Data cable, connector, and crimping system and method

Abstract

The present invention relates to data cable and methods of installing/building data cable. The cable disclosed herein is indoor/outdoor and can be configured as 4-twisted pair, or any of the numerous other types of data cable. In one embodiment, we disclose an electrical data cable comprising a plurality of insulated wires wherein the plurality of insulated wires is coupled for a first portion of the length of the data cable so as to form at least one twisted pair of wires; the plurality of insulated wires is configured in a flat, planar arrangement for a second portion of the data cable; and the plurality of insulated wires is coupled for a third portion of the length of the data cable so as to form at least one twisted pair of wires. In an alternate method, we disclose a method of attaching a connector to the electrical data cable comprising the steps of cutting the data cable at the untwisted segment and attaching a connector to the plurality of insulated wires in the untwisted segment.

Claims

1. An electrical data cable comprising a plurality of insulated wires wherein: a. the plurality of insulated wires is coupled for a first portion of the length of the data cable so as to form at least one twisted pair of wires; b. the plurality of insulated wires is configured in a flat, planar arrangement for a second portion of the data cable, further comprising a member having a plurality of grooves wherein the grooves are configured to house at least one insulated wire in the second portion of the data cable; and c. the plurality of insulated wires is coupled for a third portion of the length of the data cable so as to form at least one twisted pair of wires.

2. The electrical data cable of claim 1 wherein the number of insulated wires in the plurality of insulated wires is equal to eight.

3. The electrical data cable of claim 1 wherein a portion of the insulation on the exterior of the plurality of insulated wires is rigid.

4. The electrical data cable of claim 1 further comprising a connector electrically coupled to the plurality of insulated wires.

5. The electrical data cable of claim 4 further comprising a wall plate.

6. The electrical data cable of claim 5 wherein the wall plate further comprises a light configured to signal a current in at least one of the insulated wires.

7. The electrical data cable of claim 4 further comprising a patch panel.

8. The electrical data cable of claim 1 further comprising a connector segment mechanically coupled to the wire channel wherein the connector segment or the wire channel is electrically coupled to the plurality of insulated wires.

9. The electrical data cable of claim 8 further comprising a wall plate.

10. The electrical data cable of claim 9 wherein the wall plate further comprises a light configured to signal a current in at least one of the insulated wires.

11. The electrical data cable of claim 8 further comprising a patch panel.

12. A method of attaching a connector to an electrical data cable comprising the steps of: a. cutting a data cable at an untwisted segment of the data cable, the data cable further comprising: i. a plurality of insulated wires coupled for a first portion of the length of the data cable so as to form at least one twisted pair of wires; ii. the plurality of insulated wires configured in a flat, planar arrangement for a second portion of the data cable further comprising a member having a plurality of grooves wherein the grooves are configured to house at least one insulated wire in the second portion of the data cable; and iii. the plurality of insulated wires coupled for a third portion of the length of the data cable to form at least one twisted pair of wires; and iv. attaching a connector to the plurality of insulated wires in the flat planar arrangement of the second portion of the data cable to create an electrically conducting connection between the plurality of insulated wires and the connector.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 (prior art) is a left side view of a section of Ethernet cable having four (4) twisted pair.

(2) FIG. 2A (prior art) is a perspective view of a keystone connector attached to a wall plate.

(3) FIG. 2B (prior art) is a perspective view of an RJ45 connector.

(4) FIG. 3 (prior art) is a top view of prior art tools needed to attach a connector to cable.

(5) FIG. 4A is a top view of an embodiment of the data cable disclosed herein.

(6) FIG. 4B is a perspective view of a wire channel and a connector segment according to embodiments herein.

LIST OF REFERENCE NUMERALS

(7) TABLE-US-00001 Reference Number Description 10 Cable 11 Insulated external coating 12 Wires - list color coding 21 Keystone connector 22 Wall plate 23 Ports 24 RJ45 connector 32 Punch tool 34 Connector 36 Crimping tool 38 Cutting tool 39 Cable tester 40 Data cable 41 Untwisted segment 42 Insulated wires 43 Twisted segment 44 Wire channel 45 Insulated portion 46 Connector segment

DETAILED DESCRIPTION

(8) The present invention overcomes these hurdles in the prior art by providing a new Ethernet cable and connector system and methods of using the same. The embodiments described herein save time by reducing the number of steps and the requisite skill required to create Ethernet cables.

(9) FIG. 4A depicts embodiments of the inventive Ethernet cable 40 having an alternating twisted, untwisted pattern. In these embodiments, cable 40 could be any data cable constructed in accordance with widely accepted standards. The total number of insulated wires 42 contained within the data cable 40 could vary from as low as two, to hundreds or even thousands of wires.

(10) Today's data cables 40 are primarily comprised of eight (8) insulated, twisted pair of wires. As such, and without limitation, this configuration will be used as an exemplary data cable 40 for purposes of discussing the inventive concepts herein. Ideally, the insulated wire 42 used within the data cable 40 will adhere to a standard configuration. FIG. 4A shows a T568B wiring configuration, which could be one embodiment of the cable 40. In alternate embodiments, the wiring configuration can vary and each spool of wire could be labeled so that skilled artisans will know the exact configuration of the wires 42 in the untwisted segment 41 of the cable 40. This will save practitioners time and will reduce errors in running cable.

(11) Exemplary standards for eight twisted pair cable include: Cat 5, Cat 5e, Cat 6, and Cat 7. The embodiments disclosed herein would work with a data cable 40 falling within any of these standards as well as additional standards known to those of skill in the art.

(12) Of note, those of skill in the art will recognize that these standards allow for the provision of power through the cable 40. This configuration is known as Power Over Ethernet. The power is obtained by supplying a voltage to one or more of the insulated wires 42. The embodiments discussed herein are available with or without power over Ethernet versions. Moreover, the embodiments disclosed herein can be used with many types of wire, including, but not limited to, Plenum, direct burial, drain wire, gel filled, shielded, un-shielded, and UV protected.

(13) FIG. 4A depicts a cable embodiment having a twisted segment 43 and an untwisted segment 41. While FIG. 4A depicts two sections of the twisted segment 43 and two sections of the untwisted segment 41, in embodiments these segments continue on throughout the length of a spool of data cable 40.

(14) In the top portion of FIG. 4A, the cable insulation has been removed to show how the wires 42 are configured underneath the insulated exterior of the cable 40. In the insulated portion 45 of the cable 40, the twisted segment 43 and the untwisted segment 41 are covered with an insulated coating. Most typically, the cable 40 will be covered for its length by insulation until an installer removes the insulation when running cable or attaching connectors.

(15) As can be seen from FIG. 4A, the twisted segment 43 comprises four twisted pair of insulated wire 42 in the embodiment depicted. In the embodiment of FIG. 4A, the wires 42 could be color-coded as describe above when referring to the prior art. In alternate embodiments, the color coding scheme could be different or non-existent. Those of skill in the art will recognize that some cable 40 optionally includes a ground wire, not pictured, which could additionally be a part of the embodiments disclosed herein.

(16) Additionally, those of skill in the art will recognize that the number of insulated wires 42 within the cable 40 could vary in alternate embodiments. At a minimum, the embodiments contemplated herein would be comprised of at least two insulted wires 42 forming a single twisted pair for a portion of the cable 40, i.e., the twisted pair segment 43 and lying flat in a planar fashion for the untwisted segment 41 of the cable 40. In preferred embodiments, there would be four-twisted pair, or eight total wires 42.

(17) The twisted segment 43 of the cable 40 is typically longer than the untwisted segment 41 of the cable 40, although it some embodiments, the lengths of twisted segment 43 and the untwisted segment 41 could be equal. And in alternate embodiments, the length of the untwisted segment 41 could be longer than the length of the twisted segment 43. For purposes of illustration and without limitation, the cable 40 could alternate between twisted segments 43 and untwisted segments 41 every foot. Specifically, the twisted segment 43 of the cable 40 could be eleven inches, while the untwisted segment 41 could be an inch. This scheme could alternate every foot of the data cable 40 for the full length of the spool of cable 40.

(18) The lengths and proportionality of twisted segments 43 versus untwisted segments 41 can vary according to the type of job being performed as well as consumer and/or manufacturing preferences. In the one-foot alternating pattern described above, it would be convenient to have an untwisted segment 41 approximately every foot because that would allow less waste when cutting cable 40 for a particular run or for a particular length.

(19) FIG. 4A also depicts a wire channel 44 used to keep the wires flat and stationary in the untwisted segment 41 of the cable 40. FIG. 4B shows a perspective view of the wire channel 44 having the wires 42 lying in the individual channels within the wire channel 44. In alternate embodiments, the portion of wire 42 residing in the untwisted segment 41 could have an exterior insulated portion that is more rigid than the insulation on the wires lying within the twisted segment 43. This rigidity could assist the wire 42 in maintaining a flat, planar orientation in the untwisted segment 41 of the cable 40.

(20) In some embodiments, the wire channel 44 can be designed to mechanically couple to a connector segment 46. FIG. 4B depicts the wire channel 44 with insulated wires 42 disposed therewithin. In addition, a connector segment 46, which can be configured in some embodiments to electrically couple to wires 42, is shown. The electrical coupling could be achieved with a crimping tool, a punch tool, by hand, or similar techniques known to those of skill in the art.

(21) The connector segment 46 can also be configured in alternate embodiments to mechanically couple to wire channel 44. The mechanical connection between the wire channel 44 and the connector segment 46 could be made by snapping the two pieces together, by crimping the two pieces together, by mechanically coupling the two pieces together, by adhering the two pieces together and so forth. When the wire channel 44 is connected to the connector segment 46. The termination portion of the connector segment 46 can be either male or female and can be Ethernet, telephone wire, and the like.

(22) In one embodiment, the wire channel 44 and the connector segment 46 combine to create an RJ45 21 connector. In another embodiment, the wire channel 44 and the connector segment 46 combine to create a keystone connector 21. In some embodiments, the arms of the wire channel 44 could contain a small latching mechanism that would be configured to mechanically couple to a symmetrically receiving portion within the connector segment 46.

(23) In alternate embodiments, the cable 40 and connectors could be coupled to a wall plate or a patch panel.

(24) As previously stated, the steps required to attach a connector to a segment of data cable in the prior art were as follows: (1) cut cable 10 to length; (2) cut and remove outer casing of cable 10, exposing the four twisted pair; (3) carefully unwind the four twisted pair; (4) align each wire into the proper pattern depending upon the termination scheme, e.g., T568B; (5) straighten out the wires 12; (6) cut the ends of the wires 12 to get a clean finish; (7) stick each of the eight (8) wires 12 into the proper ports of the connector, for example and without limitation an RJ45 connector 24, or separate pairs and use punch tool for Keystone connector 21; (8) check the alignment of the wires to ensure that they are at the end of the connector 21, 24 and that there is sufficient outer casing such that the outer casing of the wire 12 is partially inside of the connector 21, 24; (9) crimp with a crimping tool 36; and (10) test the cable 10 to make sure that the proper electrical connectivity has been obtained from end-to-end.

(25) With reference to FIGS. 4A & 4B, the steps required to secure a connector to a data cable according to embodiments disclosed herein can be reduced as follows. (1) cut cable 40 to length; (2) attach connector to the wires; (3) crimp with a crimping tool or similar device to create an electrical connection between the metal ports in the connector; and (4) test the cable 40 to ensure that proper electrical connectivity has been achieved. In this method, the connector could be an off-the-shelf keystone connector 21, an off-the-shelf RJ45 connector 23, or a proprietary connector comprised of the wire channel 44 and the connector segment 46.

(26) In this method, the following steps have been eliminated for the following reasons: (1) carefully unwind the four twisted pair—there is no need to untwist the twisted pair because they have been untwisted and properly aligned in the untwisted segment 41 of the cable 40; (2) cut and remove outer casing of cable 40, exposing the four twisted pair—as above there is no need to untwist the twisted pair because they have been untwisted and properly aligned in the untwisted segment 41 of the cable 40; (3) align each wire into the proper pattern depending upon the termination scheme, e.g., T568B—there is no need to align the wires in the proper pattern because they have been pre-aligned in the proper pattern; (4) straighten out the wires—the wires 42 in the untwisted segment 41 are flat and planar so they do not have to be straightened out; (5) cut the ends of the wires to get a clean finish—the wires 42 in the untwisted segment of the cable 40 are of uniform length, thereby obviating the need to cut for a clean finish; and (6) check the alignment of the wires to ensure that they are at the end of the connector 21, 23 and that there is sufficient outer casing such that the outer casing of the wire is partially inside of the connector 21, 23—the wires 42 in the untwisted segment of the cable 40 are of uniform length, thereby obviating the need to ensure that there is a sufficient outer casing on the cable 40.

(27) Those of skill in the art will recognize throughout this specification that when like terms are used to describe features and functionalities of various portions of a particular embodiment, those same features and functionalities could be present in additional embodiments having aspects with like terms. In addition, the teachings of the invention disclosed herein could be used with other types of cables such as telephone and video cables, as will be recognized by those of skill in the art.

(28) The articles “a” and “an” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to include the plural referents. Claims or descriptions that include “or” between one or more members of a group are considered satisfied if one, more than one, or all of the group members are present in, employed in, or otherwise relevant to a given product or process unless indicated to the contrary or otherwise evident from the context. The terms “coupled to” or “connected to” are intended to mean both a direct coupling or connection as well as a coupling or connection where there are one or more intermediary elements, devices, parts, and the like.

(29) The invention includes embodiments in which exactly one member of the group is present in, employed in, or otherwise relevant to a given product or process. The invention also includes embodiments in which more than one or the entire group of members is present in, employed in or otherwise relevant to a given product or process. Furthermore, it is to be understood that the invention encompasses all variations, combinations, and permutations in which one or more limitations, elements, clauses, descriptive terms, etc., from one or more of the listed claims is introduced into another claim dependent on the same base claim (or, as relevant, any other claim) unless otherwise indicated or unless it would be evident to one of ordinary skill in the art that a contradiction or inconsistency would arise.

(30) Where elements are presented as lists, (e.g., in Markush group or similar format) it is to be understood that each subgroup of the elements is also disclosed, and any element(s) can be removed from the group. It should be understood that, in general, where the invention, or aspects of the invention, is/are referred to as comprising particular elements, features, etc., certain embodiments of the invention or aspects of the invention consist, or consist essentially of, such elements, features, etc. For purposes of simplicity those embodiments have not in every case been specifically set forth in so many words herein. It should also be understood that any embodiment or aspect of the invention can be explicitly excluded from the claims, regardless of whether the specific exclusion is recited in the specification. The entire contents of all the references (including literature references, issued patents and published patent applications and websites) cited throughout this application are hereby expressly incorporated by reference.

(31) Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated, that embodiments may be variously combined or separated without departing from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.