Universal Cable System with Keyed Profile and Integrated Pull Cord
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Solution Overview
Problem
Traditional wiring systems, particularly low-voltage wiring, require multiple types of cables and connectors for different applications, leading to increased installation complexity, cost, and the need for specialized training and tools, making them difficult and time-consuming to install and modify, especially in residential and commercial structures.
Innovation Solution
A universal cable system featuring a unique keyed profile cable with an integrated pull cable, which can be connected using a single tool and self-crimping connectors, allowing for a single-wire solution suitable for various applications, including LED lighting, internet, and POE systems, reducing the need for multiple wires and connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of cables and connectors are used for different low-voltage wiring applications, then the system can support diverse functions (lighting, internet, telephone, POE), but the installation complexity, cost, and time increase significantly
Solution Approach 1:
The patent implements a universal cable system where a single cable type with standardized connectors can be used across multiple low-voltage wiring applications including LED lighting, internet, telephone, and POE systems. This eliminates the need for separate cable types (CAT-5, CAT-6, etc.) and different connector varieties, allowing one cable to serve multiple functions while maintaining application-specific performance requirements through standardized interface designs.
2Reliability
If multiple connector types are required for different cable applications, then each application can be optimized, but the need for multiple tools and specialized training increases installation cost and difficulty
Solution Approach 1:
The standardized connector design allows a single connector type to work across all low-voltage applications, eliminating the need for technicians to learn multiple connector types and associated tools. The universal connector maintains reliable connections for lighting, data, and power applications while requiring only one tool type for installation, making the system accessible to DIY users without specialized training.
Solution Approach 2:
The connector incorporates a self-crimping mechanism that automatically secures the cable to the connector without requiring manual wiring or complex crimping tools. This self-service feature eliminates the need for specialized installation tools and training, allowing anyone to reliably install connectors by simply inserting and crimping the cable into the connector body.
3Adaptability or versatility
If traditional cable pulling methods are used through conduits and cable chases, then cables can be installed in new and existing structures, but the process is laborious, time-consuming, and risks cable damage
Solution Approach 1:
The cable system incorporates an integrated pull cable that is separable from the main cable assembly. This allows the pull cable to be used temporarily during installation to pull the main cable through conduits and cable chases, then be removed after installation. This segmentation enables easier cable installation without permanently increasing cable complexity or requiring specialized pulling equipment.
4Productivity
If improper cable handling during pulling occurs, then cable installation can proceed, but jacket or wire damage may occur requiring cable re-pulling and causing intermittent electrical problems
Solution Approach 1:
The cable is pre-assembled with connectors attached at the factory under controlled conditions, ensuring proper connection integrity before field installation. This preliminary action eliminates the risk of improper field crimping or connector attachment that could damage cables or create intermittent electrical problems, as all connections are established using precision equipment during manufacturing.
Solution Approach 2:
The self-crimping connector automatically secures the cable with consistent, factory-quality crimping force during installation, eliminating variability in manual crimping pressure that could lead to poor connections or cable damage. This self-service mechanism ensures reliable cable attachment without requiring technician skill or specialized tools, preventing intermittent electrical problems caused by improper crimping.
Data Source
AI summary
A universal cable system includes a cable, which may include a keyed profile and an optional, integrated pull cable for low-voltage applications in residential and commercial structures, both old and new construction, which may further includes a connector, which does not require individual splicing of the wires from the cable. The connector may be self-crimping or crimped with a tool. During installation of the connector onto the cable, conductors in the connector may be simultaneously spliced to the wires of the cable during crimping.