Low-Profile Cable Armor Structure to Prevent Stud Hang-Ups
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Solution Overview
Problem
Existing armored cables with pronounced peaks and deep valleys cause installation difficulties, leading to installer fatigue and potential damage to studs due to hang-ups during installation.
Innovation Solution
A novel armored cable design featuring a flat profile with smaller valleys and a continuous metal sheath formed by helically wrapping a metal strip, where each revolution includes a first section with a curved profile, a second section extending along the lengthwise axis, and a third section terminating within a recess of an adjacent revolution, minimizing valley depth and enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional metal armor with pronounced peaks and deep valleys is used, then the cable provides adequate protection, but the cable grabs and hangs up on edges of studs during installation
Solution Approach 1:
The patent changes the geometric parameters of the metal armor profile from traditional pronounced peaks and deep valleys to a flattened profile with reduced peak height and shallower valleys. Specifically, the peak height is reduced to less than 0.125 inches and valley depth is reduced to less than 0.0625 inches, which eliminates the hanging effect on studs while maintaining protective function
Solution Approach 2:
Instead of having the metal armor protrude outward with sharp peaks, the patent inverts the approach by flattening the outer surface and creating a more streamlined profile that slides over obstacles rather than catching on them, effectively reversing the traditional aggressive protective profile
2Productivity
If traditional metal armor with deep valleys is used, then the cable maintains structural integrity, but installer fatigue increases and installation speed decreases
Solution Approach 1:
By changing the dimensional parameters of the armor profile (reducing peak height to <0.125 inches and valley depth to <0.0625 inches), the cable installs more smoothly through framing members without requiring frequent readjustment, thereby increasing installation speed and reducing installer fatigue
3Ease of operation
If the metal armor profile is flattened, then installation ease improves, but the cable diameter and bend radius decrease
Solution Approach 1:
The patent carefully controls the flattening parameters to achieve optimal balance: peak height is limited to less than 0.125 inches and valley depth to less than 0.0625 inches. This controlled flattening reduces the overall cable diameter and bend radius compared to traditional profiles, improving ease of installation in tight spaces while maintaining adequate protection
4Strength
If the metal armor is made more flexible, then the cable can bend easier, but crush-resistance may be reduced
Solution Approach 1:
The patent modifies the geometric parameters of the metal armor (peak height <0.125 inches, valley depth <0.0625 inches) which creates a profile that is both flatter and more flexible, allowing the cable to bend easier while the continuous interlocking structure maintains adequate crush-resistance protection
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.