Monolithic Cable Braid Flare Tool With Living Hinge Flexure
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Solution Overview
Problem
Existing cable preparation tools for flaring or opening braided shielding layers are complex and costly due to their multi-component assemblies and moving parts.
Innovation Solution
A cable braid flare tool with a monolithic, flexible body featuring hingedly connected gripping arms and lever arms, utilizing a living hinge and flexure for compressive force application without moving parts, allowing for efficient flaring through a single-piece construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-component assemblies with moving parts are used for flaring braided shielding layers, then the flaring function is effective, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple components (gripping arms, lever arms, torsion spring, and housing) into a single integrated tool body. The gripping arms and lever arms are formed as one piece from a flexible material, eliminating the need for separate moving parts while maintaining the flaring function. This combining approach directly reduces device complexity and manufacturing cost while preserving reliability.
Solution Approach 2:
The tool body is constructed from a flexible material that can deform elastically to provide the necessary gripping and flaring forces. The flexible material replaces rigid moving parts with springs and joints, achieving the same functional effect through material properties rather than mechanical assemblies. This reduces the number of components while maintaining the effectiveness of the flaring operation.
2Reliability
If multi-component assemblies with moving parts are used for flaring braided shielding layers, then the flaring function is effective, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple discrete components into a single monolithic tool body, which can be manufactured as one piece using processes like injection molding. This eliminates the need for assembly operations, reduces inventory of multiple parts, and lowers manufacturing costs while maintaining the effective flaring function.
Solution Approach 2:
The flexible material used for the tool body can be manufactured at low cost and the tool can be disposed of or replaced economically. This approach trades the durability of expensive multi-component tools for the economic advantage of inexpensive single-piece tools, particularly beneficial for disposable or frequently replaced hand tools.
3Device complexity
If a monolithic flexible body with hingedly connected arms is used, then the device complexity is reduced, but the mechanism for applying compressive force must be simplified
Solution Approach 1:
The flexible material itself provides the elastic restoring force needed to apply compressive force to the braided shielding layer. When the user applies force to open the gripping arms, the flexible material stores elastic energy and automatically generates the return force needed for flaring. This self-service mechanism eliminates the need for separate springs or force-generating components, simplifying the device while maintaining adequate force application.
Solution Approach 2:
The patent changes the physical parameters of the tool body material, using a flexible material with appropriate elastic properties. By selecting material with the right combination of flexibility and elastic recovery, the tool can generate sufficient compressive force without mechanical springs. The force generation is achieved through material parameter selection rather than mechanical force mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool provides a simplified, reliable, and cost-effective solution for flaring braided shielding layers with improved accuracy and efficiency, reducing production costs and enhancing user operation.
Implementation Method 1
A flexure is arranged between the first lever arm and the second lever arm and biases the first and second lever arms into a predetermined position
Implementation Method 2
The gripping arms 20,30 are hingedly or pivotally connected to one another via an integral and/or living hinge 24. The hinge 24 enables the gripping arms 20,30 to be biased both toward one another, as well as away from one another
Data Source
Figure 1
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AI summary
A braid flaring tool (10) having a first gripping portion or arm (20) and a second gripping portion or arm (30) hingedly connected to the first gripping portion. The first and second gripping portions (20, 30) define a cable space (25) therebetween sized or configured to receive a cable (100). A first lever arm (40) and a second lever arm (50) extend from the first gripping portion (20) and the second gripping portion (30), respectively. A flexure (60) is arranged between the first lever arm (40) and the second lever arm (50) and biases the first and second lever arms (40, 50) into a predetermined position.