System and method for terminating Ethernet cable

Abstract

A termination system includes: an Ethernet cable including eight conductors; a wire holder is coupled to an Ethernet cable and includes eight arms arranged in a pattern, each arm including a first recess extending to an end of the arm. Each conductor is associated with one of the arms and includes a portion positioned within the first recess. The termination device also includes a connector having eight apertures arranged in the pattern, and eight contact bushings each disposed within one of the apertures and sized to receive one of the arms. The conductor associated with each arm is in electrical contact with the associated contact sleeve, and the termination cap is coupled to the cable.

Description

Background Art

[0001] Ethernet cables are useful for quickly transmitting large amounts of data. However, Ethernet cables can be exposed to corrosive, high-voltage environments, making their use in subsea or marine applications challenging. To facilitate the use of Ethernet cables in subsea applications, complex and expensive termination devices are required. These termination devices require skill and specialized manufacturing processes, and due to their complexity, they often require expensive testing and inspection before use. Summary of the Invention

[0002] In one aspect, a termination system includes a cable and a wire rack, the cable including a first number of conductors, the wire rack being coupled to the cable and including a second number of arms arranged in a first pattern, the second number being equal to the first number. Each arm includes a first recess extending to an end of the arm. A portion of one of the first number of conductors is positioned within the first recess. The connector includes a third number of apertures arranged in a second pattern, the second pattern corresponding to the first pattern, each of a plurality of contact sleeves being disposed within one of the apertures, and each of the plurality of contact sleeves being sized to receive one of the arms. The conductors associated with the arms are in electrical contact with the contact sleeves, and a termination cover is coupled to the cable.

[0003] The termination system may further include the cable being an Ethernet cable, and wherein the first quantity, the second quantity, and the third quantity are each equal to eight.

[0004] The termination system may further include arms each including a latch member that engages an associated contact sleeve to retain the arm within the contact sleeve.

[0005] The termination system may further include arms, wherein each arm includes a second recess opposite the first recess, and wherein a portion of the conductor is disposed within each of the first recess and the second recess.

[0006] The termination system may further include a termination shoe positioned to cover the termination cover and form a high pressure seal therebetween.

[0007] The termination system may further include connectors each including an annular outer wall, and wherein a compression ring is positioned between the termination cover and the outer wall, the compression ring compressing the termination shoe against the outer wall and the termination cover.

[0008] The termination system may also include wherein each of the arms extends parallel to a long axis of the wire rack.

[0009] The termination system may further include wherein each contact sleeve includes a reduced diameter portion arranged to engage a portion of the conductor in each of the first recess and the second recess.

[0010] In another aspect, a termination system includes an Ethernet cable including eight conductors and a wire rack coupled to the Ethernet cable and including eight arms arranged in a pattern, each arm including a first recess extending to an end of the arm. Each conductor is associated with one of the arms and includes a portion positioned within the first recess. The termination device also includes a connector and eight contact sleeves, the connector having eight apertures arranged in the pattern, each of the eight contact sleeves being disposed within one of the apertures and each sized to receive one of the arms. A conductor associated with each arm is in electrical contact with the associated contact sleeve, and a termination cover is coupled to the cable.

[0011] The termination system may further include the cable being an Ethernet cable, and wherein the first quantity, the second quantity, and the third quantity are each equal to eight.

[0012] The termination system may further include arms each including a latching member that engages an associated contact sleeve to retain each arm within the contact sleeve.

[0013] The termination system may further include arms each including a second recess opposite the first recess, and wherein a portion of the conductor is disposed within each of the first recess and the second recess.

[0014] The termination system may further include a termination shoe positioned to cover the termination cover and form a high pressure seal therebetween.

[0015] The termination system may further include a connector including an annular outer wall, and wherein a compression ring is positioned between the termination cover and the outer wall, the compression ring compressing the termination shoe against the outer wall and the termination cover.

[0016] The termination system may further include arms, each of the arms extending parallel to a longitudinal axis of the wire rack.

[0017] The termination system may further include a contact sleeve including a reduced diameter portion arranged to engage a portion of the conductor in each of the first recess and the second recess.

[0018] In yet another aspect, a method of terminating an Ethernet cable includes connecting a wire rack to the Ethernet cable, the wire rack including eight arms extending parallel to one another along a long axis, and each of eight conductors extending along one and only one of the arms along a first side and a second side opposite the first side in a direction parallel to the long axis. The method also includes positioning each of the eight contact sleeves in an aperture formed in a connector, inserting each of the arms into the contact sleeves such that a corresponding conductor of each arm forms an electrical connection with the corresponding contact sleeve, and partially positioning a termination cover within the connector to cover the wire rack.

[0019] The method may further include forming a first recess on the first side of each arm portion, and forming a second recess on the second side of each arm portion.

[0020] The method may further include positioning the termination shoe to overlie the termination cover and form a high pressure seal therebetween.

[0021] The method may further include inserting a compression ring between the termination cover and the outer wall of the connector, and pressing the termination shoe against the outer wall and the termination cover.

[0022] Other technical features will be apparent to those skilled in the art from the following drawings, description and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] To easily understand the discussion of any particular element or action, the most significant digit in a reference number refers to the reference number in which the element is first introduced.

[0024] Figure 1 A portion of a termination device of an Ethernet cable including a filler sleeve and wire rack is shown.

[0025] Figure 2 Shown Figure 1 Portions of the termination device are shown prior to insertion into the connector.

[0026] Figure 3 Shown Figure 1 The portion of the termination device shown is inserted into Figure 2 The situation after the connector.

[0027] Figure 4 Yes Figure 3 0 is a cross-sectional view of a portion of the termination device shown in FIG. 1 taken along the centerline of one of the arms.

[0028] Figure 5 Yes Figure 3 0 is a cross-sectional view of a portion of the termination device shown in FIG. 1 taken along the centerline of one of the arms.

[0029] Figure 6 Shown as Figure 3 The termination device shown in , which has a supporting wedge portion attached.

[0030] Figure 7 Shown as Figure 6 The termination device shown in FIG. 1 has a termination cover attached thereto.

[0031] Figure 8 Shown as Figure 7 The termination device shown in FIG. 1 has a termination boot attached.

[0032] Figure 9 With the pressure ring 902 attached Figure 8 A cross-sectional view of a termination device taken along the long axis of a wire frame.

[0033] Figure 10 With the pressure ring 902 attached Figure 8 A cross-sectional view of a termination device taken along the long axis of a wire frame. DETAILED DESCRIPTION

[0034] Before explaining any embodiments of the present invention in detail, it should be understood that the present invention is not limited in its application to the details of construction and the arrangement of components set forth in this specification or illustrated in the following drawings. The present invention is capable of other embodiments and can be practiced or implemented in various ways. Furthermore, it should be understood that the phraseology and terminology used herein are for descriptive purposes only and should not be considered limiting.

[0035] Various techniques related to systems and methods will now be described with reference to the accompanying drawings, in which the same reference numerals represent the same elements throughout. The drawings discussed below and the various embodiments used to describe the principles of the present invention in this patent document are intended to be illustrative only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will appreciate that the principles of the present invention can be implemented in any suitably arranged device. It should be understood that the functions described as being implemented by certain system elements can be performed by multiple elements. Similarly, for example, an element can be configured to be able to perform the functions described as being implemented by multiple elements. Many innovative teachings of the present application will be described with reference to exemplary, non-limiting embodiments.

[0036] It should be understood that the words or phrases used herein should be interpreted broadly, unless expressly limited in some examples. For example, the terms "including," "having," "comprising," and their derivatives are meant to include without limitation. The singular forms "a," "an," and "the" are also intended to include the plural forms, unless the context clearly indicates otherwise. In addition, the term "and / or" used herein refers to and covers any and all possible combinations of one or more of the associated listed items. The term "or" is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrase "associated with," "associated with," and its derivatives may mean including, included within, interconnected with, containing, contained within, connected to or connected with, connected to or connected with, communicable with, collaborative with, interlaced, juxtaposed, close to, bound to or bound with, having, having the characteristics of, etc. Furthermore, although multiple embodiments or configurations may be described herein, any feature, method, step, component, etc. described with respect to one embodiment may also be applicable to other embodiments without specific remark to the contrary.

[0037] In addition, terms such as "first," "second," and "third" may be used herein to refer to various elements, information, functions, or actions, but should not be considered limiting in any way. Instead, these ordinal numbers are used to distinguish between different elements, information, functions, or actions. For example, a first element, information, function, or action may be referred to as a second element, information, function, or action, and similarly, a second element, information, function, or action may be referred to as a first element, information, function, or action without departing from the scope of the present invention.

[0038] Additionally, the term "adjacent to" can mean that an element is relatively close to another element but not in contact with the other element, or that an element is in contact with another part, unless the context clearly indicates otherwise. Furthermore, the phrase "based on" is intended to mean "based at least in part on" unless otherwise specified. The terms "about" or "substantially" or similar terms are intended to encompass variations in value within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of 20% is considered within the meaning of these terms unless otherwise specified.

[0039] The cable 102 described herein includes one or more conductors 108 surrounded by a cable jacket 106 that protects the conductors 108 from environmental influences (e.g., electromagnetic shielding, corrosion protection, thermal protection, etc.) or from physical damage. Although the cable 102 can be any type of cable 102 including a data cable 102, a power cable 102, or a combination of both, Figure 1The cable 102 is shown in the form of an Ethernet cable 122 .

[0040] The Ethernet cable 122 includes eight color-coded conductors 108. The conductors 108 are twisted into four pairs of conductors 108, each of two pairs, for Gigabit Ethernet connections, and two pairs of conductors 108, each of four pairs, for 10 / 100 Ethernet connections. Typically, CAT6, CAT7, and CAT8 Ethernet cables 122 are used for Gigabit Ethernet connections. However, the actual type of cable 102 is not critical to the arrangement shown herein.

[0041] In order to connect the cable 102 to another device, the end of the cable 102 must be terminated. Termination involves attaching one or more components to the cable 102 to support the various conductors 108 in a desired manner to facilitate the connection.

[0042] For termination Figure 1 The cable 102 is secured to the filler sleeve 104 and attached to the end of the cable 102. A portion of the filler sleeve 104 fits under the cable jacket 106, so that the cable jacket 106 serves to hold the filler sleeve 104 in place. In some configurations, other fastening means (e.g., crimping, adhesives, etc.) are used to enhance the connection between the cable 102 and the filler sleeve 104. The filler sleeve 104 provides a resilient surface to seal to the cable 120 so that it does not deform under pressure.

[0043] The wire frame 112 is attached to the filler sleeve 104 to provide a support mechanism for the conductor 108. In a preferred configuration, the wire frame 112 includes a plurality of attachment legs 128 that engage the filler sleeve 104 to attach the wire frame 112 to the filler sleeve 104 without requiring any special tools or skills for attachment. In a preferred configuration, the wire frame 112 is formed from a plastic material, such as PEEK, while the filler sleeve 104 is formed from a metal material. However, if desired, the two components can be formed as a single piece from a single material.

[0044] The wire frame 112 includes a plurality of arms 114 extending parallel to a long axis 120 of the wire frame 112. The number of arms 114 generally corresponds to the number of conductors 108 within the cable 102. In the illustrated configuration, eight arms 114 are provided, with each arm 114 supporting a different conductor 108 from the cable 102. However, some configurations may use more or fewer arms 114 than conductors 108, as may be desired for a particular application.

[0045] Each conductor 108 passes through a portion of the wire rack 112 to an exit aperture 124 located adjacent one of the arms 114. Portions of the insulation 110 covering and protecting each wire are removed to expose the conductors 108.

[0046] A first recess 116 is formed on a first side of each of the arms 114, while a second recess 118 is formed on the side of each arm 114 opposite the first recess 116. Each second recess 118 is positioned adjacent to the exit aperture 124 to receive the portion of the associated conductor 108 that still includes its insulation 110. The conductor 108 extends around the arm end 126, and the uninsulated portion of the conductor 108 then extends downwardly along the first recess 116.

[0047] Each of the first recess 116 and the second recess 118 may include a flat portion or a tapered portion. The tapered recesses 116, 118 may include V-shaped or U-shaped recesses 116, 118 that better constrain the conductor 108 in a desired position.

[0048] As will be noted, the wire rack 112 is easily attached to the cable 102 without requiring any special tools or skills. Additionally, each of the conductors 108 is positioned and exposed as needed to complete the termination without requiring special tools or skills.

[0049] Figure 2 The next step in the termination of the Ethernet cable 122 is shown in which the wire rack 112 is received within the connector 202. The connector 202 includes an outer wall 212 that defines a recessed space 214 in the connector 202. In the illustrated construction, the outer wall 212 is annular, although other shapes and arrangements are possible.

[0050] The Ethernet base 210 extends from the connector 202 within the recessed space 214 and defines eight apertures 204. The apertures 204 are arranged in a pattern corresponding to the pattern of the arms 114. Any pattern can be used as long as the pattern of the arms 114 matches the pattern of the apertures 204. The orthogonal pattern shown in the illustrated design facilitates data transmission (communication). Each pair is shown perpendicular to each other.

[0051] A contact sleeve 206 is inserted into each of the apertures 204 to provide a contact surface for each of the conductors 108 that is a more conductive conductor than the Ethernet base 210 in which the aperture 204 is formed. Each contact sleeve 206 is substantially an annular cylinder and is Figure 4 The Ethernet base 210 and the contact sleeve 206 are formed as a single body. The contact sleeve 206 may comprise a plated copper alloy and be overmolded with PEEK.

[0052] Four additional power connectors 208 extend from the connector 202 within the recessed space 214. These power connectors 208 may be used to facilitate power connections or any other desired connections.

[0053] Figure 3 The termination device is shown after the wire rack 112 is inserted into the connector 202. In this arrangement, each arm 114 is positioned within one of the apertures 204 defined by the Ethernet base 210.

[0054] Figure 4 and Figure 5 yes Figure 3 . As shown, the contact sleeve 206 is inserted into the aperture 204 and includes an inner bore sized to receive the arm 114 and its associated conductor 108. The contact sleeve 206 includes an undercut 402 that is arranged to engage a latch member 404 formed as part of each arm 114. The engagement of the undercut 402 and the latch member 404 helps retain the wire frame 112 in the connector 202.

[0055] Each contact sleeve 206 also includes a reduced diameter portion 406 that is sized to engage the conductor 108 to compress the conductor 108 tightly against the contact sleeve 206, thereby forming an electrical connection. Upon entry, the arms 114 will each resiliently deflect (similar to a cantilever) until removed from the contact sleeve 206.

[0056] like Figure 6 , the support wedge 602 is positioned on the exterior of the cable jacket 106 in the area where the wire rack 112 engages the filler sleeve 104 and where the filler sleeve 104 is inserted under the cable jacket 106. In this position, the support wedge 602 transfers pressure to the cable jacket 106 to enhance retention of the filler sleeve 104 within the cable jacket 106.

[0057] Figure 7 1 and 2. The placement of the termination cover 702 over the wire rack 112 and the Ethernet base 210 is shown. The termination cover 702 includes a base portion 704 and a cable portion 706. The base portion 704 is shaped to generally match the shape of the Ethernet base 210 so that when installed, the base portion 704 and the Ethernet base 210 mate with each other. The inner profile of the base portion 704 is sized so that it holds the attachment legs 128 in place when installed. The outer shape of the termination cover 702 provides a smooth profile for the termination shoe 802 to sit upon.

[0058] The cable portion 706 is generally cylindrical and includes an aperture sized to tightly engage the outer surface of the cable jacket 106 and / or the support wedge 602. When installed, the support wedge 602 also supports the termination cover 702. In other configurations, the cable portion 706 can be sized to engage and form a seal with another component, such as the wire rack 112.

[0059] The next component for the termination of the Ethernet cable 122 is the termination shoe 802, which is placed on the termination cover 702, as shown in FIG. Figure 8 The termination boot 802 is a resilient member, such as an elastic material, that covers the termination cover 702 and the power connector 208. The outer surface of the cable jacket 106 contacts the termination boot 802, so that the termination boot 802, the cable jacket 106 and the termination cover 702 form a seal therebetween.

[0060] like Figure 9 , a compression ring 902 is positioned within the connector 202 and is operable to compress the termination boot 802 against the outer wall 212 and the termination cover 702, thereby forming an additional seal between the external environment and the connection formed between each conductor 108 and the connector 202. To enhance the seal between the termination boot 802 and the outer wall 212, the termination boot 802 may include one or more ridges 904. The ridges 904 are pressed against the outer wall 212 to form the desired seal.

[0061] In some configurations, the outer surface of the connector 202 includes a groove that is arranged to receive a sealing member (e.g., an O-ring, etc.). A metal sheath (not shown) can be assembled over the sealing member to cover the termination boot 802, the pressure ring 902, and the recessed space 214, thereby further sealing the area. In some configurations, a sealant or other substance is added to the space between the metal sheath and the recessed space 214. If desired, a grounding ring (not shown) can be positioned within the groove of the pressure ring 902 and assist in terminating the cable shield. When the outer sheath (not shown) is installed, the grounding ring is fixed in place.

[0062] To complete the termination of cable 102 (specifically, Ethernet cable 122), a portion of cable jacket 106 is removed to expose conductors 108. Filler sleeve 104 is then positioned so that a portion of filler sleeve 104 is located beneath cable jacket 106. Each conductor 108 extends through wire frame 112, with each conductor 108 passing through exit aperture 124. A portion of each conductor 108 is stripped to remove insulation 110 and expose conductor 108. Conductor 108 is then positioned so that the still-insulated portion extends along second recess 118, the stripped or unstripped portion passes around arm end 126, and the stripped portion of conductor 108 passes along first recess 116.

[0063] Next, the wire frame 112 is inserted into the connector 202 by inserting each arm 114 into one of the contact sleeves 206 disposed in one of the apertures 204. Once positioned, the conductor 108 surrounding each arm 114 contacts the contact sleeve 206 to form a secure electrical connection.

[0064] The support wedge 602 is installed adjacent to the wire rack 112 and then the termination cover 702 is positioned over the support wedge 602, the wire rack 112 and the Ethernet base 210. The termination cover 702 contacts the Ethernet base 210 and may contact the cable jacket 106 or the wire rack 112.

[0065] Next, the termination shoe 802 is positioned over the termination cover 702 and the power connector 208 to form a seal. Figure 9 As shown in FIG, the termination boot 802 contacts the cable jacket 106, the termination cover 702, and the power connector 208 to form the desired seal.

[0066] The compression ring 902 is positioned within the termination boot 802 to compress it against the outer wall 212 of the connector 202. The compression ring 902 urges the termination boot 802 into sealing contact with the outer wall 212 of the connector 202 to enhance the seal.

[0067] Thus, the construction shown facilitates the termination of Ethernet cables 122 without the need for any special tools and requires little to no special skills, thereby reducing the cost and lead time of terminating such cables 102. In particular, the termination described herein does not require welding or any subsequent NDT (non-destructive testing), such as CT (computed tomography) testing on the terminated joint, thereby significantly reducing assembly time and costs (including third-party testing). In addition, the termination device allows all components to be disassembled without damage and eliminates the complexity and specialized training required to assemble the termination device. The arrangement also allows for reuse of the product and reduces overall waste. In addition, no special tools (such as crimping / swaging tools or machines) are required to perform the assembly, and no potting solution is required to provide strain relief. Thus, the arrangement discussed herein allows Ethernet cables 122 that were not originally intended for subsea applications to be used in subsea or marine applications.

[0068] Although the exemplary embodiments of the present invention have been described in detail, those skilled in the art will understand that they can make various changes, substitutions, variations and alterations herein without departing from the spirit and scope of the invention in its broadest form.

[0069] Nothing in this application should be construed as implying that any particular element, step, act, or function is essential to the scope of the claims: the scope of patented subject matter is limited only by the allowed claims. Furthermore, these claims are not intended to utilize means-plus-function claim construction unless a participle is followed by the explicit words "means for..."

Claims

1. A termination system, comprising: a cable comprising a first number of conductors; a wire rack coupled to the cable and comprising a second number of arms arranged in a first pattern, the second number being equal to the first number, each arm including a first recess extending to an end of the arm, a portion of one of the first number of conductors being positioned within the first recess; a connector comprising a third number of apertures arranged in a second pattern, the second pattern corresponding to the first pattern; a plurality of contact sleeves, each contact sleeve disposed within one of the apertures and each contact sleeve sized to receive one of the arms, the conductor associated with the arm being in electrical contact with the contact sleeve; as well as A termination cover is coupled to the cable.

2. The termination system according to claim 1, wherein: The cable is an Ethernet cable, and wherein the first number, the second number, and the third number are each equal to eight.

3. The termination system according to claim 1, wherein: Each arm includes a latch member that engages an associated contact sleeve to retain the arm within the contact sleeve.

4. The termination system according to claim 1, wherein: Each arm includes a second recess opposite the first recess, and wherein a portion of the conductor is disposed within each of the first recess and the second recess.

5. The termination system according to claim 4, wherein: Each contact sleeve comprises a reduced diameter portion arranged to engage the portion of the conductor in each of the first and second recesses.

6. The termination system according to claim 1, wherein: The termination system also includes a termination shoe positioned to cover the termination cover and form a high pressure seal with the cable.

7. The termination system according to claim 1, wherein: The connector comprises an annular outer wall, and wherein a compression ring is positioned between the termination cover and the outer wall, the compression ring being located above the termination shoe and pressing the termination shoe against the outer wall.

8. The termination system of claim 1, wherein: Each of the arms extends parallel to the long axis of the wire frame.

9. A termination system, comprising: an Ethernet cable comprising eight conductors; a wire rack coupled to the Ethernet cable and comprising eight arms arranged in a pattern, each arm including a first recess extending to an end of the arm, each conductor associated with one of the arms and including a portion positioned within the first recess; a connector comprising eight apertures arranged in said pattern; eight contact sleeves, each contact sleeve disposed within one of the apertures and each contact sleeve sized to receive one of the arms, the conductor associated with the arm being in electrical contact with the contact sleeve; as well as A termination cover is coupled to the cable.

10. The termination system of claim 9, wherein: The contact sleeves are arranged orthogonally to match the pattern of the arms.

11. The termination system according to claim 9, wherein: The cable is an Ethernet cable, and wherein the first quantity, the second quantity, and the third quantity are each equal to eight.

12. The termination system of claim 9, wherein: Each arm includes a latch member that engages an associated contact sleeve to retain the arm within the contact sleeve.

13. The termination system of claim 9, wherein: Each arm includes a second recess opposite the first recess, and wherein a portion of the conductor is disposed within each of the first recess and the second recess.

14. The termination system of claim 13, wherein: Each contact sleeve comprises a reduced diameter portion arranged to engage the portion of the conductor in each of the first and second recesses.

15. The termination system of claim 9, wherein: The termination system also includes a termination shoe positioned to cover the termination cover and form a high pressure seal with the cable.

16. The termination system of claim 9, wherein: The connector comprises an annular outer wall, and wherein a compression ring is positioned between the termination cover and the outer wall, the compression ring being located above the termination shoe and pressing the termination shoe against the outer wall.

17. The termination system of claim 9, wherein: Each of the arms extends parallel to the long axis of the wire frame.

18. A method of terminating an Ethernet cable, the method comprising: connecting a wire rack to the Ethernet cable, the wire rack comprising eight arms extending parallel to one another along a long axis; extending each of the eight conductors along one and only one of the arms in a direction parallel to the long axis along a first side and a second side opposite the first side; positioning each of eight contact sleeves in an aperture formed in the connector; inserting each of the arms into one of the contact sleeves so that the corresponding conductor of each arm makes electrical connection with the corresponding contact sleeve; as well as Position the termination cap to cover the wire rack.

19. The method of claim 18, further comprising forming a first recess on the first side of each arm portion and forming a second recess on the second side of each arm portion.

20. The method of claim 18, further comprising positioning a termination boot to cover the termination cover and form a high pressure seal with the cable.

21. The method of claim 18, further comprising inserting a compression ring on the termination shoe between the termination cover and an outer wall of the receptacle connector, and pressing the termination shoe against the outer wall.

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