Environmentally Hardened Ethernet Cable With DB-9 Connectors

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Solution Overview

Problem

Conventional CAT-5 cabling systems face reliability issues and limited power transmission capabilities in environmentally harsh conditions, particularly due to mechanical design flaws in connectors and the inability to efficiently distribute power over long distances without significant signal degradation or increased costs.

Innovation Solution

Employment of a data and power distribution cable with reliable DB-9 connectors, high-performance physical layer transceivers operating at lower clock rates, and full duplex switched packet transmission techniques, along with a power distribution system that includes a power bus and shielded wires to support higher voltage and current, enabling extended operational distances and increased reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional CAT-5 cabling with RJ-45 connectors is used, then installation cost and ease of connection are improved, but reliability in harsh environments deteriorates due to mechanical design flaws

Engineering Contradiction:

Improveinstallation costVSAvoidconnector reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces expensive, unreliable RJ-45 connectors with simpler, more robust DB-9 connectors that are mechanically harder and more reliable in harsh environments. While DB-9 connectors may require more careful installation, their superior mechanical design eliminates the reliability issues of RJ-45 connectors, effectively trading installation convenience for long-term reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Length of stationary object

If transmission distance is extended beyond 100 meters, then network coverage is improved, but signal attenuation and power distribution capabilities deteriorate

Engineering Contradiction:

Improvetransmission distanceVSAvoidsignal quality

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The patent changes the electrical parameters of the transmission system by using lower clock rates for physical layer transceivers, which extends the usable transmission distance beyond the standard 100-meter limit while maintaining signal integrity. This parameter change allows longer cable runs without significant signal degradation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite cable design that integrates both data transmission conductors and power distribution conductors in a single cable assembly. This composite structure enables simultaneous delivery of data and power over extended distances, solving both signal attenuation and power distribution limitations.

Inventive Principle:

Principle #40Composite materials

3Length of stationary object

If fiber optic cable is used for longer distances, then transmission capability is improved, but installation cost and complexity deteriorate

Engineering Contradiction:

Improvetransmission distanceVSAvoidinstallation cost

Core Design Contradiction:

Length of stationary objectVSEase of manufacture

Solution Approach 1:

The patent provides a cost-effective alternative to fiber optic cable by using extended-distance copper cabling with modified electrical parameters. This approach achieves long-distance transmission capabilities without the high capital and installation costs associated with fiber optic infrastructure, making it economically viable for neighborhood-scale networks.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Power

If power distribution over CAT-5 is attempted, then power delivery to remote devices is improved, but voltage drop and current limitations worsen

Engineering Contradiction:

Improvepower distribution capabilityVSAvoidvoltage drop

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent uses a composite cable design with heavier gauge power conductors integrated alongside data conductors. This allows sufficient current carrying capacity to overcome voltage drop over long distances while maintaining data transmission integrity. The composite structure enables both power and data to be delivered effectively to remote devices.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the electrical parameters by using lower voltage levels and adjusted current distribution to minimize power losses. By changing the operational parameters of power delivery, the system achieves effective power distribution over extended distances without excessive voltage drop.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8045565B1Method and apparatus for an environmentally hardened ethernet network system

Publication Date: 2011.10.25 RATEZE REMOTE MGMT LLC

AI summary

In an environmentally hardened network, a data and power distribution cable is employed in connection with reliable end connectors, high performance physical layer transceivers clocked at a lower rate than is specified and full duplex switched packet transmission techniques between switched nodes in order to extend operational distance between network elements. In a specific embodiment, the data and power distribution cable comprises a data distribution element, a power distribution element, an optional strain distribution element, an optional hollow conduit, and an extra shield and outdoor sheath. The cable may incorporate: 1) a Gel filled outdoor UTP (CAT-5) cable; 2) end connectors of type DB-9 [D-Sub] for connection of the UTP to network equipment; 3) power transmission cable of wire gauge sufficient to carry the power required by network equipment (switches, etc) for the specific segment of the network; and optionally 4) a hollow conduit that permits installation of optical fiber before or after installation of the cable.