Coaxial cable including tubular bimetallic inner layer with folded edge portions and associated methods

A coaxial cable comprising:

• an inner conductor, an outer conductor and a dielectric material layer therebetween;
• said inner conductor comprising a tubular bimetallic layer having a pair of opposing longitudinal edge portions at a longitudinal seam;
• said tubular bimetallic layer comprising an inner metal layer and an outer metal layer bonded thereto, said outer metal layer having a higher electrical conductivity than said inner metal layer, and said inner metal layer having a lower melting temperature than said outer metal layer;
• at least one of the opposing longitudinal edge portions comprising an end portion of said inner metal layer extending beyond a corresponding end portion of said outer metal layer and being folded over onto itself adjacent the corresponding end of said outer metal layer and defining a non-joined interface therewith;
• the longitudinal seam comprising a welded joint between at least portions of said inner metal layer.

A method for making a coaxial cable comprising an inner conductor, an outer conductor and a dielectric material layer therebetween, the method comprising:

• forming the inner conductor by at least
• forming a bimetallic strip into a tubular bimetallic layer having a pair of longitudinal edge portions and comprising an inner metal layer and an outer metal layer bonded thereto, at least one of the longitudinal edge portions defining at least one folded edge portion comprising an end portion of the inner metal layer extending beyond a corresponding end portion of the outer metal layer and being folded adjacent thereto and defining a non-joined interface therewith, and
• welding at least portions of the longitudinal seam to form a welded joint between at least portions of the outer metal layer;
• forming the dielectric material layer surrounding the inner conductor;
• and
• forming the outer conductor surrounding the dielectric material layer.

A method for making a coaxial cable comprising an inner conductor, an outer conductor and a dielectric material layer therebetween, the method comprising:

• forming the inner conductor by at least
• forming a bimetallic strip into a tubular bimetallic layer having a pair of longitudinal edge portions and comprising an inner metal layer and an outer metal layer bonded thereto, at least one of the longitudinal edge portions defining at least one folded edge portion comprising an end portion of the inner metal layer extending beyond a corresponding end portion of the outer metal layer and being folded over onto itself adjacent the corresponding end portion of the outer metal layer and defining a non-joined interface therewith, and
• welding at least portions of the longitudinal seam to form a welded joint between at least portions of the outer metal layer;
• forming the dielectric material layer surrounding the inner conductor;
• and
• forming the outer conductor surrounding the dielectric material layer.