outer conductor and continues to insulate it from the outside if a low smoke zero halogen jacket burns away. Methods of testing and installation are described.

A method of forming a terminating end of a cable, comprising the steps of: providing a cable; cutting a circumferential slit through an outer insulation layer; clamping a first section of the outer insulation layer with a first clamping device, and clamping a second section of the outer insulation layer with a second clamping device; displacing the first clamping device, separating the first section from the second section and exposing a section of a metal braid; displacing the first clamping device; pushing and pressing the exposed section to fold the exposed section into a braid protrusion portion; loosening the first and second clamping devices, and removing the cable from the first and second clamping devices; cutting the braid protrusion portion with a cutting device to form a protruding braid portion, the protruding braid portion; and removing the first section of the outer insulation layer and a first protruding braid portion.

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.

A method in the manufacturing of an insulated electric high voltage DC termination or joint includes the steps of providing an insulated electric high voltage DC cable including an inner conductor; a polymer based insulation system, the polymer based insulation system comprising an insulation layer and a semiconducting layer; and an outer grounding layer; removing the grounding layer and the semiconducting layer in at least one end portion of the high voltage DC cable, thereby exposing the insulation layer in the at least one end portion of the high voltage DC cable; covering the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable by a cover impermeable to at least one substance present in the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable in a non-homogenous distribution; subjecting the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable for a heat treatment procedure, while being covered by the cover, thereby equalizing the concentration of the at least one substance in the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable; and removing the cover. Instead of using a temporary cover, which is later removed, as the impermeable barrier, a field grading adapter or joint body mounted at the end of the DC cable during the manufacturing of the high voltage DC termination or joint may be used.

A method for forming a conductive structure is disclosed, the method comprising the steps of: forming a metallic frame having a plurality of metal parts separated from each other; forming an insulating layer over the top surface or the bottom surface of the plurality of metal parts; and forming a conductive pattern layer on the insulating layer for making electrical connections with at least one portion of the plurality of metal parts.

A method in the manufacturing of an insulated electric high voltage DC termination or joint includes providing an insulated electric high voltage DC cable including a high voltage DC conductor, a polymer based insulation system surrounding the high voltage DC conductor, the polymer based insulation system including an insulation layer and a semiconducting layer surrounding the insulation layer, and a grounding layer surrounding the semiconducting layer, removing the grounding layer and the semiconducting layer in at least one end portion of the high voltage DC cable, thereby exposing the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable, mounting a field grading adapter or joint body in the at least one end portion of the high voltage DC cable, thereby covering the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable, the field grading adapter or joint body being part of the high voltage DC termination or joint, wherein at least one substance is present in the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable in a non-homogenous distribution; and subjecting the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable for a heat treatment procedure, while being covered by the mounted field grading adapter or joint body, thereby equalizing the concentration of the at least one substance in the insulation layer of the polymer based insulation system in the at least one end portion of the high voltage DC cable.

A method of forming a coaxial wire that includes providing a sacrificial trace structure using an additive forming method, the sacrificial trace structure having a geometry for the coaxial wire, and forming a continuous seed metal layer on the sacrificial trace structure. The sacrificial trace structure may be removed and a first interconnect metal layer may be formed on the continuous seed layer. An electrically insulative layer may then be formed on the first interconnect metal layer, and a second interconnect metal layer is formed on the electrically insulative layer. Thereafter, a dielectric material is formed on the second interconnect metal layer to encapsulate a majority of an assembly of the first interconnect metal layer, electrically insulative layer and second interconnect metal layer that provides said coaxial wire. Ends of the coaxial wire may be exposed through opposing surfaces of the dielectric material to provide that the coaxial wire extends through that dielectric material.

An apparatus for processing a cable including an insulating member, a shielding layer, and a conductor, the apparatus includes a frame forming a housing having an aperture configured to receive an end portion of the cable; a first gripping member disposed within the housing and being configured to grip the cable; and a second gripping member disposed within the housing and being configured to grip the cable; wherein the second gripping member is mounted within the housing so as to be movable relative to the first gripping member to effect fanning and cutting of a portion of the shielding layer.

A coaxial cable and method of construction thereof are provided. The coaxial cable includes an elongate central conductive member; a dielectric insulative layer encasing the central conductive member; an outer protective sheath, and a braided EMI shield layer including hybrid yarn sandwiched between the dielectric insulative layer and the outer protective sheath. The hybrid yarn includes an elongate nonconductive filament and an elongate continuous conductive wire filament. The wire filament is interlaced in electrical communication with itself or other wire filaments along a length of the EMI shield layer to provide protection to the central conductive member against at least one of EMI, RFI or ESD. The method includes providing a central conductive member; forming a dielectric insulative layer surrounding the central conductive member; braiding an EMI shield layer including hybrid yarn about the insulative layer, and forming an outer protective sheath about the braided EMI shield layer.

A coaxial cable connector with a grounding insert that is between a fastener and and a post to provide electrical continuity therebetween.