Flat-Profile Cable Armor for Smoother Pulling Through Studs
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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 valley width between peaks and allowing for easier installation by minimizing hang-ups and tangles.
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 excessive hang-ups and gets stuck on studs during installation
Solution Approach 1:
The patent modifies the geometric parameters of the armor profile by reducing the valley width between peaks and optimizing the curvature of the peaks. This parameter change creates a flatter overall profile that minimizes interference with studs and obstacles during installation, directly resolving the hang-up problem while maintaining protective function
Solution Approach 2:
The patent employs curved peak sections with optimized radius of curvature to create a smoother armor profile. The curved geometry allows the cable to better conform to irregular surfaces and pass through tight spaces without getting caught on studs, improving ease of installation
2Strength
If deeper and wider valleys are used in the armor profile, then the cable provides enhanced protection, but the cable causes more hang-ups and requires readjustment during installation
Solution Approach 1:
The patent optimizes the valley width parameter to a specific range that balances protection and installability. By controlling the valley width to be within a precise range, the cable maintains adequate protective capability while minimizing the depth and width of valleys that cause hang-ups, thereby reducing installation time and readjustment requirements
Solution Approach 2:
The patent applies different geometric characteristics to different sections of the armor profile. The peaks are designed with specific curvature radii for optimal protection, while the valleys are controlled to have limited depth and width. This local differentiation allows the cable to provide enhanced protection where needed while maintaining smooth passage through installation obstacles
3Ease of operation
If a flatter armor profile is used, then the cable installs more easily through studs, but the cable may compromise crush-resistance and structural integrity
Solution Approach 1:
The patent identifies and controls critical geometric parameters including peak curvature radius, valley width, and profile height within specific ranges. These parameter specifications ensure that the flatter profile provides adequate crush-resistance while maintaining the installation advantages of a reduced overall height and smoother contour
Solution Approach 2:
The patent specifies material properties and compositional requirements for the armor covering that complement the flatter geometric profile. By selecting materials with appropriate mechanical properties, the cable maintains sufficient crush-resistance and structural integrity even with the reduced profile depth, thereby enabling easier installation without compromising strength
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.