Cable Package With Continuous Opening For Tension Control
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Solution Overview
Problem
Conventional wire packages are not durable enough to withstand the conditions encountered by electricians during installation, often breaking or causing the cable to tangle, and require multiple electricians to manage and pull multiple reels, making the process labor-intensive and strenuous.
Innovation Solution
A cable package design featuring a chamber with a continuous opening that applies pressure to the cable, maintaining back tension and preventing unwinding, allowing a single electrician to handle multiple wires with reduced effort, and incorporating a winding pattern that forms an ellipse to maintain stability and prevent tangling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire packages are used, then multiple electricians can manage multiple reels, but the packages break or cause cable tangling under field conditions
Solution Approach 1:
The package is divided into a rigid outer shell and an inner reel assembly that can rotate independently. The reel is segmented into flanges that guide the cable, separating the structural support function from the cable payment function. This segmentation allows the rigid shell to provide durability while the flexible reel assembly ensures smooth cable payment without tangling.
Solution Approach 2:
The patent introduces an intermediary mechanism - the flanged reel assembly - that mediates between the rigid package structure and the flexible cable. The flanges act as intermediaries that guide the cable layers, preventing tangling while the rigid shell maintains package integrity under field conditions.
2Productivity
If multiple electricians are used to pull wire from reels, then the wire can be installed, but the process is labor intensive and strenuous
Solution Approach 1:
The patent combines multiple cable reels into a single integrated package structure. Multiple electricians can now work from one package, merging the functionality of multiple separate reels into one unit. This reduces the number of handling operations needed and decreases labor intensity while maintaining productivity.
Solution Approach 2:
The package design serves multiple functions simultaneously: it provides structural protection, enables rotation during cable payment, guides cable layers through flanges, and accommodates multiple reels. This multi-functionality allows a single package to replace multiple separate reel systems, reducing the number of electricians needed.
3Strength
If the package structure is made rigid to withstand field conditions, then durability improves, but the cable may become tangled during payment
Solution Approach 1:
The package is segmented into a rigid outer shell for strength and a flexible inner reel assembly for cable management. The reel can rotate and flex independently within the rigid shell, allowing the cable to pay off smoothly without tangling while the shell maintains package strength under field conditions.
Solution Approach 2:
Different parts of the package have different mechanical properties: the outer shell is rigid for durability, while the inner reel assembly is more flexible to accommodate cable payment. The flanges have specific local geometry that guides the cable, creating localized control over cable behavior without compromising overall package strength.
Data Source
AI summary
Consistent with embodiments of the invention, a cable package may be provided. The cable package may comprise a cable and a chamber. The cable may comprise a winding and at least one free end. The chamber may define an internal volume containing the cable. The chamber may comprise a continuous opening. The continuous opening may comprise at least one surface arranged to apply pressure to a portion of the cable located proximate to the continuous opening.