Magnetized cable for improved cable management

Abstract

A magnetized cable (101) in which the magnetic force of the cable is configured to assist in aligning and maintaining the alignment of the cable while the cable is looped for storage, and also assists in maintaining the coiled configuration of the cable when the cable is wound or looped. Embodiments of the magnetized cable (101) may include an elongated flexible magnetized component (EFMC) (201) of a flexible polymer, such as rubber and / or one or more other suitable materials, in combination with magnetic particles including iron, neodymium, ferrite, cobalt, nickel, and / or other suitable magnetic elements or compounds. The EFMC (201) may be exposed to a strong magnetic field to generate a permanent magnet. The EFMC (201) may be encapsulated within a sheath (210) of braided textile yarn or another suitable material.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 63 / 482,006, filed January 27, 2023, the entire contents of which are incorporated herein by reference.

[0002] (Technical field) TECHNICAL FIELD This application relates generally to cables used with electronic products, and more particularly to the management of such cables. [Background technology]

[0003] Electronic products such as laptop computers, smartphones, etc. often use cables for input and output of power, data, audio, etc. When not in use, such cables frequently become tangled, causing frustration to users. Summary of the Invention [Problem to be solved by the invention]

[0004] This specification discloses a magnetized cable configured so that the persistent magnetic field generated by the cable assists in aligning and maintaining the alignment of the cable while the cable is looped, wound, or otherwise coiled for storage or transport, and, when in a coiled state, in maintaining the cable in a coiled state while also allowing a user to easily unwind the cable by hand. [Means for solving the problem]

[0005] In one aspect, the disclosed magnetized cable includes an elongated flexible magnetizing component (EFMC) and one or more bare or insulated conductive wires. The EFMC is manufactured to generate a sustained magnetic force when at least some portions of the magnetized cable and at least some other portions of the magnetized cable are in close proximity to one another, e.g., while the magnetized cable is coiled or being coiled, such that at least some portions of the magnetized cable are magnetically attracted to at least some other portions of the magnetized cable. The EFMC may include a flexible polymer base or binder composed of rubber, silicone, silicone rubber, chlorinated polyethylene, or another suitable material in combination with a plurality of magnetic particles randomly or otherwise distributed within and / or on the flexible polymer base. The magnetic particles may include particles of any suitable magnetic element, compound, or alloy, including, by way of non-limiting example, ferrite, iron, cobalt, nickel, neodymium, ferric oxide, alnico, samarium, and the like. The magnetic particles may be produced by grinding or otherwise processing a magnetic material.

[0006] EFMCs may be manufactured by extruding, molding, or otherwise processing a pliable polymer binder to produce an elongated, flexible component that can be cut to any desired length. Magnetic particles may be combined with the pliable polymer binder during and / or after the formation of the elongated, flexible component. The magnetic particles may then be magnetically aligned by exposing the elongated, flexible component to a strong magnetic field generated by one or more magnets. Various configurations of north and south poles may be used to enhance the magnetic pull of the resulting EFMC.

[0007] In at least one embodiment, the magnetic cable has a generally rectangular cross-section defining first and second substantially flat, parallel major surfaces, and the persistent magnetic field is configured such that the first major surface is in a first polarity region of the persistent magnetic field and the second major surface is in a second polarity region of the persistent magnetic field, thereby providing a magnetic attraction force between the major surfaces when the major surfaces are in close proximity to one another, e.g., during coiling of the cable or when the cable is already in a coiled state. In some embodiments, the cross-section may have an aspect ratio, e.g., a width-to-height ratio in the range of about 2 to 10.

[0008] In some embodiments, one or more of the wires may be embedded within and surrounded by the EFMC. In some embodiments, the EFMC may define one or more elongated grooves for accommodating one or more of the wires. The magnetized cable may further include a cable jacket or sheath that encapsulates and secures the one or more conductive wires and the EFMC. In sheathed embodiments, the sheath may be constructed from a polymer, such as plastic, nylon, rubber, or another suitable material, that encapsulates and secures the EFMC and wires. The sheath may be implemented with a braided or woven fabric. The fabric may be natural or synthetic.

[0009] In another aspect, a disclosed method for manufacturing a magnetized cable includes forming an elongated flexible component, incorporating magnetic particles into and / or on the elongated flexible component, and magnetizing the flexible component by exposing it to a strong magnetic field generated by one or more magnets to produce an EFMC as a flexible permanent magnet, wherein at least some portions of the EFMC, e.g., a first major surface of the EFMC, are magnetically attracted to at least some other portions of the EFMC, e.g., a second major surface of the EFMC. The magnetically attracted portions of the EFMC may be configured to assist or otherwise facilitate the process of coiling or rolling the magnetized cable for storage. One or more conductive wires may be incorporated within or adjacent to the EFMC, and an optional sheath may be formed to encapsulate and secure the EFMC and one or more wires. The EFMC and one or more wires may then be cut to a desired length. Electrical connectors may be attached to both ends of the magnetized cable. The elongated flexible component may comprise a polymer selected from rubber, silicone, silicone rubber, or chlorinated polyethylene or other materials.

[0010] The magnetized cable may have a generally rectangular cross-section, and the persistent magnetic force may include a first polar region corresponding to a first major surface defined by the generally rectangular cross-section and a second polar region corresponding to a second major surface defined by the generally rectangular cross-section.

[0011] Incorporating one or more conductive wires may include forming the EFMC around the one or more conductive wires such that the wires are embedded in the EFMC. Alternatively, the wires may be incorporated adjacent to the EFMC but not embedded within it. These embodiments may further include encapsulating the EFMC and one or more conductive wires within a sheath of braided nylon or another suitable material, with the wires positioned within a void defined by the sheath and the EFMC.

[0012] The technical advantages of the present disclosure will become readily apparent to those skilled in the art from the drawings, description, and claims contained herein. The object and advantages of the embodiments will be realized and attained at least by the elements, features, and combinations particularly pointed out in the claims.

[0013] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the scope of the claims set forth in this disclosure.

[0014] A more complete understanding of the present embodiments and their advantages can be obtained by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like features, and in which: [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 shows a perspective view of a magnetized cable. [Figure 2] 1 shows a cross section of an unsheathed magnetized cable. [Figure 3] 1 shows a coated embodiment of a magnetized cable. [Figure 4] 1 shows a flow diagram of a method for manufacturing a magnetized cable. DETAILED DESCRIPTION OF THE INVENTION

[0016] Exemplary embodiments and their advantages are best understood by referring to FIGS. 1-4, where like numbers are used to indicate like and corresponding parts unless otherwise specified.

[0017] In the following description, details are set forth as examples to facilitate discussion of the disclosed subject matter, however, it will be apparent to those skilled in the art that the disclosed embodiments are exemplary and do not encompass all possible embodiments.

[0018] Throughout this disclosure, hyphenated forms of reference numbers refer to specific instances of elements, while non-hyphenated forms of reference numbers refer to elements generically. Thus, for example, "Device 12-1" refers to an instance of a class of devices that may be collectively referred to as "Device 12," any of which may be collectively referred to as "Device 12."

[0019] Referring now to the drawings, FIG. 1 shows a perspective view of a magnetized cable assembly 100 including an elongated, flexible magnetized cable 101 including one or more bare or insulated conductive wires (not visible in FIG. 1 ) connected to electrical connectors 120 at both ends of the magnetized cable 101. The magnetized cable 101 incorporates magnetic particles that are magnetized to generate a persistent magnetic field in which some surface regions of the magnetized cable 101 are within the north pole region of the magnetic field and other surface regions of the magnetized cable 101 are within the south pole region of the magnetic field. In at least some embodiments, the orientation and strength of the persistent magnetic field, in combination with the geometry and dimensions of the magnetized cable 101, allow for efficient storage and handling of the magnetized cable 101 by facilitating coiling the magnetized cable 101 from an extended or uncoiled state, and also allows the magnetized cable 101 to remain in a coiled state once coiled while also allowing the magnetized cable 101 to be easily manually uncoiled from the coiled state.

[0020] Embodiments of the magnetized cable 101 may have a rectangular or nearly rectangular cross-section including a pair of opposing, substantially flat, parallel major surfaces and a pair of substantially flat, parallel minor surfaces. In these rectangular embodiments, the persistent magnetic field may be oriented to generate a north pole region encompassing one of the major surfaces and a south pole region encompassing the other major surface. Those skilled in the art will appreciate that in such embodiments, the magnetized cable 101 features north and south pole faces that contact each other when the cable is coiled or otherwise wrapped around itself, for example, before storing the magnetized cable 101 when not in use. Those skilled in the art will further appreciate that the magnetized cable 101 is not limited to a rectangular configuration, and that storage and handling advantages of the magnetized cable 101 may be realized in other configurations, including, but not limited to, circular and other elliptical cross-sectional configurations.

[0021] 2 and 3 show cross sections of unsheathed (FIG. 2) and coated (FIG. 3) implementations of magnetized cable 101. The unsheathed implementation of magnetized cable 101 shown in FIG. 2 includes an elongated, flexible magnetic member, referred to herein simply as elongated flexible magnetizing component (EFMC) 201, that encompasses one or more conductive wires 203. While FIG. 2 shows magnetized cable 101 featuring three wires (203-1, 203-2, and 203-3), other implementations may use fewer or more wires 203.

[0022] The EFMC 201 may include any suitable combination of a flexible base material and magnetized particles randomly or otherwise distributed on or within the base. The base material may be implemented with any of a variety of natural or synthetic polymers that exhibit suitable flexibility. In at least some embodiments, the base material is or includes a soft natural or synthetic rubber, silicone, silicone rubber, or chlorinated polyethylene material that exhibits sufficient flexibility and other desirable properties, including, but not limited to, low electrical and thermal conductivity, high thermal and chemical stability, and low toxicity. The base material may be produced by any suitable manufacturing process, including an extrusion process, a compression molding process, or the like. The magnetized particles may include magnetic particles exposed to a magnetic field strong enough to align the magnetic orientation of the magnetic particles. The source material may be milled or otherwise processed to produce a magnetic powder that can be readily incorporated into the base material.

[0023] The unsheathed magnetized cable 101 shown in FIG. 2 features a rectangular or nearly rectangular cross-section, optionally with rounded or beveled corners, defining substantially flat, parallel, opposing major surfaces 202-1 and 202-2. The illustrated magnetized cable 101 includes three wires 203-1, 203-2, and 203-3 embedded in an EFMC 201. Each wire 203 shown in FIG. 2 includes a conductive core 205 encapsulated within an optional insulating coating 204. In at least one embodiment, the conductive core 205 is implemented with tin-plated copper, and the insulating coating 204 is implemented with highly flexible PVC. Other implementations may use different materials for the conductive core 205 and the insulating coating 204.

[0024] The wires 203 shown in FIG. 2 include two wires 205-1 and 205-3 having a larger diameter or smaller gauge and a third wire 205-2 having a smaller diameter or larger gauge. However, again, the number of wires 203 included in the magnetized cable 101 and the diameter of each wire 203 are design choices that may vary from implementation to implementation. The wires 203 may be incorporated into the EFMC 201 while it is being formed. For example, the magnetized cable may be manufactured by an extrusion process in which one or more wires 203 are fed through an extrusion tool as the EFMC 201 is extruded around the one or more wires 203. Other embodiments may incorporate the wires 203 into the EFMC 201 after it is formed.

[0025] 2 further illustrates a magnetic field indicator 220 for communicating the orientation of the persistent magnetic field generated by the magnetized cable 101. The magnetic field indicator 220 in FIG. 2 indicates that the “N” face, i.e., first major surface 202-1, of the magnetized cable 101 is in the north-pole region of the magnetic field, and simultaneously, the “S” face, i.e., second major surface 202-2, of the magnetized cable 101 is in the south-pole region of the persistent magnetic field. In the illustrated configuration, it will be readily apparent that when the magnetized cable 101 is coiled on itself, whether for storage or otherwise, the portion of the first major surface 202-1 in one loop of the coiled cable will be in close proximity to the portion of the second major surface 202-2 in the next adjacent loop of the coiled cable, and that the persistent magnetic field provides a magnetic attraction between the opposing major surfaces that actively assists the coiling process as the cable magnetically “snaps” on itself. In at least some embodiments, the strength of the persistent magnetic field is sufficient to maintain the opposing major surfaces of the magnetized cable 101 in contact with each other after the person or device coiling the cable releases the cable.

[0026] Some embodiments implement a Halbach array configuration with alternating magnetic field polarity, e.g., NSNS, to increase the magnetic flux on one side of the magnetic assembly.

[0027] The covered magnetized cable 101 shown in FIG. 3 , like the uncovered magnetized cable 101 shown in FIG. 2 , includes an EFMC 201 and a set of three wires 203-1, 203-2, and 203-3. However, unlike the magnetized cable 101 of FIG. 2 , the magnetized cable 101 of FIG. 3 includes a sheath 210 that surrounds and encapsulates the EFMC 201 and wires 203. Furthermore, while the wires 203 shown in FIG. 2 are embedded within the EFMC 201, the wires 203 shown in FIG. 3 are not embedded within the EFMC 201. Instead, the wires 203 of FIG. 3 are positioned within a gap 207 defined between the EFMC 201 and the surrounding sheath 210. The EFMC 201 of FIG. 3 occupies a significant portion of the cavity defined by the interior of the sheath 210, and the gap 207 is not large enough to leave any appreciable distance between the sidewalls of the wires 203 and the sheath 210 or the EFMC 201. Instead, the gap is sized to hold the wire 203 closely adjacent to the sheath 210 and adjacent portions of the EFMC 201. In at least one embodiment, the sheath 210 is constructed from a braided, woven nylon, although other suitable materials may be used. In at least one additional embodiment, the sheath 210 is constructed from an extruded polymer.

[0028] Similar to the magnetized cable 101 of FIG. 2, the sheathed magnetized cable 101 shown in FIG. 3 includes a persistent magnetic field represented by magnetic field indicator 220. The magnetized cable 201 shown in FIG. 3 has an elliptical cross-section defining first and second substantially flat, parallel major surfaces 202-1 and 202-2, and the persistent magnetic field conveyed by indicator 220 positions the first major surface 202-1 in a north-pole region of the persistent magnetic field and the second major surface 202-2 in a south-pole region of the persistent magnetic field. This configuration, similar to the configuration shown in FIG. 2, facilitates efficient handling and storage of the magnetized cable 101 by providing a magnetic field that actively assists the coiling process and also facilitates maintaining the magnetized cable 101 in a coiled position after the cable is coiled. Because the wire 203 is not embedded in the EFMC 201, the EFMC 201 can be manufactured independently of the wire 203.

[0029] 4, a flow diagram illustrates an exemplary method 400 for producing a magnetized cable 101. Although the flow diagram suggests an order or sequence of the operations illustrated, the drawings are not intended to be so limiting, and unless an order of two or more operations is expressly disclosed, the operations of method 400 may be performed in different sequences where appropriate.

[0030] The illustrated method 400 includes grinding and / or otherwise processing a source of magnetic material to produce a magnetic powder containing magnetic particles (operation 402). The source of magnetic material may include scrap, recycled, waste, or otherwise previously used magnetic material.

[0031] 4 further includes forming a flexible elongated component by combining magnetic particles with an EFMC-based material (operation 404). The EFMC-based material may include rubber, silicone, silicone rubber, or another suitable material. The EFMC-based material may be extruded, molded, or otherwise formed into the elongated flexible component, and the magnetic particles may be combined with the base material either during or after the forming process to produce a random or non-random distribution of magnetic particles within the flexible elongated component.

[0032] After the formation process, the flexible elongated component may be exposed (operation 406) to a magnetic field of sufficient strength and duration to align or substantially align the magnetic orientation of all or substantially all of the magnetic particles, establishing a persistent magnetic field within the flexible elongated component, thereby transforming the combination of the flexible elongated component and the magnetic particles into an elongated flexible permanent magnet, referred to herein as an EFMC.

[0033] As shown in FIG. 4 , method 400 may further include incorporating one or more bare or insulated conductive wires within or around the EFMC (operation 410). In some embodiments, the EFMC may be formed to include one or more elongated grooves suitable for receiving or engaging the one or more wires. In these embodiments, the one or more wires may be incorporated after the EFMC is formed. In other embodiments, the one or more wires may be present when the EFMC is formed, such that the EFMC is formed around and encapsulates the one or more wires.

[0034] The method 400 shown in FIG. 4 further includes an optional act (act 412) for encapsulating the EFMC and one or more wires within a suitable sheath.

[0035] In other embodiments, the magnetized cable may be produced by providing a flexible magnet in a tube form, the flexible magnet including a polymer having a magnetic material, and the flexible magnetic tube may be positioned around and / or adjacent to one or more insulated or bare metallic conductive wires before securing the one or more wires and magnetic tube by heat shrinking, adhesive bonding, or another suitable method.

[0036] In some embodiments, the flexible magnet may be supplied in tape form, which may be secured to the length of the cable by heat shrinking, adhesive bonding, or other methods.

[0037] In some embodiments, one or more magnetic wires may be added parallel to existing conductors in the cable, while in other embodiments, magnetic wires may be used to replace existing conductors in the cable.

[0038] In some embodiments, a magnetic sheath may be added around an existing non-magnetized cable.

[0039] In another embodiment, individual (discrete) magnetic beads or shapes may be arranged along the length of the cable.

[0040] In some embodiments, magnetic flux concentrators may be used. Magnetic flux concentrators are pieces of ferrous material that can be used to direct or enhance magnetic flux in a particular direction. In embodiments featuring a rectangular cross-section cable (e.g., magnetized cable 101 in FIG. 1), the flat surfaces of the cable allow for a larger surface area (and therefore a larger magnetic force) between cable loops.

[0041] In some embodiments, additional magnetization may be added to connectors at either end of the magnetized cable. The connectors are typically larger in cross section than the cable between them, allowing for greater capacity for more magnetic material and stronger magnetization. The strong magnetic attraction at the ends of the cable can provide tactile and / or audible feedback to the user that the cable is tightly coiled.

[0042] The present disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments herein that would be understood by a person skilled in the art. Similarly, where appropriate, the appended claims encompass all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments herein that would be understood by a person skilled in the art. Furthermore, any reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted, arranged, capable of, configured, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component so long as it is so adapted, arranged, capable of, configured, enabled to, operable to, or operative to, regardless of whether it or that particular function is activated, turned on, or unlocked.

[0043] All examples and conditional language recited herein are intended as educational objects to assist the reader in understanding the concepts contributed by the inventor to advance the present disclosure and the art, and are not to be construed as being limited to such specifically recited examples and conditions. Although embodiments of the present disclosure have been described in detail, it should be understood that various changes, substitutions, and alterations can be made thereto without departing from the spirit and scope of the present disclosure.

Claims

1. A magnetized cable, one or more conductive wires; an elongated flexible magnetizing component (EFMC) configured to generate a sustained magnetic force that causes at least some portions of the magnetized cable to be magnetically attracted to at least some other portions of the magnetized cable when the magnetized cable is coiled; A magnetized cable comprising:

2. The EFMC is a flexible polymer binder; magnetic particles distributed within said flexible polymer binder; 2. The magnetized cable of claim 1, comprising:

3. 3. The magnetized cable of claim 2, wherein the magnetized cable has a generally rectangular cross-section defining a pair of substantially flat, parallel major surfaces, a first of the major surfaces being in a first polarity region of a sustained magnetic field, and a second of the major surfaces being in a second polarity region of the sustained magnetic field.

4. 3. The magnetized cable of claim 2, wherein the magnetic orientation of the magnetic particles is substantially aligned to generate the persistent magnetic force.

5. 10. The magnetized cable of claim 1, further comprising a sheath enclosing said EFMC and said one or more conductive wires.

6. 6. The magnetized cable of claim 5, wherein the sheath comprises a natural or synthetic woven sheath.

7. The magnetized cable of claim 5 , wherein the sheath comprises an extruded polymer sheath.

8. 10. The magnetized cable of claim 1, wherein at least one of the one or more conductive wires is embedded within and surrounded by the EFMC.

9. 10. The magnetized cable of claim 1, wherein at least one or more conductive wires are positioned within elongated grooves of the EFMC.

10. 10. The magnetized cable of claim 1, wherein at least one of the one or more conductive wires comprises an insulated wire comprising an insulating material surrounding a conductive core.

11. 1. A method for manufacturing a magnetized cable, comprising: forming an elongated flexible magnetized component (EFMC); exposing the EFMC to a magnetic field of sufficient strength to create a persistent magnetic field, the persistent magnetic field being oriented such that at least some portions of the EFMC are magnetically attracted to at least some other portions of the EFMC when the magnetized cable is coiled; incorporating one or more conductive wires within or adjacent to the EFMC; A method comprising:

12. The method of claim 11 , wherein forming the EFMC comprises forming a flexible polymer base and incorporating magnetic particles into the flexible polymer base.

13. The cross section of the magnetized cable is substantially rectangular, and the persistent magnetic force is a first polar region corresponding to a first major surface defined by the substantially rectangular cross-section; a second polar region corresponding to a second major surface defined by the substantially rectangular cross-section; 13. The method of claim 12, comprising:

14. 12. The method of claim 11, wherein the EFMC comprises a polymer selected from rubber, silicone, silicone rubber, and chlorinated polyethylene.

15. The method of claim 11 , wherein forming the EFMC comprises extruding the EFMC.

16. The method of claim 11 , wherein forming the EFMC comprises forming the EFMC by a compression molding process.

17. The method of claim 11 , wherein forming the EFMC comprises forming the EFMC by an injection molding process.

18. The method of claim 11 , wherein the step of incorporating one or more conductive wires comprises forming the EFMC around at least one of the one or more conductive wires.

19. The method of claim 11 , further comprising encapsulating the EFMC and the one or more conductive wires in a sheath.

20. 20. The method of claim 19, wherein incorporating the one or more wires comprises incorporating the one or more wires in a gap defined between the sheath and the EFMC.

Images