Flat cable and modular rotary anvil to make same

A flat electrical cable comprising:

• an upper layer of polyester having a ribbed surface;
• a lower layer of polyester connected to the upper layer along substantially continuous parallel space apart ultrasonically bonded seams;
• and
• individual strands of copper conductors lying substantially parallel and adjacent to the seams between the upper and lower layers, wherein the seams positioned between adjacent conductors have a textured surface pattern, and wherein the seams positioned along edges of the flat electrical cable have a substantially smooth surface pattern.

A flat electrical cable comprising:

• an upper layer of polyester having a ribbed surface;
• a lower layer of polyester connected to the upper layer along substantially continuous parallel space apart ultrasonically bonded seams;
• and
• individual strands of copper conductors lying substantially parallel and adjacent to the seams between the upper and lower layers, wherein the seams positioned between adjacent conductors have a textured surface pattern, wherein the seams positioned along edges of the flat electrical cable have a first zone and a second zone, and wherein
• the first zone is adjacent to one conductor of the conductors and extends substantially parallel to the one conductor, and the first zone having a knurled textured surface pattern, and where
• the second zone is located between the first zone and one edge of the edges, and the second zone having a smooth textured surface patterns.

A flat cable comprising:

• an upper insulator layer;
• a lower insulator layer connected to the upper insulator layer along substantially continuous parallel spaced apart seams;
• and
• an intermediate layer comprised of conductor groups which lie adjacent and substantially parallel to the seams, and wherein the conductor groups do not have an adhesive residue thereon.

A flat electrical cable comprising:

• an upper insulator layer;
• a lower insulator layer connected to the upper layer along substantially continuous parallel spaced apart seams;
• and
• an intermediate layer comprised of individual strands of conductors which lie adjacent and substantially parallel to the seams, and the conductors do not have an adhesive residue thereon, wherein the seams positioned between adjacent conductors have a first textured surface pattern, and wherein the seams positioned along edges of the flat electrical cable have a second surface pattern, and wherein a surface roughness of the first textured surface pattern is greater than a surface roughness of the second textured surface pattern.