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  System, method, and apparatus for installing removing flat cable with respect to a protective sleeveUSPTO Application #: 20060183360Title: System, method, and apparatus for installing removing flat cable with respect to a protective sleeve Abstract: A tool for installing and removing flexible flat cable with respect to a protective sleeve has a groove for receiving the cable. The cable slides into and is formed into an arc by the groove and is supported evenly on both sides of the cable. With the full width of the cable in the groove, the tool slides down the length of the cable into the sleeve for the cable to be removed. As the tool slides into the sleeve, there is a smooth transition of the cable from flat to curved, and the cable and sleeve separate. The tool is slid through the sleeve as far as necessary for the needed action. After alternations to the sleeve or cable are complete, the tool is used to replace the cable back into the sleeve by reversing these steps. (end of abstract)
Agent: Dillion & Yudell, LLP - Austin, TX, US Inventors: Shawn Michael Nave, George G. Zamora USPTO Applicaton #: 20060183360 - Class: 439098000 (USPTO) Related Patent Categories: Electrical Connectors, With Circuit Conductors And Safety Grounding Provision, Grounding To Conductive Sheath Of Cable The Patent Description & Claims data below is from USPTO Patent Application 20060183360. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Technical Field [0002] The present invention relates in general to an improved tool for handling flat cable and, in particular, to an improved system, method, and apparatus for installing and removing flexible flat cable into and out of, respectively, a protective sleeve or track for dynamic applications. [0003] 2. Description of the Related Art [0004] Flexible flat cables have a plurality of electrical conductors that are molded inside a flexible, electrically insulative material or conduit. The conductors, which may be round or flat in cross-section, typically have very small dimensions and are spaced apart in a parallel configuration on narrow center-to-center spacings. These small dimensions place significant importance on handling or working with flat cables because the fragile conductors they contain are easily damaged. Because of the high cost of such flat cables, there must be assurance that the flat cable is not folded or crimped when it is handled during maintenance operations. [0005] In some dynamic applications, such as high-speed robotic library pickers, flat cables are required to flex for millions of cycles without an electrical continuity failure or interruption. Under such conditions, the flat cables may be placed inside an elongated flexible sleeve or track in order to protect and extend the life of the flat cable. The sleeve typically has a rectangular cross-sectional profile that is similar to the shape of the flat cable. The sleeve controls the direction in which the flat cable can flex and the radius of curvature of the bend in the flat cable. Thus, the sleeve acts as an exoskeleton that further protects the flat cable. [0006] Some sleeves do not fully envelop the flat cable, but are open on one side to permit the flat cable to be mounted in and removed from the sleeve. However, the small, fragile conductors in the flat cable can be damaged easily when the flat cable is placed in or taken out of the sleeve if the handling procedures are not performed carefully. Unfortunately, there are relatively frequent occasions in which handling of the flat cable is required after the flat cable is already installed in the sleeve. For example, the length of the flat cable and the sleeve may need to be altered, or a portion of the flat cable may need to be removed from the sleeve in order to change mounting hardware on the sleeve and/or flat cable. In addition, if only a small change is needed, or a change in only one end of the mounting hardware, it is laborious to completely remove all of the hardware from the flat cable and slide the entire flat cable out of the sleeve. For particularly long flat cables, this requires a significant amount of time and floor space to stretch out the entire flat cable. Thus, an improved system, method, and apparatus for installing and removing flexible flat cable into and/or out of a protective sleeve for dynamic applications is needed. SUMMARY OF THE INVENTION [0007] One embodiment of a system, method, and apparatus for installing and removing flexible flat cable into and out of a protective sleeve utilizes a tool having a single part that is snapped over the flat cable to allow the flat cable to smoothly slide into and out of the sleeve. The tool can partially remove the flat cable from the sleeve while protecting the flat cable from being damaged. After removal, the tool can also be used to easily and protectively return the flat cable into the sleeve. In addition, the tool does not require the entire flat cable to be removed from the sleeve. Moreover, existing hardware at an unaltered end of the flat cable assembly can be left in place. In addition, the tool can be used while a majority of the flat cable is rolled up. Furthermore, the tool can initially be applied to and engage any portion of the flat cable located outside of the sleeve. Thus, the tool does not need to start at the terminal ends of the flat cable in order to be utilized. [0008] The tool is designed to work in conjunction with the protective sleeve, which fully contains the flat cable but has an opening that aids in the sleeve being able to flex. The flat cable generally fills the entire width of the sleeve when installed. Using the tool, the flat cable can be removed through the opening in the sleeve. The tool works by sliding part of the flat cable that is not in the sleeve into a groove that is formed in the tool. The groove forms the flat cable into an arcuate shape, giving it a smooth radius by supporting it evenly on both sides of the flat cable. The flat cable does not get creased or folded. With the full Width of the flat cable located in the groove of the tool, the tool can slide down the longitudinal length of the flat cable and into the sleeve in order to remove the flat cable. As the tool slides into the sleeve, there is a smooth transition of the flat cable from a flat shape to a curved shape. As the tool moves into the sleeve, the flat cable and sleeve separate because of the interaction between the flat cable and the tool. The tool slides through the sleeve as far as necessary for the needed action. After the alterations to the sleeve and/or flat cable are complete, the tool can be used to replace the flat cable back into the sleeve by sliding the tool back through the sleeve in a smooth, safe motion. Finally, the tool is removed from the flat cable by sliding the flat cable back out of the groove in the tool. [0009] Another aspect of the tool of the present invention is that an outside wall of the tool (i.e., the portion located radially outside of the groove) is flexible to aid in allowing the flat cable to easily enter and exit the groove. In addition, the edges of the tool along the groove are very smooth so as to not catch or shave the flat cable. In contrast, prior art solutions required removal of the entire flat cable from the sleeve, or removal of the hardware from both ends of the flat cable assembly, and for the entire flat cable to be removed from the sleeve. [0010] The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the preferred embodiment of the present invention, taken in conjunction with the appended claims and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0011] So that the manner in which the features and advantages of the invention, as well as others which will become apparent are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only an embodiment of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments. [0012] FIG. 1 is an isometric view of a flat cable insertion and removal tool constructed in accordance with the present invention. [0013] FIG. 2 is a sectional front view of the tool of FIG. 1. [0014] FIG. 3 is a sectional front view of a flat cable located in a protective sleeve/track. [0015] FIG. 4 is an isometric view of the tool of FIG. 1 prior to removing the flat cable from the sleeve of FIG. 3. [0016] FIG. 5 is an isometric view of the tool of FIG. 1 at an initial stage of removing the flat cable from the sleeve, after the stage of FIG. 4. [0017] FIG. 6 is an isometric view of the tool of FIG. 1 at a subsequent stage of removing the flat cable from the sleeve, after the stage of FIG. 5. [0018] FIG. 7 is an isometric view of the tool of FIG. 1 at a subsequent stage of removing the flat cable from the sleeve, after the stage of FIG. 6. [0019] FIG. 8 is an isometric view of the tool of FIG. 1 at a subsequent stage of removing the flat cable from the sleeve, after the stage of FIG. 7. [0020] FIG. 9 is a sectional front view of the flexible flat cable located in the tool of FIG. 1 during removal and/or installation with respect to the protective sleeve. DETAILED DESCRIPTION OF THE INVENTION Continue reading... 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