Miniature controlled-impedance transmission line cable and method of manufacture

A method for making a controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, said method comprising:

• (a) forming a respective inner dielectric layer around each conductor of a pair of conductors separately;
• (b) thereafter forming a respective outer dielectric layer around each of said inner dielectric layers separately, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor;
• (c) thereafter heating and thereby fusing together portions of the respective outer dielectric layers in side-by-side relationship substantially without altering the inner dielectric layers of the conductors, the respective inner dielectric layers being of a composition having a higher melting temperature than the composition of said outer dielectric layers.

A method for making a controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, said method comprising:

• (a) forming a respective inner dielectric layer around each conductor of a pair of conductors separately;
• (b) thereafter forming a respective outer dielectric layer around each of said inner dielectric layers separately, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor;
• (c) helically twisting said conductors together and thereby forcibly abutting the respective outer dielectric layers against each other in side-by-side relationship, and thereafter bonding said outer dielectric layers to each other substantially without altering the inner dielectric layers of the conductors.

A method for making a controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, said method comprising:

• (a) forming a respective inner dielectric layer around each conductor of a pair of conductors separately;
• (b) thereafter forming a respective outer dielectric layer around each of said inner dielectric layers separately, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor;
• (c) thereafter bonding the outer dielectric layer of one of said conductors to the outer dielectric layer of the other of said conductors in side-by-side relationship in a manner reducing the respective thicknesses of the respective outer dielectric layers, relative to their respective thicknesses as formed in step (b), in the region transversely separating said conductors substantially without altering the inner dielectric layers of the conductors.

A controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, and the outer dielectric layer of one of said conductors being joined by a bond to the outer dielectric layer of the other of said conductors in side-by-side relationship substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors, so as to form a controlled-impedance transmission line having a substantially uniform transverse spacing and dielectric constant between said conductors throughout the length of said transmission line.

A controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, and the outer dielectric layer of one of said conductors being joined by a bond to the outer dielectric layer of the other of said conductors in side-by-side relationship such that the respective outer dielectric layers are altered from their condition as applied to the respective conductors substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors.

controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, the respective outer dielectric layers being joined by a bond, formed by heating and resultant fusion of portions of the respective outer dielectric layers, in side-by-side relationship substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors, said inner dielectric layers being of a composition having a higher melting temperature than the composition of said outer dielectric layers.

A controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, and the outer dielectric layer of one of said conductors being joined by a bond to the outer dielectric layer of the other of said conductors in side-by-side relationship substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors such that the respective outer dielectric layers of said conductors have respective thicknesses in the region transversely separating said conductors which are less than their thicknesses as applied to the respective conductors.

A controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, and the outer dielectric layer of one of said conductors being joined by a bond to the outer dielectric layer of the other of said conductors in side-by-side relationship substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors, said conductors being held in a helically twisted relationship to each other by said bond.

A controlled-impedance transmission line comprising a pair of elongate electrical conductors extending generally in transversely separated, side-by-side relationship, each of said conductors being surrounded by a respective inner dielectric layer and a respective outer dielectric layer, each inner and outer dielectric layer being applied to a respective one of said conductors independently of the other one of said conductors, each outer dielectric layer of a respective conductor being of a different composition than that of the inner dielectric layer of the respective conductor, and the outer dielectric layer of one of said conductors being joined by a bond to the outer dielectric layer of the other of said conductors in side-by-side relationship substantially without alteration of the respective inner dielectric layers of the conductors from their condition as applied to the respective conductors, a further dielectric layer surrounding the respective outer dielectric layers, a conductive shield surrounding said further dielectric layer, and an outer insulating jacket around said shield which penetrates said shield.