Laminated conductive material, multiple conductor cables and methods of manufacturing such cables

A method of forming a cable having a relatively flexible electrical conductor integral with a relatively rigid electrically conductive terminal wherein said terminal (1) is generally flat, (2) is thicker in cross-section than at least one region of said conductor, and (3) derives its relative rigidity by virtue of the relative thicker cross-section, said method comprising the steps of:

• (A) providing a relatively rigid laminate of cross-sectional thickness substantially equal to that required for said terminal;
• said laminate comprising two electrical conductive structural layers separated by an electrically conductive barrier layer;
• (B) selectively reducing portions of said laminate in cross-section to the barrier layer, by a process which is constrained by the barrier layer, so as to (i) increase the relative flexibility of said cable in said at least one region, and (ii) define, in situ, said conductor and said terminal;
• and
• (C) covering said conductor at least in part with a flexible insulating material.

A method of forming a cable having a plurality of speed relatively flexible electrical conductors each integral with a relatively rigid electrically conductive terminal wherein said terminals (1) are generally flat, (2) are thicker in cross-section than said relatively flexible electrical conductors, and (3) derive their relative rigidity by virtue of their relative thicker cross-section, said method comprising the steps of:

• (A) providing a relatively rigid laminate of a cross-sectional thickness substantially equal to that required for said terminal;
• said laminate having two structural electrically conductive laminae spaced apart by an electrically conductive barrier layer;
• (B) selectively reducing portions of said laminate in cross-section to the barrier layer so as to define, in situ, said terminals, and said conductors, said terminals being approximately of said thickness;
• and
• (C) laminating said conductors between a pair of flexible insulating films so as to support and maintain said conductors together with their terminals in spaced relation to one another.

A method of forming a cable having a plurality of spaced metallic electrically conductive elements, each of said elements including at least one relatively rigid terminal and at least one region of relative flexibility wherein said terminals (1) are thicker in cross-section than the regions of relative flexibility, and (2) derive their relative rigidity by virtue of their relative thicker cross-section, said method comprising the steps of:

• (A) providing a composite metallic sheet of a cross-sectional thickness substantially equal to that required for said relatively rigid terminals;
• said sheet comprising two laminae, each comprising one of copper and an alloy in which copper is a major constituent, spaced by and in intimate electrically conductive contact throughout with an electrically conductive barrier layer, said laminae and said barrier layer being etchable by at least one selection of mutually exclusive etchants;
• (B) chemically milling said composite metallic sheet to (i) increase the relative flexibility of said sheet in the regions and (ii) define in situ a plurality of spaced elements including said terminals, said chemical milling involving:
• first chemically milling one of said laminae, using an etchant which is not an etchant for the barrier layer, so as to remove metal from selected portions thereof to a depth constrained by said barrier layer so as partially to define, in situ, a pattern of said elements including said terminals;
• bonding a first insulating sheet to said milled lamina;
• then chemically milling the other of said laminae, using an etchant which is not an etchant for the barrier layer, so as to remove metal from selected portions thereof to a depth constrained by said barrier layer so as to further define, in situ, the pattern;
• subsequently stripping the barrier layer using an etchant, which is not an etchant for the laminae, to define, in situ, said pattern;
• and bonding a second insulating sheet to said other milled lamina.

A cable when made by a method of forming a cable having a relatively flexible electrical conductor integral with a relatively rigid electrically conductive terminal wherein said terminal (1) is generally flat, (2) is thicker in cross-section than at least one of said conductor, and (3) derives its relative rigidity by virtue of the relative thicker cross-section, said method comprising the steps of:

• (A) providing a relatively rigid laminate of cross-sectional thickness substantially equal to that required for said terminal;
• said laminate comprising two electrical conductive structural layers separated by an electrically conductive barrier layer;
• (B) selectively reducing portions of said laminate in cross-section to the barrier layer, by a process which is constrained by the barrier layer, so as to (i) increase the relative flexibility of said cable in said at least one region, and (ii) define, in situ, said conductor and said terminal;
• and
• (C) covering said conductor at least in part with a flexible insulating material.

A cable when made by a method of forming a cable having a plurality of spaced relatively flexible electrical conductors each integral with a relatively rigid electrically conductive terminal wherein said terminals (1) are generally flat, (2) are thicker in cross-section that relatively flexible electrical conductors, and (3) derive their relative rigidity by virtue of their relative thicker cross-section, said method comprising the steps of:

• (A) providing a relatively rigid laminate of a cross-sectional thickness substantially equal to that required for said terminals;
• said laminate having two structural electrically conductive laminae spaced apart by an electrically conductive barrier layer;
• (B) selectively reducing portions of said laminate in cross-section to the barrier layer so as to define, in situ, said terminals, and said conductors, said terminals being approximately of said thickness;
• and
• (C) laminating said conductors between a pair of flexible insulating films so as to support and maintain said conductors together with their terminals in spaced relation to one another.

A cable when made by a method of forming a cable having a plurality of spaced metallic electrically conductive elements, each of said elements including at least one relatively rigid terminal and at least one region of relative flexibility wherein said terminals (1) are thicker in cross-section than the regions of relative flexibility, and (2) derive their relative rigidity by virtue of their relative thicker cross-section, said method comprising the steps of:

• (A) providing a composite metallic sheet of a cross-sectional thickness substantially equal to that required for said relatively rigid terminals;
• said sheet comprising two laminae, each comprising one of copper and an alloy in which copper is a major constituent, spaced by and in intimate electrically conductive contact throughout with an electrically conductive barrier layer, said laminae and said barrier layer being etchable by at least one selection of mutually exclusive etchants;
• (B) chemically milling said composite metallic sheet to (i) increase the relative flexibility of said sheet in the regions and (ii) define in situ a plurality of spaced elements including said terminals, said chemical milling involving:
• first chemically milling one of said laminae, using an etchant which is not an etchant for the barrier layer, so as to improve metal from selected portions thereof to a depth constrained by said barrier layer so as partially to define, in situ, a pattern of said elements including said terminals;
• bonding a first insulating sheet to said milled lamina;
• then chemically milling the other of said laminae, using an etchant which is not an etchant for the barrier layer, so as to remove metal from selected portions thereof to a depth constrained by said barrier layer so as to further define, in situ, the pattern;
• subsequently stripping the barrier layer using an etchant, which is not an etchant for the laminae, to define, in situ, said pattern;
• and bonding a second insulating sheet to said other milled lamina.