Electricity: conductors and insulators – Anti-inductive structures – Conductor transposition
Reexamination Certificate
1999-03-02
2001-02-27
Kincaid, Kristine (Department: 2831)
Electricity: conductors and insulators
Anti-inductive structures
Conductor transposition
Reexamination Certificate
active
06194652
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to multiconductor cables used for transmitting electrical signals, and particularly to the attachment, during manufacture of the cables, of connectors at the ends of the cable for providing electrical connections to the cable conductors.
While the present invention has utility with various types of signal transmitting cables, it has particular use with cables comprising twisted pairs of wires used in the telecommunication industry. By “twisted pairs” it is meant that the two wires of each pair are wound around one another in a pair of intertwined spirals; the twisting together of the two wires being effective for noise suppression. Each pair of wires provides a separate communication channel and, for signal routing purposes, all the wires within the cable terminate at preselected (“dedicated”) contacts (e.g., prongs of plug-type connectors) of the two end connectors. Thus, within each connector, all the wire pairs are in preselected sequence and, for each wire pair, the two wires (typically referred to in the telecommunications industry as “tip” and “ring” wires) are likewise in preselected orientation (the tip wire always being, for example, to the left of the ring wire with a given orientation of the connectors).
In the manufacture of such telecommunication cables, continuous cables are made, cut to desired lengths, and connectors are attached to each cable end. The latter process comprises removing the cable sheathing at the cable ends, identifying and sorting the wire pairs into a preselected pattern, untwisting end lengths of wires from each wire pair, and disposing the two wires of each pair in proper side-by-side relation. When the cables are of the “flat” ribbon type, comprising side-by-side pairs of wires in fixed relationship over the lengths of the cables, no sorting of the wire pairs is necessary. However, owing to the twisting of the wires of each pair around one another, it is not possible to know in advance, upon the cutting of the cables, the relative side-by-side positions of the wires of each pair. Thus, in all instances, it is necessary to selectively untwist the wires of each wire pair more or less as is necessary to dispose the two wires in proper side-by-side relationship.
The wires are color encoded, e.g., the ring wire is always of a darker color then the tip wire, and a human operator has little difficulty in identifying the wires of each wire pair and properly positioning them. It is desired, however, to automate the connector assembling process and a quite serious problem encountered is that of designing a machine to perform the wire pair selective untwisting and side-by-side sorting process. Indeed, while various aspects of cable manufacture are substantially completely automated, successful automation of the process of side-by-side sorting of the wires of each pair has not been achieved. Such process is greatly simplified in accordance with this invention.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, the inventive manufacturing process begins with the first ends of a pair of color encoded, twisted wires already respectively connected (as hereinafter described) to two dedicated contacts of a first cable connector. Second ends of the two wires are then connected, on a random basis, to respective “intermediate” contacts of a second cable connector. Each intermediate contact is connected by separate conductive paths to both contacts of the second connector corresponding to the dedicated contacts of the first connector. Then, dependent on which wire is connected to which dedicated contact of the first connector, one conductive path from each intermediate contact in the second connector is broken such that the corresponding dedicated contacts of the two connectors are respectively interconnected by the two wires.
In a preferred embodiment, the first ends of the wire pair are also randomly connected to the dedicated contacts of the first connector. Thus, visual observation, based upon the color encoding of the wires, is first made to determine which wire is, in fact, connected to which dedicated contact of the first connector. In this embodiment, either wire of each wire pair, regardless of how the wire is color encoded, can function as a tip or ring wire. In an alternative, less preferred embodiment [by attorney], the first ends are connected, under human control, in preset side-by-side relation, whereby color detection only of the randomly made wire connections in the second connector is necessary.
As described, the second connector, in accordance with this invention, includes intermediate contacts each, at least initially, connected to two contacts of the second connector. The first connector, however, can comprise a known type connector including no intermediate contacts but merely typical externally accessible contacts. With such known first connectors, the cable wires are connected (randomly or not) directly and solely to respective contacts of the first connector. In an alternative embodiment, for reduction of parts inventory, the first connector is identical to the second connector and includes two intermediate contacts for each wire pair with both intermediate contacts being connected to both contacts dedicated to each wire pair. In this arrangement, the first ends of a wire pair are first respectively connected (preferably randomly) to a pair of intermediate contacts of the first connector. Then, for establishing a starting condition of the wire first ends being exclusively connected to respective dedicated contacts of the first connector, one conductive path from each intermediate contact is broken.
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Epstein Michael Y.
Kincaid Kristine
Lucent Technologies - Inc.
Mayo, III William H
Schanzer Henry I.
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