ELECTRICAL CABLE WITH STRENGTH MEMBER

• US 20110056723A1
• Filed: 03/18/2010
• Published: 03/10/2011
• Est. Priority Date: 09/10/2009
• Status: Active Grant

• Current Assignee: Vocollect, Inc. (Honeywell International Inc.)
• Original Assignee: Vocollect, Inc. (Honeywell International Inc.)
• Inventors: Hines, Don, Reynolds, Paul, Slippy, Gordon
• Granted Patent: US 8,241,053 B2
• Time in Patent Office: Days
• US Class Current: 174/73.1
• CPC Class Codes: H01R 13/2421 using coil springs
• CPC Class Codes: H01R 13/5808 formed by a metallic element crimped around the cable H01R4/185 takes precedence
• CPC Class Codes: H01R 13/5845 the strain relief being achieved by molding parts around cable and connections
• CPC Class Codes: H01R 13/6275 Latching arms not integral with the housing H01R13/6276, H01R13/6277, H01R13/6278 take precedence
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/86 Parallel contacts arranged about a common axis
• CPC Class Codes: H02G 15/007 Devices for relieving mechanical stress
• CPC Class Codes: Y10T 29/49181 by deforming

Abstract

A cord assembly for an electronic device includes a cord having an insulation layer with a first end and an exterior surface, as well as at least one electrical conductor extending within the insulation layer. A strength member also extends within the insulation layer and includes a first end extending beyond the first end of the insulation layer. A securing element couples the first end of the strength member with the first end of the insulation layer along the exterior surface. The strength member is pre-tensioned to carry any additional tensile loads on the cord, at least initially. The cord assembly may also include a strain relief member molded over the first end of the strength member and the securing element.

Claims

1. A cord assembly for an electronic device, comprising:

a cord including an insulation layer having a first end with an exterior surface and at least one electrical conductor extending within the insulation layer;

a strength member extending within the insulation layer generally alongside of the at least one conductor and including a first end extending beyond the insulation layer at the first end;

a securing element to couple the first end of the strength member with the first end of the insulation layer at the exterior surface; and

a strain relief member secured to the cord at the first end of the insulation layer, a portion of the strain relief member being molded over the end of the strength member and the securing element,

wherein the strength member is pre-tensioned such that any additional tensile loads placed on the cord are carried at least initially by the strength member.

2. The cord assembly of claim 1, wherein the strength member includes a Kevlar strand.

3. The cord assembly of claim 1, wherein the securing element includes a crimping member configured to be crimped around the first end of the strength member and the insulation layer to maintain pre-tension on the strength member.

4. The cord assembly of claim 3, wherein the crimping member includes a flange, the flange extending radially outwardly from the cord and held within the strain relief member.

5. The cord assembly of claim 4, wherein the strain relief member includes a connecting notch dividing the molded strain relief member into forward and rear portions and adapted to mate with a rigid housing of a peripheral device.

6. The cord assembly of claim 5, wherein the flange of the crimping member is disposed within the forward portion of the strain relief member so as to be positioned within the rigid housing to strengthen the connection between the peripheral device and the cord assembly.

7. The cord assembly of claim 1, further comprising:

a pre-tensioning element engaging the first end of the strength member to pre-tension the strength member, wherein a portion of the strain relief member is molded over the pre-tensioning element.

8. The cord assembly of claim 7, wherein the pre-tensioning element is a coil spring, and the first end of the strength member engages the coil spring to compress the spring, which results in pre-tensioning of the strength member.

9. The cord assembly of claim 8, wherein the coil spring abuts the first end of the insulation layer, the coil spring being compressed between the insulation layer and the first end of the strength member.

10. The cord assembly of claim 1, wherein the insulation layer of the cord includes a second end with a second exterior surface, the strength member includes a second end extending beyond the second end of the insulation layer, and the assembly further comprises:

a second securing element to couple the second end of the strength member with the second end of the insulation layer at the second exterior surface.

11. The cord assembly of claim 10, wherein the second securing element includes a second crimping member configured to be crimped around the second end of the strength member and the insulation layer to maintain pre-tension on the strength member.

12. The cord assembly of claim 11, further comprising:

a connector configured to couple with the electronic device, the connector including a connector housing with front and rear ends, a contact plate attached to the front end of the connector housing, and a pre-mold member molded over the second end of the strength member and the second crimping member,

wherein the pre-mold member receives the at least one conductor between the contact plate and the cord.

13. The cord assembly of claim 12, further comprising:

a strain relief member molded at least partially between the connector housing and the pre-mold member, the strain relief member extending beyond the rear end of the connector housing.

14. The cord assembly of claim 12, wherein the connector housing further includes engagement members configured to couple the connector to the electronic device, the engagement members being adapted to break away from the electronic device before a tensile load on the cord is carried by the at least one conductor or the insulation layer.

15. The cord assembly of claim 12, further comprising:

a second pre-tensioning element engaging the second end of the strength member to pre-tension the strength member, wherein a portion of the pre-mold member is molded over the second pre-tensioning element.

16. A method of strengthening a cord assembly having a cord with an insulation layer, at least one conductor running within the insulation layer, a strength member running within the insulation layer, and a securing element, the method comprising:

applying a pre-tension force to the strength member at a first end of the strength member; and

crimping the securing element onto the first end of the strength member and the insulation layer to maintain the pre-tension force in the strength member,

wherein pre-tension force permits the strength member to at least initially carry any additional tensile load placed on the cord.

17. The method of claim 16, wherein the strength member includes a Kevlar strand.

18. The method of claim 16, further comprising:

molding a strain relief member over the securing element and the first end of the strength member.

19. The method of claim 18, wherein applying a pre-tension force to the strength member includes compressing a coil spring disposed between the insulation layer and the first end of the strength member and molded within the strain relief member.

20. The method of claim 18, further comprising:

coupling a connector housing to the strain relief member, the connector housing configured to couple the cord assembly to an electronic device and further configured to break away from the electronic device before an additional tensile load on the cord is carried by the at least one conductor or the insulation layer.