Multilayer woven high density electrical transmission cable and method

A method of producing individual woven multilayer electrical transmission cables comprising:

• (a) weaving a continuous length of cable structure which includes a plurality of said multilayer cable sections and a plurality of breakout cable sections, and said breakout cable sections being formed at opposing ends of said multilayer cable sections;
• (b) weaving said multilayer cable sections by the steps of:
• (i) weaving a first cable layer be weaving a first plurality of warp elements extending longitudinally in a warp direction in said cable layer with a weft element wherein at least a number of said warp elements consists of first electrical signal conductors,
• (ii) simultaneously weaving a second cable layer by weaving a second plurality of warp elements extending longitudinally in a warp direction in said second cable layer with said weft element wherein at least a number of said warp elements consists of second electrical signal conductors, and
• binding said first and second cable layers together at points along the length of said multilayer cable section, with warp binder elements woven in between said first and second cable layers,
• (c) weaving said breakout cable sections by the steps of:
• (i) breaking out said fist signal conductors from said first cable layer on one side of said multilayer cable section in a configuration wherein said first signal conductors are not woven with any other elements,
• (ii) breaking out said second signal conductors from said second cable layer on an opposite side of said multilayer cable sections opposite from said one side in a configuration wherein said second signal conductors are not woven with any other elements,
• (iii) weaving a woven tab consisting of said weft yarn and the remaining of said warp elements in said first and second cable layers exclusive of said first and second signal conductors, and weaving said woven tab between said first and second conductors for separating said first and second conductors for identification;
• and
• (d) severing said cable structure across selective sections of said cable structure to produce individual multilayer transmission cables having a high density of signal conductors.

A method of weaving a high density, high speed multilayer electrical signal transmission cable comprising:

• weaving a first cable layer which includes a number of first electrical signal conductors extending longitudinally in the cable layer in a warp direction interwoven with a weft element;
• weaving a second cable layer section which includes a number of second electrical signal conductors extending longitudinally in said cable layer in a warp direction interwoven with said weft element;
• simultaneously weaving said first and second cable layers in a manner in which said first and second cable layers are flush with one another, and weaving warp binding elements between said first and second cable layers to bind said layers together in said flush configuration as unitary multilayer cable structure;
• breaking out said first and second signal conductors at each end of said first and second cable layers on sides of said unitary multilayer cable structure in a manner in which said first and second signal conductors are not woven;
• and
• terminating said first and second signal conductors at each end of said first and second cable layers by connection to terminal connectors.