Quick-Connect Twisted Pair Cables With Flattened Regions
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Solution Overview
Problem
Connecting twisted pair cables to connectors is time-consuming and requires multiple steps, and existing methods do not effectively reduce electromagnetic cross-talk for high-speed signal transmission.
Innovation Solution
The development of quick-connect twisted pair cable systems featuring elongate lengths with alternating tubular and flattened regions, allowing for easy attachment of connectors without cutting, stripping, or additional equipment, and incorporating a quick plug connector that can cut and make electrical contact with the cables at flattened regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional twisted pair cable connection methods are used, then reliable electrical connection is achieved, but the connection process is time-consuming and requires multiple steps including cutting, stripping, and crimping
Solution Approach 1:
The cable is prepared in advance with periodic flattened regions where the outer insulation is pre-compressed and wire pairs are pre-positioned. This preliminary preparation eliminates the need for on-site cutting, stripping, and arrangement operations, allowing connectors to be attached directly to the pre-prepared regions.
Solution Approach 2:
The cable structure is segmented into alternating tubular and flattened regions along its length. The flattened regions serve as dedicated connection zones separated from the continuous tubular regions, enabling multiple connection points along the cable without interfering with the twisted pair structure in other areas.
2Productivity
If twisted pair cables are used for high-speed signal transmission, then cost-effective networking is achieved, but electromagnetic cross-talk between pairs increases
Solution Approach 1:
Different regions of the cable have different structural properties: tubular regions maintain the twisted pair configuration for signal transmission, while flattened regions provide localized electromagnetic shielding and isolation. This local variation in structure allows high-speed transmission while controlling cross-talk at connection points.
Solution Approach 2:
The flattened regions act as intermediary zones between connected devices and the twisted pair transmission medium. These regions provide a transition zone where electromagnetic fields are contained and managed, reducing cross-talk between adjacent pairs during connection and transmission.
3Reliability
If connectors are attached to twisted pair cables using traditional methods, then reliable electrical connection is achieved, but the installation process requires specialized tools and multiple steps
Solution Approach 1:
The flattened regions are self-contained structures that inherently guide and position the wire pairs for connector attachment. The pre-compressed insulation and pre-positioned wires in flattened regions enable connectors to be attached directly without requiring external tools for stripping, arranging, or securing the wires.
Solution Approach 2:
The connection function is merged with the cable structure itself through the integrated flattened regions. Rather than being separate preparation and connection steps, the cable's periodic flattened structure combines the functions of insulation removal, wire positioning, and connector attachment into a single integrated feature.
Data Source
AI summary
Described herein are quick-connect twisted pair cables, cable systems and methods of installing/connecting them. For example, a quick-connect twisted pair cable may include a plurality of pairs of insulated wires within an outer insulating cover; within the insulating cover each of the plurality of pairs of insulated wires are wrapped around each other within elongate tubular body regions, and unwrapped (e.g., parallel) in flattened regions between the elongate tubular body regions. A quick plug connector may be configured as a standard (e.g., RJ-45) connector type.