US20060000517A1

US20060000517A1 - Wire and separation prep-tool

Info

Publication number: US20060000517A1
Application number: US10/880,305
Authority: US
Inventors: Wade Enloe
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-06-30
Filing date: 2004-06-30
Publication date: 2006-01-05

Abstract

A wire and separation prep-tool comprising of a hand-held prolate cylindrical rod shaft base member with one dull radial pointed conically narrowed end for penetrating the space between twisted pair wires, with no harm or injury to said wires, then physically expanding the distance between the wires as the tool is further pushed and penetrates further as the main shaft's conical walls increase in diameter; then moving adjacent in the direction of the opposite end: a single diametrically cut circular groove cut in and around the base shaft deep enough to hold, align and to separate said twisted pair wires into two single wires with an operator's hand pull. Finally, with multiple strokes per wire in this same groove, the tool can completely straighten a single wire from its pre-form wound; then continuing adjacent, a wider singular diametrical cut circular groove cut in and around the main base shaft to rub multiple times against a sheathed group of twisted wire pairs and smooth out inside kinks from the outside near the end to be terminated; then continuing adjacent, a designated length of an insulated tubular hand grip formed around the mid-section of the cylindrical rod for a 360 degree tubular grip; then continuing adjacent, a series of five diametrically cut circular grooves cut in and around the mains base shaft so to allow the field operator to correctly hold and pre-align five singular wires for the ease of plural wires installation into a female RJ-45 jack receptacle; then continuing adjacent, located at the center of the flat perpendicular end of the second end of the cylindrical rod shaft base is a centered rectangular notch thru the longitudal and horizontal axis which allows a sideways entry, perpendicular insertion of plural wires into the notch for narrowing, flattening, and pre-aligning into the prescribed positions for ease of these plural wires installation into a male RJ-45 plug. In summary, and as described herein, this compact tool invention has a total of five (5) distinct and integral subparts identified within to perform six different tasks on Category 1-10 twisted wire pair cables.

Description

REFERENCES CITED: [REFERENCED BY]



3906561	September, 1975	Bawa	7/5
4025998	May 1977	Eppler	29/566
4444228	April, 1984	Demirjian	140/23
4620573	November, 1986	Meder.	140/123
4713874	December 1987	Shwartz	29/566
4797988	January, 1987	Bowden Jr.	29/566.4
5771945	June, 1998	Jenner, et al.	140/123
6584670	July, 2003	Costa	29/564.7
6601615	August, 2003	Hammond	140/23
6604268	August, 2003	Fujita, et al.	29/33F

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

“Not Applicable”

STATEMENT TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

“Not Applicable”

DESCRIPTION

1. Technical Field
The present invention relates to a twisted wire preparation tool and more particularly to a hand held, inexpensive, compact, prolate, lightweight, multiple-tasks performer, labor-saving, and simple-to-use tool which enables the tool-operator's maneuverability, and ability to properly separate, straighten and align single and plural wires for two different types of RJ-45 connectors, female plugs and male jacks, without inflicting harm to the jacket sheath, wire or wire insulation.
2. Background of the Invention
In the telecommunications, electronics and computer industries, shielded (STP) and unshielded twisted pair (UTP) wires have been the faster performance replacement wire for coaxial cable, not only used for networking but also for the traditional telephone. There are 10 different types of STP/UTP categories and, depending on what you want to achieve, you would need the appropriate type of cable. Yet all sheathed/unsheathed jacket cables and their twisted pair wires in these categories can be separated, straightened and aligned with this new tool invention. Here are UTP Categories 1-6 that serve most applications worldwide at this time.

The Different UTP/STP Twisted Pair Wire Categories

Cat. 1 Data rate up to 1 Mbps Traditional telephone ISDN (one wire)
Cat. 2 Data rate up to 4 Mbps Token Ring
Cat. 3 Data rate up to 10 Mbps Token Ring and 10 BASE-T
Cat. 4 Data rate up to 16 Mbps Token Ring
Cat. 5 Data rate up to 100 Mbps Ethernet
Cat. 6 Data rate up to 16 MMbps Fast Ethernet and Token Ring
Cat. 5e Data rate up to 1000 Mbps Gigabit Ethernet
Cat. 6 Data rate up to 1000 Mbps Gigabit Ethernet
Cat. 7-10 Data rate up to 10,000 Mbps Shielded Twisted Pairs in Research and Military

The number identified in each category (example: Cat. 2), where the number two refers to the number of twists per inch inside the wire sheath (and the quality of a connection in a jack). The “twist” effect of each pair in the cables will cause any interference presented/picked up on one cable to be cancelled out by the cable's partner which twist around the initial cable. Please note that Cat. 1 is only a single wire, yet may be serviced by this tool also.
In general, the number of twisted wires, wire length, wire type, and physical separators also dictate the performance of twisted wire pairs. Cat. 2, Cat. 3, Cat. 4 Cat. 5 and Cat. 6 are network wire specifications. Cat. 5 and Cat. 6 have become today's standards and most widely used with four twisted wire pairs per sheathed cable due to the growth and continued demand for faster data transmission speeds for private, public and governmental entities.
Lastly, STP/UTP wire cables are terminated with standard connectors, jacks, plugs and punchdowns. The standard jack/plug is often referred to as a RJ-45, but that is really a telco designation for the “modular 8-10 pin connector” terminated with a UPOC pinout used for telephones. The male plug on the end of a patchcord is called a “plug” and the female receptacle on the wall outlet is a “jack”. These may connect into the hub or computer's network card.
This Wire And Separation Prep-Tool invention prepares twisted wire pairs in two general ways with convenient 5 subparts, so to be inserted into either a plug or jack. In addition, this hand tool invention reduces the harm and damage inflicted when compared to wires that are frequently separated with a knife, screwdriver or other nonconforming items. Nicks, cuts and other damage causes significant amount of undesirable Radio Frequency (RF) transmissions. Plus, this combination tool reduces the time and effort to straighten and untwist the twisted pair wires when compared to “hand & fingers” which is still the predominant standard in the industries, and since it has 5 specific subpart tool instruments per this one tool invention, it reduces the amount of tools required by the operator and the amounts thereby expensed.
Therefore, it will be appreciated that there is a big need for a multi-task tool which enhances the practicability of terminating Categories 1-10, RJ-45 connectors, by properly separating, straightening, and aligning any twisted wire pair so to match the plug or jack requirements quickly and economically.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an improved twisted wire preparation tool that has 5 multiple task subpart tool functions to perform six distinct tasks.
It is a further object of the present invention to provide a twisted wire preparation tool which appreciably enhances termination of RJ-45 connectors in STP/UTP Categories 1-10 in the field for new wire and receptacle installation, repair, maintenance and/or new wire installation on a new product at it's manufacturing plant.
It is a still further object of the present invention to provide a compact, lightweight, inexpensive, and multi-task time reducing twisted wire preparation tool that penetrates and separates twisted wire pairs safely, quickly straightens single wire, aligns single and plural wires correctly for proper insertion into RJ-45 jacks, and narrows and flattens single and plural wires for proper insertion into RJ-45 plugs.
It is a still further object of the present invention to provide a unique twisted wire multi-preparation tool which has multiple task functions that minimizes the time for labor & organization while minimizing overall tool expense.
In general, this is a solid prolate cylindrical shaped rod shaft that has two ends; the first end being a conically narrowed round dull pointer for safely penetrating twisted wire pairs; adjacent is the overall expanding conical shape shaft which assists with it's inherent expanding diameter wall slope to increase the distance of separation space between the two twisted wires, as they are continually penetrated with the tool, until the two wires are caught by and semi-held into opposing groove channels at the top by the first diametrical cut circular groove. Thus by the operator pushing the tool's pointed tip about an inch forward in between the wires until they rest in the first diametrical cut circular groove, this allows the wires preformed compression to assist in adhering to the tool's first concentric groove's walls just long enough to allow the operator, by hand, to pull up horizontal and leverage the longitudal rod shaft base tool to forcefully continue separating several inches (1-7 inches) in length of the twisted pair wire's ends entirely apart into two single wires without harm.
Then the operator replaces one of the same wires back into the groove and applies thumb holding pressure to the wire and uses the same single diametrical cut circular groove to continuously rub the wire into . . . stroke the single wire up and down and allow this repetitive motion in this groove helps re-mold and straighten the wire with this procedure. Once each wire has been straightened in such a manner, then the wires are ready for the next of one of two steps depending on which RJ-45 connector is the require target.
For the RJ-45 “jack”, place the wires in proper order according to the schematics and insert the straightened five single wires, each one into one of the five evenly-spaced diametrically cut circular grooves, traverse and horizontal to the tool's longer longitudal shaft, thereby pre-aligning all 5 wires (10 wires total: two sets of five) into the specifically spaced grooves matching the same wire pattern as this proposed connector. Once the wires are ready, insert in the jack and lock down with a standard crimp tool.
For the RJ-45 “plug”, it's different. First, position the straightened wires into the order prescribed by the schematics. Then, find the rectangular notch centered into the longitudal and horizontal axis at the flat end of the second end to push the connecting wires' ends sideways into this notch. This notch will narrow and pre-align these wires into a specific sized pattern exactly like that of the target RJ-45 plug. If needed, trim the wires for either the RJ-45 plug or jack wire placement prior to actual wire insertion in either the notch or five grooves, respectfully, for immediate final crimping of the wires into the plug or jack.
Located 360 degrees around the entire outside diameter of only the middle section of the prolate cylindrical rod shaft is an insulating tubular hand grip. It lies, by, and between the single wider sheath groove on one side and the inner and closest of the 5 plural wire diametrically circular grooves on the other side. It enhances grip while minimizing low-voltage shock of any live electrical wires.
This lightweight hand tool may fit in a top shirt pocket, pants pocket, briefcase or tool pouch just like a similar sized fountain pen. This gives it a compact status and is further significant because this one tool invention has 5 tool subparts that technically perform the job of 6 tools as described here within.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 identifies the REFERENCES of all major subpart components and illustrates the Side View of the entire WIRE AND SEPARATION PREP-TOOL, including all particular subpart components in accordance with the present invention.
FIG. 2 is a Top View of the entire WIRE AND SEPARATION PREP-TOOL in accordance with the present invention.
FIG. 3 is a First End View of the round tip, diametrical shaft, and concentric hand grip.
FIG. 4 is a Second End View of the centered notch, diametrical shaft and concentric hand grip.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, a prolate cylindrical rod shaft tool having two opposing ends longitudal, one conically narrowed to a small dull pointed round mammilated end (see REF. 1), the other end perpendicularly blunt yet notched (see REF. 7). Located in between the two opposing ends is a strategic series of diametrically cut circular grooves of various depths and widths along the longitudal base shaft for specific tasks and applications (see REF. 3, 4, 6), along with an adhering concentric insulating tubular hand grip located in the middle section (see REF. 5).

This tool is a hand tool. The tool's length is 5.1″ (″=inches) and has a maximum diameter of 0.25″ except less where strategically grooved diametrically. Also with reference to FIG. 1, REF. 1, 2, 3, 4, 6, the prolate cylindrical rod shaft longitudal tool has five (5) subparts described below able to collectively perform six (6) distinct and different tasks.



SUBPART	FIG./REF.	TASK

Subpart 1:	FIG. 1, REF. 1:	First End for Wire Separation and
		Conical Shaft Spreader
Subpart 2:	FIG. 1, REF. 3:	Single Wire Grooves for Holding and
		Separating TWP

(second Subpart 2 task):	Single Wire Groove for Holding and
	Straightening 1 wire

Subpart 3:	FIG. 1, REF. 4:	Widest Groove for Smoothing Cable
		Jacket Sheath
Subpart 4:	FIG. 1, REF. 6:	5 Wire Grooves for pre-aligning
		wires into RJ-45 jack
Subpart 5:	FIG. 1, REF. 7:	Second End Notch for pre-aligning
		5 wires into RJ-45 plug

This hand tool is similar to the size, weight of 250 grams, and, even, the prolate shape of a solid fountain pen. It's convenient and compact size allows it to be carried in a shirt or pant's pocket, tool pouch or briefcase. A number of materials are suitable for the cylindrical rod shaft tool, as well as for the insulating tubular hand grip. The first subpart of this tool invention is a dull pointed mammilated end of 0.05″ diameter and 0.1″ long for penetrating twisted wires as seen in FIGS. 1-3, REF. 1. This point must be a rounded yet have a dull point so not to break, cut, scrape, inflict nor harm an individual wire's outer insulated coating. The connecting shaft from the first end's point must be a narrowed shape of 0.04″ diameter and 0.07″ length to enter between, catch and hold the two twisted flexible wires. Once the space between the twisted wires is penetrated, the next 0.355″ of overall conical base shaft shape progressively assists in separating the wires with it's inherent expanding diameter from 0.04″ to 0.23″, and 50 degree increasing slope as it leads away from the first end. As the wire is manually pushed up the conical shape for about an inch, the increasing diameter increases the distance of separation between said twisted two wires, until the two wires are automatically caught by, and semi-held into an adjacent position by the first diametrical cut circular groove (described more below as “second subpart”), where then the operator may pull on the tool outward and thereby separate up to seven inches of the two wires ends entirely. Now the wires are ready for straightening and trimming, as required.
The second subpart of this tool invention is the first end's first singular diametrical cut circular groove around the rod shaft located proximal down shaft of the greatest diameter of the conical shape as seen in FIGS. 1-2, REF. 3, and 0.605″ from the first end. The single groove's walls are diametrically concentric, convex to the horizontal axis, and planar back face which provides an excellent guide surface with which to hold and realign wire. The groove's floor is convex and assists in holding the wire. Upon penetrating, dividing, and widening the two wires of the twisted wire pair with the tool as described, the operator can now begin to apply hand force to be able to pull or push the tool horizontally up the wire's longitudal axis in the same direction as the wires twist pattern and separate this pair into two single wires. Again, at this time, a common commercial wire cutting apparatus may be needed in the procedure to trim the length and/or the insulated plastic coating, and/or the outer loose jacket sheath, if needed.
The third subpart referenced herein includes a wider singular diametrically cut circular groove of 0.19″ diameter and 0.2″ length with obtuse walls of 140 degrees angled outward, as seen in FIGS. 1-2, REF. 4. The groove's floor channel is concave. These wall and floor channel angles allow for safely rubbing this groove part of the tool back and forth on the plastic protecting jacket sheath on the ending 2 or 3 inches that surrounds a group of twisted wire pairs. The result here is to smooth kinks and ridges protruding from the loose jacket sheath and to assist in aligning and preparing twisted wire pairs for the following procedures, outlined herein, and finally, for plural wire termination into a RJ-45 plug or jack. This diametrical groove is located in between and proximal 0.35″ from the aforementioned single narrower groove and 0.24″ from the tubular grip adhered to the base tool shaft described here below.
The fourth subpart of this tool invention is the series of five evenly and strategically spaced, diametrically cut circular grooves in and around into the cylindrical shaft rod that assist to hold and pre-align up to five wires to then be fitted directly into a R-45 jack. FIGS. 1-2, REF. 6 illustrates these five diametrical grooves that have an individual length of 0.032″, a combined total length of 0.61″ from the first to the fifth, individual diameters of 0.16″, and are evenly spaced at 0.112″ apart. The grooves' walls are convex and 90 degrees perpendicular to the longitudal axis to assist in holding the wires in place for alignment. The grooves floor is flat and deep enough to assist in holding the wires in place for alignment. Once the wires straightened and pre-aligned, they are removed from the tool and placed into the RJ-45 jack receptacle and an acceptable industry punch-down tool is used to push lock the pre-aligned wires into a permanent connection.
The fifth subpart of this tool invention is the centered rectangular notch, 0.04″ height by 0.25″ width by 0.48″ length, located at and thru the second end of the longitudal shaft rod as shown in FIGS. 1 and 4, REF. 7. The purpose of this centered longitudal rectangular notch is to allow easy placing, arrangement, narrowing, and pre-aligning of the separated and straightened plural wires, of Category 1-10 twisted wire pairs, for insertion into a RJ-45 plug receptacle. Upon proper plural wire arrangement and alignment and the actual wire insertion into a RJ-45 plug, an acceptable industry crimper is used to lock down the wires in their precise connector position.
As stated above, this hand tool also features an insulating concentric tubular hand grip made from plastic, rubber or other material that surrounds and tightly adheres to the outer cylindrical tool shaft in the middle area so to not slip as seen in FIGS. 1-4, REF. 5. The grip's dimensions are 2.3″ length and 0.005″ thick, 0.265″ outside diameter, and located 1.64″ from the end of the first end and 1.63″ from the second end. The hand grip gives the operator's hand a more secure surface to grasp and provides an insulated protecting material in case the wire is live and low voltage shock is a potential threat. The color of said grip may be produced black or any other color.
This hand tool contains five referenced subpart tool functions that perform a total of six tasks. This hand tool is a weight-saving alternative to carrying and operating six tools; a cost saving alternative—inexpensive option to purchasing six different tools; and, a time saving alternative that will reduce the organization and actual labor time of handling six different tools for the same job.
Alternatively, this hand tool's length may be manufactured several inches shorter or longer. This hand tool's diameter may be manufactured larger or smaller. This hand tool's singular and plural grooves may be manufactured deeper or shallower or increased in quantity should Industry Standards dictate so for more wires in a receptacle. This hand tool's concentric tubular hand grip may be manufactured in various lengths, colors, and from various materials, including, but not limited to, plastic, rubber or synthetic materials. This hand tool's cylindrical base shaft may be manufactured from many types of materials, including, but not limited to, plastic, carbon fiber, metal, alloys, wood, rubber, or any mix hereof, and in various colors or finishes. Thus, this hand tool's weight may change due to the compositions and/or mixes made thereof.

Claims

1. A hand tool for separating twisted wire pairs, said tool comprising a prolate cylindrical rod shaft base having a first end and a second opposing end and a longitudal axis extending between the first end and the second end;

2. A tool as in claim 1 wherein the prolate shape of said hand tool increases the design appeal and marketability;

3. A tool as in claim 2 wherein said tool comprising a prolate cylindrical rod shaft base has an outside diameter of 0.25″ except at the first end and all other diametrical locations along the longitudal axis where diametrical cut circular grooves are located along the rod shaft indicated herein and where the insulating concentric hand grip slightly expands the main tool shaft's diameter;

4. A tool as in claim 3 wherein the first end having a narrowing mammilated pointed round end, then narrowing in diameter, and then progressively expanding conically in diameter at an acute angle of 50 degrees until reaching the maximum base shaft diameter. The first end point is protrusively centered longitudally, so to easily penetrate the air space between flexible twisted wire pairs, yet dull, and radially blunt enough, not to inflict cuts nor scraping on the insulated wires while forcefully separating them as the wires slide onto and up the conical rod shaft by human force;

5. A tool as in claim 4 wherein a single diametrical cut circular groove is located approximately 0.605″ from the first end and it's concentric sidewalls, perpendicular to the longitudal axis, allow twisted wire pairs to be held oppositely while separating them entirely apart as the operator pulls the tool up horizontally to the tool's longitudal axis;

6. A tool as in claim 5 wherein the same single diametrical cut circular groove identified in claim 6 above will also bend and straighten an individual wire with repeat rubbing and stroking of the groove's walls against the wire until smooth and straight;

7. A tool as in claim 6 wherein a second proximal single diametrical cut circular groove is located for rubbing and smoothing a cable jacket sheath along. The groove is located by and between the first end's first singular diametrical cut circular groove, as described in claims 5 and 6, and the rubber/plastic cylindrical tubular grip, described in claim 10. This groove accepts, aligns and smoothes the cable's jacket sheath by manual rubbing force on the Category 1-10 twisted wire pairs in their original plastic protector jacket sheaths. Continued rubbing smoothes out obvious lumps and ridges, which allows pre-preparation of the cable end prior to separating the twisted wire pairs;

8. A tool as in claim 7 wherein the second end of the cylindrical rod shaft base is a horizontal flat circular end perpendicular to the longitudal axis;

9. A tool as in claim 8 wherein a series of five evenly-spaced diametrical cut circular grooves are near the second end to pre-aligning plural wires for a connection into a RJ-45 jack receptacle. All five grooves' walls are convexly perpendicular to the base tool's longitudal axis to assist in holding said wires in the each channel. The five diametrical cut circular grooves are located between and proximal to the flat circular perpendicular second end and the plastic/rubber concentric insulating hand grip described in claim 10;

10. A tool as in claim 9 wherein a insulating cylindrical tube hand grip adheres diametrically along and around the outside middle area of the base rod shaft, lying in between the first end's wide single sheath groove and the first of the evenly-spaced plural diametrical cut circular grooves towards the second end;

11. A tool as in claim 10 wherein a rectangular notch is positioned precisely thru the center longitudal and horizontal axis of the flat perpendicular circular end of the second end, extending from and thru the shaft end and extending back in length towards the direction of the first end. This notch provides narrowing and pre-alignment of plural wires for a RJ-45 plug connection receptacle;

12. A tool as in claim 11 wherein this one multi-hand tool invention contains five referenced tool subparts, each with a distinct and different performance task of preparing Shielded and Unshielded Twisted Pair wires in specific ways described herein for RJ-45 plug and jack receptacle connections, and, all together, eliminating literally nonexistent and potentially expensive multiple tool purchases, thus saving preparation and organizing time and the number of tools and weight carried by an operator;

13. A tool as in claim 12 wherein this one hand tool invention is an inexpensive time-saving alternative to purchasing and using six separate tools, and, especially cost and time saving when compared to the time savings in labor costs where untwisting wires and straightening wires by actual hand is still the predominant technique of the Industries;

14. A tool as in claim 13 wherein is a lightweight, convenient to use, compact, stiff tensile strength to penetrate, pull on, leverage and separating up to seven inches of twisted wire pairs into singles without breaking the wires or the tool;

15. A tool as in claim 14 wherein a method for separating twisted wire pairs is established;

16. A tool as in claim 15 wherein a method for straightening a single wire is established;

17. A tool as in claim 16 wherein a method for pre-aligning one set of five wires for duplicate placement into a female RJ-45 jack connector receptacle is established;

18. A tool as in claim 17 wherein a method for narrowing and pre-aligning one set of five wires for duplicate placement into a male RJ-45 plug connector receptacle is established;

19. A tool as in claim 18 wherein the quantity of 1-5 wires pre-aligned may vary depending on the actual wire connection needs of the operator, but allows five here;

20. A tool as in claim 19 wherein the prolate slender and compact shape increases the design appeal and the operator's convenience in carrying ability in a top shirt pocket, pants pocket, as well as in a tool pouch, tool box or briefcase.