Readily Strippable Cable With Segmented Insulation

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Solution Overview

Problem

Existing electrical cables require tools for stripping, leading to time-consuming and potentially injurious processes, especially in complex installations like ductless mini-split AC systems, where multiple wires need to be separated and connected without compromising insulation or damaging conductors.

Innovation Solution

A readily-strippable cable design featuring a continuous electrically insulating layer with uniformly positioned weak portions that allow for tool-free exposure of wires by applying force perpendicular to the cable length, utilizing knit lines created during extrusion to facilitate easy separation without damaging the cable sheathing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional wire stripping tools (utility knives, wire strippers) are used to expose conductors, then the insulation can be removed, but the process is time-consuming and requires skilled labor

Engineering Contradiction:

Improveease of wire strippingVSAvoidinstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The cable sheathing is segmented into discrete sections between adjacent wires, allowing each wire to be independently exposed by breaking the sheathing at these predetermined segments. This segmentation enables rapid, tool-free access to conductors without requiring skilled stripping operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cable is manufactured with pre-formed weak portions in the sheathing at predetermined locations between wires. These preliminary structural features are created during cable production, so that during installation, the sheathing can be easily broken at these predetermined points without requiring any stripping tools or skilled labor.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If utility knives are used for stripping cables, then the insulation can be removed, but workplace cut and pierce injuries occur frequently

Engineering Contradiction:

Improveease of wire strippingVSAvoidworkplace injuries

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The dangerous mechanical cutting action of utility knives is replaced with a simple breaking action at predetermined weak portions of the sheathing. This substitution eliminates the need for sharp blades while achieving the same functional result of exposing conductors, thereby eliminating cut and pierce injuries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cable structure itself provides the means for its own preparation. The predetermined weak portions in the sheathing allow installers to easily break and separate the sheathing from individual wires without requiring external cutting tools, making the cable self-preparing and eliminating the harmful cutting operation.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If outer sheathing is cut away to expose individual wire jacketing, then wires can be stripped, but the risk of accidental puncture to protective jacketing increases

Engineering Contradiction:

Improveease of wire separationVSAvoidintegrity of protective jacketing

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The sheathing is designed with non-uniform local quality: strong in most areas to protect wires, but with predetermined weak portions between wires that are intentionally weaker. This local quality differentiation allows easy separation at specific locations while maintaining overall structural integrity and protecting the wire jacketing from accidental damage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The sheathing is segmented into discrete sections between adjacent wires through predetermined weak portions. This segmentation allows each wire to be independently accessed by breaking only at the weak portions, preventing accidental puncture of the protective jacketing on the wires themselves while enabling easy wire separation.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If complex cabling with multiple individually-sheathed wires is used for mini-split AC systems, then all electrical requirements can be met, but the installation complexity and time increase significantly

Engineering Contradiction:

Improveelectrical system requirementsVSAvoidcable installation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple individually-sheathed wires required for mini-split AC systems (AC power wires, DC signal conductors, ground wires) are merged into a single cable assembly with a common outer sheathing. This merging maintains all required electrical separations while simplifying handling and installation to a single cable rather than multiple separate wires.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unified cable assembly is segmented into individual wire sections through predetermined weak portions in the outer sheathing. This segmentation allows each wire to be independently accessed and prepared for connection by simply breaking the sheathing at the weak portions, eliminating the need to strip multiple separate cables while maintaining all electrical requirements.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9545743B2Readily strippable cable

Publication Date: 2017.01.17 RECTORSEAL LLC

AI summary

A cable having conductors that may be easily exposed in preparation for electrical connection, without requiring the use of tools, is provided. The insulating layer of the cable has at least one relatively weak portion extending along the length of the cable that is configured to allow the insulating layer to split, thereby exposing the wire without the use of tools.