Multifolded composite tape for use in cable manufacture and methods for making same

A composite tape for use in cable manufacture, the composite tape comprising:

• a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material into a first folded laminate;
• a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate;
• a folded edge of the first folded laminate aligned with a folded edge of the second folded laminate to position the first and second folded laminates fold-to-fold;
• a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the first and second folded laminates;
• a fourth laminate constructed similar to the third laminate, the dielectric material of the fourth laminate bonded to a second opposing plane formed by the dielectric material of the first and second folded laminates;
• and
• the conductive material interfaces of the first and second folded laminates opened to define four channels.

A composite tape for use in cable manufacture, the composite tape comprising:

• a first laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the first laminate folded conductive material-to-conductive material into a first folded laminate having a conductive material interface;
• a second laminate constructed and folded similar to the first folded laminate to form a second folded laminate;
• a folded edge of the first folded laminate aligned with a folded edge of the second folded laminate to position the first and second folded laminates fold-to-fold;
• at least a third laminate of at least one sheet of dielectric material bonded to at least one sheet of conductive material, the dielectric material of the third laminate bonded to a first plane formed by the dielectric material of the first and second folded laminates;
• and
• the conductive material interfaces of the first and second folded laminates opened to define a plurality of channels.

A method for making a composite tape for use in cable manufacture, the method comprising:

• providing a first laminate of at least one layer of conductive material bonded to at least one layer of dielectric material;
• folding the first laminate conductive material-to-conductive material to form an interface of conductive material;
• providing a second folded laminate constructed and folded similar to the first folded laminate;
• butting the first and second folded laminates fold-to-fold;
• providing a third laminate and a fourth laminate, the third laminate and the fourth laminate each having at least one layer of conductive material bonded to at least one layer of dielectric material;
• bonding the layer of dielectric material of the third laminate to a first plane of dielectric material formed by the dielectric material of the butted first and second folded laminates;
• bonding the layer of dielectric material of the fourth laminate to a second opposing plane of dielectric material formed by the dielectric material of the butted first and second folded laminates;
• and
• opening the conductive material interfaces to form a plurality of fin-like shielding members that extend radially from a center axis and longitudinally along a length of the laminates to define a plurality of channels.

A method for making a composite tape for use in cable manufacture, the method comprising:

• providing a laminate of at least one layer of conductive material bonded to at least one layer of dielectric material, the laminate having a length and a width;
• folding the laminate along its length repeatedly to form a multiple of longitudinal accordion pleats, each pleat having either a dielectric material interface or a conductive material interface disposed therein;
• bonding the dielectric material interfaces;
• and
• opening the conductive material interfaces to form a plurality of fin-like shielding members extending radially from a center axis and longitudinally along the length of the laminate to define a plurality of channels.

A communications cable comprising:

• a tubular jacket;
• a composite tape contained within the jacket including two or more fin-like shielding members joined at a center axis, each shielding member extending radially from the center axis and longitudinally along a length to define two or more channels, each shielding member having an internal portion of a first material disposed between portions of a second material;
• and
• at least one twisted pair of insulated conductors disposed in each of the channels.