Pigtail Wire Assembly With Removable Casing for Faster Installation
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Solution Overview
Problem
The installation and stripping process of bundled network and low voltage cables, such as fiber optic, coaxial, and twisted pair cables, is tedious and time-consuming due to the need to strip buffer materials and hytrel tubes, which complicates the separation and connection of individual wires.
Innovation Solution
A pigtail wire assembly featuring a removable spiral casing that houses individual wires, allowing selective exposure of bare wire segments without stripping the entire cable jacket, combined with a fan out kit for easy separation and connection to connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the entire cable jacket and buffer material are stripped to access individual wires, then complete access to bare wires is achieved, but the installation process becomes tedious and time-consuming
Solution Approach 1:
The cable jacket is divided into multiple sections along its length, with certain segments made removable or openable to expose bare wires only at specific locations. This segmentation allows installers to access wires at designated points without stripping the entire cable jacket, significantly reducing installation time while maintaining ease of access where needed.
Solution Approach 2:
The cable jacket is pre-configured with predetermined removable sections or openable segments during manufacturing. This preliminary preparation eliminates the need for on-site stripping of the entire jacket, as the accessible sections are already prepared and positioned for easy wire extraction and connection.
2Ease of operation
If the cable jacket is completely removed to separate and connect individual wires, then full access is obtained, but the complexity of the installation process increases
Solution Approach 1:
The cable jacket is segmented into fixed and removable portions, with bare wire sections pre-exposed at predetermined locations. This segmentation simplifies the installation process by eliminating the need to strip the entire jacket, reducing installation complexity while maintaining ease of wire separation at accessible points.
Solution Approach 2:
Specific sections of the cable jacket are extracted or removed only where wire access is required, rather than removing the entire jacket. This selective extraction reduces installation complexity by limiting the scope of jacket removal to only the necessary segments.
3Ease of operation
If buffer material and hytrel tube are stripped from each wire, then bare wire access is achieved, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The cable jacket is pre-configured with predetermined removable sections or openable segments during manufacturing. This preliminary preparation eliminates the need for on-site stripping of the entire jacket, as the accessible sections are already prepared and positioned for easy wire extraction and connection.
Solution Approach 2:
The cable jacket is divided into multiple sections along its length, with certain segments made removable or openable to expose bare wires only at specific locations. This segmentation allows installers to access wires at designated points without stripping the entire cable jacket, significantly reducing installation time while maintaining ease of access where needed.
Data Source
AI summary
Disclosed is a wire assembly that includes, in certain embodiments, a plurality of wires each extending from a first end to a second end, the first end of each wire being terminated by a connector. The wire assembly also includes a cable jacket and a casing. The cable jacket bundles the plurality of wires over a first region of the assembly which is positioned between the first end and the second end of the plurality of wires. The casing is coupled to the cable jacket and disposed around a second region of the assembly which is positioned proximate the second end of the plurality of wires. The casing is at least partially removable by hand so as to expose a segment of at least one of the plurality of wires.