Low-Profile Cable Armor to Prevent Hang-Ups During Pulling
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Solution Overview
Problem
Prior art metal-clad cables have pronounced peaks and deep valleys, causing installation difficulties such as hang-ups and installer fatigue when passing through studs or cable trays due to increased friction and entanglement.
Innovation Solution
A novel armored cable assembly with a flat exterior armor profile, featuring a metal sheath formed by a continuous strip wound in helical revolutions with specific section lengths and profiles that minimize valley depth and maximize flexibility, allowing easier installation and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal armor has pronounced peaks and deep valleys, then crush resistance is improved, but installation difficulty increases due to hang-ups and friction
Solution Approach 1:
The patent changes the geometric parameters of the metal armor profile from pronounced peaks and deep valleys to a flatter profile with reduced peak height and valley depth. This parameter modification maintains adequate crush resistance while significantly reducing installation friction and hang-ups on studs and cable trays.
Solution Approach 2:
The patent applies different profile characteristics to different parts of the metal armor structure. The flat exterior profile reduces friction during installation, while the underlying helical construction and material properties maintain the necessary crush resistance. This local differentiation resolves the contradiction between installation ease and structural strength.
2Stability of the object's composition
If metal armor has deep valleys between peaks, then flexibility is reduced, but if valleys are minimized, then crush resistance may be compromised
Solution Approach 1:
The patent modifies the valley depth parameter to be minimal or eliminated, creating a flatter profile that improves flexibility and reduces entanglement during installation. The helical construction and material selection compensate for the reduced valley depth, maintaining adequate crush resistance.
Solution Approach 2:
The patent uses helically wound metal strips that combine the flat profile geometry with the inherent flexibility of the metal material. This composite approach allows the armor to achieve both flexibility for easy installation and sufficient crush resistance through the helical construction and material properties.
3Ease of manufacture
If metal armor profile is traditional with pronounced peaks, then manufacturing is simplified, but installation time increases due to readjustment and fatigue
Solution Approach 1:
The patent changes the profile parameters to a flat configuration, which can be manufactured using standard helical winding processes. The manufacturing complexity is not significantly increased, while installation speed and productivity are dramatically improved due to reduced friction and elimination of hang-ups on studs and cable trays.
Solution Approach 2:
The patent creates a metal armor profile that dynamically interacts with installation surfaces by minimizing contact friction. The flat profile allows the cable to slide smoothly over studs and cable trays without catching or requiring readjustment, thereby increasing installation speed and reducing installer fatigue.
4Ease of operation
If metal armor has deep valleys, then cable entanglement increases, but if valleys are minimized, then profile complexity increases
Solution Approach 1:
The patent minimizes the valley depth parameter to create a flat profile that prevents cable entanglement and hang-ups during installation. The profile appears simple and flat externally, while the helical construction provides the necessary structural properties, effectively reducing profile complexity while improving entanglement resistance.
Data Source
AI summary
Disclosed is a cable assembly including at least one conductor and a metal sheath disposed over the at least one conductor, the metal sheath including a continuous strip of metal having a plurality of revolutions. A first revolution of the plurality of revolutions may include a first section having a curved profile extending into an interior cavity of the metal sheath, and a second section extending from the first section, the second section extending along a lengthwise axis, wherein a length of the second section, along the lengthwise axis, is at least two times as large as a diameter of the first section when the metal sheath is in a linear configuration. The first revolution may further include a third section extending from the second section, the third section including a free end terminating within a recess defined by a curved profile of a first section of an adjacent revolution.