Interconnect cable having insulated wires with a conductive coating
A cable assembly includes a plurality of wires. Each wire has a first end, intermediate section, and a second end. The intermediate sections of the respective wires are detached from each other. A conductive shield surrounds the respective intermediate sections of the plurality of wires. Each wire includes a conductor, an insulating layer that surrounds the conductor, and a conductive coating formed on an outside surface of the insulating layer.
1. A cable assembly comprising:
a plurality of wires, each having a first end, a second end, and an intermediate section, the intermediate sections of respective wires of the plurality of wires being detached from each other; and
a conductive shield surrounding the respective intermediate sections of the plurality of wires;
wherein each wire of the plurality of wires includes:
a conductor;
an insulating layer that surrounds the conductor; and
a conductive coating applied on an outside surface of the insulating layer, said conductive coating being graphene; and
wherein said conductive coating lowers the mutual capacitance between adjacent insulated wires and cross-talk measured between the plurality of wires is less than −34 dB below 5 MHz.
2. The cable assembly according to claim 1 , wherein a thickness of the conductive coating is less than 0.005 mm (0.0002 inch).
3. The cable assembly according to claim 1 , further comprising at least one non-insulated wire positioned within an interior space defined by the conductive shield.
4. The cable assembly according to claim 1 , wherein the first and second ends of the plurality of wires are attached in a side-by-side manner to form a ribbon.
5. The cable assembly according to claim 1 , wherein a thickness of the insulating layer surrounding the conductor is about 0.025 to 0.64 mm (0.001 to 0.025 inch).
6. The cable assembly according to claim 1 , wherein the wire includes a conductor having a gauge of 36 AWG to 52 AWG.
7. The cable assembly according to claim 6 , wherein the conductor is selected from the group of conductors consisting of: copper, silver-plated copper, tin-plated copper, and gold-plated copper.
8. The cable assembly according to claim 1 , wherein a mutual capacitance between any two of the plurality of wires is less than 2pF when a length of the plurality of wires is about 0.91 meter (3 feet) long.
9. The cable assembly according to claim 1 , wherein an outer diameter of the cable is about 12.7 mm (0.500 inch) and a number of wires of the plurality of wires is about 500.
10. A method for manufacturing a cable assembly comprising:
providing a plurality of conductors;
forming an insulating layer around each conductor of the plurality of conductors to thereby form separate insulated wires;
forming a conductive coating by an application process on an outside surface of the insulating layer of each wire, said conductive coating being graphene;
applying a braided shield over the plurality of wires; and
applying a sheath over the braided shield:
wherein cross-talk measured between the plurality of wires is less than −34 dB below 5 MHz.
11. The method according to claim 10 , wherein a thickness of the conductive coating is less than 0.010 mm.
12. The method according to claim 10 , further comprising providing at least one non-insulated wire within an interior space defined by the conductive shield.
13. The method according to claim 10 , wherein first and second respective ends of the plurality of wires are attached in a side-by-side manner to form a ribbon.
14. The method according to claim 10 , wherein a thickness of the insulating layer surrounding the conductor is about 0.05 mm (0.002 inch).
15. The method according to claim 10 , wherein the conductor within the wire is a conductor having a gauge of 36 AWG to 52 AWG.
16. The method according to claim 10 , wherein a mutual capacitance between any two of the plurality of wires is less than 2pF when a length of the plurality of wires is about 0.91 meter (3 feet) long.
17. The method according to claim 10 , wherein an outer diameter of the cable is about 12.7 mm (0.5 inch) and a number of wires of the plurality of wires is about 500.