Flat-Profile Cable Armor for Smooth Stud Installation
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Solution Overview
Problem
Prior art armored cables have pronounced armor profiles that cause hang-ups during installation, especially when routing through wooden or metal studs, leading to inefficiencies and increased installation time.
Innovation Solution
A novel armored cable assembly with a flat metal sheath profile, featuring helically wrapped sections with curved, planar, and angled free ends, reducing the diameter and minimizing valleys between peaks, allowing for easier installation and reduced tangling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional pronounced armor profiles are used, then the cable provides adequate protection and structural integrity, but the cable causes hang-ups and gets caught on studs during installation
Solution Approach 1:
The patent modifies the geometric parameters of the armor profile by reducing the depth and width of valleys between peaks, creating a flatter overall profile. This parameter change allows the cable to pass through studs and obstructions during installation without catching or hanging up, while still maintaining adequate protection when the cable is properly installed
2Strength
If deeper and wider valleys are used in the armor profile, then the cable provides better flexibility and protection, but the cable causes excessive hang-ups when routed through studs
Solution Approach 1:
The patent optimizes the dimensional parameters of the armor sections by reducing valley depth and width while maintaining peak height and interlocking capability. This allows the cable to maintain crush-resistance through proper metal interlocking while significantly reducing installation time by eliminating hang-ups on studs and obstructions
3Ease of operation
If a flat profile is used, then the cable installs smoothly without hang-ups, but the cable may have reduced crush-resistance
Solution Approach 1:
The patent achieves a balance by creating a flatter profile that reduces hang-ups while maintaining adequate crush-resistance through optimized metal thickness, interlocking mechanisms at the peaks, and proper helical wrapping tension. The flat profile refers to reduced valley depth rather than complete elimination of protective features
Solution Approach 2:
The patent may utilize composite construction combining metal armor sections with other protective materials or coatings that enhance crush-resistance without requiring deep valleys, allowing a flatter profile to provide both ease of installation and adequate protection
Data Source
AI summary
Disclosed is an armored cable assembly which may include a plurality of conductors and a metal sheath disposed over the plurality of conductors. The metal sheath may have a plurality of revolutions extending helically along a lengthwise axis, each of the plurality of revolutions including a first section having a curved profile, a second section extending from the first section, the second section having a planar profile, and a third section extending from the second section. The third section may include a free end angled towards an interior cavity of the metal sheath, the free end extending past a plane defined by a bottom most point of the first section of an adjacent revolution, the plane extending perpendicular to the second section.