Seamless flat-round conductive cable for a retractable cord reel

• US 6,372,988 B1
• Filed: 09/24/1999
• Issued: 04/16/2002
• Est. Priority Date: 01/07/1997
• Status: Expired due to Term

• Current Assignee: Astronics Connectivity Systems & Certification Corp. (Astronics Corporation), Shattuc Cord Specialties, Inc.
• Original Assignee: Telefonix Incorporated (Astronics Corporation), Shattuc Cord Specialties, Inc.
• Inventors: Burke, Paul C., Runzel, John S.
• Primary Examiner(s): Reichard, Dean A.
• Assistant Examiner(s): WALKENHORST, DAVID W
• Application Number:
  US09/405,742
• Time in Patent Office: 935 Days
• Field of Search: 174/68.1, 174/69, 174/70.R, 174/72.TR, 174/72.A, 174/113.R, 174/117.R, 174/117.F, 174/149.R, 174/27, 242/370, 242/385, 242/360, 242/230, 242/234
• US Class Current: 174/69
• CPC Class Codes: B65H 2701/34 electric cords or electric power cables
• CPC Class Codes: B65H 75/38 involving the use of a core or former internal to, and supporting, a stored package of material
• CPC Class Codes: B65H 75/4434 actuated by pulling on or imparting an inclination to the material
• CPC Class Codes: B65H 75/4449 Arrangements or adaptations to avoid movable contacts or rotary couplings, e.g. by the use of an expansion chamber for a lenght of the cord or hose
• CPC Class Codes: B65H 75/486 Arrangements or adaptations of the spring motor
• CPC Class Codes: H01B 7/08 Flat or ribbon cables
• CPC Class Codes: H01B 7/40 with arrangements for facilitating mounting or securing
• CPC Class Codes: H02G 11/02 using take-up reel or drum
• CPC Class Codes: H04M 1/15 Protecting or guiding telephone cords

Abstract

A seamless flat-round conductive cable is adapted for use in a retractable cord reel having a spool on which a round portion of the cable is wound and a cable expansion chamber in which a flat portion of the cable is disposed. The cable has a plurality of seamless conductive members, each of which may include an inner conductor and an outer insulating layer. The cable includes a first cable portion with a substantially flat configuration and a second cable portion with a substantially round configuration. The first cable portion includes a plurality of conductive members which are held together in a substantially flat configuration by, alternatively, bonding, jacketing or weaving the conductive members together. The second cable portion includes a plurality of conductive members, each of which is seamlessly connected to i.e., integral with, the respective conductive members of the first cable portion. The conductive members of the second portion are preferably twisted to form a substantially round configuration.

Claims

1. A flat-round electrical cable for a retractable cord reel, the reel having a spool and an expansion chamber;

the cable comprising;

a first cable portion adapted to be held in the expansion chamber of the reel, said first cable portion comprising a plurality of elongated, seamless conductive members, each conductive member having a conductor substantially covered by an insulating layer, and means for maintaining said first cable portion in a substantially flat configuration;

a second cable portion adapted to be retractably held on the spool of the reel, said second cable portion comprising a plurality of elongated, seamless conductive members, each conductive member having a conductor substantially covered by an insulating layer, each of said conductive members of said second cable portion being seamlessly continuous with respective ones of said conductive members of said first cable portion, said second cable portion having a substantially round configuration.

2. A cable as in claim 1 wherein said plural conductive members of said first cable portion are arranged in a substantially parallel, side-by-side configuration.

3. A cable as in claim 1 wherein said plural conductive members of said second cable portion are twisted in a substantially round configuration.

4. A cable in claim 1, further comprising a jacket covering said second cable portion.

5. A cable as in claim 4, wherein said jacket comprises nylon braid.

6. A cable as in claim 4, wherein said jacket comprises an insulating elastomer.

7. A cable as in claim 1 wherein each of said conductors comprises a multiplicity of wire strands.

8. A cable as in claim 1 wherein said means for maintaining said first cable portion in said substantially flat configuration comprises a chemical bond.

9. A cable as in claim 1, wherein said means for maintaining said first cable portion in a substantially flat configuration comprises thermal-bonding of said insulating layers of adjacent said conductive members.

10. A cable as in claim 1, wherein said means for maintaining said first cable portion in a substantially flat configuration comprises a jacket.

11. A cable as in claim 10, wherein said jacket is conductive material.

12. A cable as in claim 1, wherein said means for maintaining said first cable portion in a substantially flat configuration comprises strands woven between said conductive members of said first cable portion.

13. A cable as in claim 1, further comprising means for maintaining said second cable portion in a substantially round configuration.

14. A cable as in claim 1, further comprising a jacket surrounding said second cable portion.

15. A cable as in claim 14, wherein said jacket comprises braided conductive material.

16. A cable as in claim 1, wherein said means for maintaining said first cable portion in a substantially flat configuration comprises a continuous braided jacket of conductive material, and wherein said braided jacket extends over both said first and second portions of said cable.

17. A retractable cord reel with a seamless electrical cable comprising:

a support;

a spool rotatably mounted in said support;

an expansion chamber adjacent said spool;

a first cable portion disposed in said expansion chamber, said first cable portion having a flat configuration and comprising a plurality of elongated, seamless conductive members, each conductive member having a conductor substantially covered by an insulating layer;

a second cable portion retractably held on said spool, said second cable portion having a substantially round configuration and comprising a plurality of elongated, seamless conductive members, each conductive member having a conductor substantially covered by an insulating layer, each of said conductive members of said second cable portion being seamlessly continuous with respective ones of said conductive members of said first cable portion.

18. A cable as in claim 17 further comprising a third cable portion having a substantially round configuration, said first cable portion being disposed between said second and third cable portions, said third cable portion comprising plural elongated, seamless conductive members, each conductive member having a conductor substantially covered by an insulating layer, each of said conductive members of said third cable portion being seamlessly continuous with respective ones of said conductive members of said first cable portion.

19. A cable as in claim 17, further comprising comprises a continuous braided jacket of conductive material covering said first and second cable portions.

20. A cable as in claim 19 wherein said inner conductor comprises a multiplicity of electrically conductive wire strands.

21. A method of forming a flat-round cable comprising the steps of:

(a) pulling plural conductive members for a predetermined first length, said conductive members being parallel and side-by-side relative to one another;

(b) bonding said first length of conductive members together to form a substantially flat first portion;

(c) continuing to pull said plural conductive members for a second length; and

(d) twisting said second length of conductive members to form a substantially round second portion.

22. A method as in claim 21 further comprising the step of applying an insulating jacket to said second portion.

23. A method as in claim 21 further comprising the step of applying a continuous, seamless layer over both said first and second cable portions.

24. A method as in claim 23 wherein said continuous, seamless layer comprises a braided layer.

25. A method as in claim 21 wherein the step of bonding comprises chemical bonding.

26. A method as in claim 21 wherein step (d) comprises the steps of:

(d1) providing a plurality of reels on a rotating carriage, each of said reels having a length of conductive members disposed thereon;

(d2) causing said rotating carriage to rotate while said seamless conductive members are being pulled during said step (c).

27. A method as in claim 21 further comprising the steps installing said first cable portion in an expansion chamber of a retractable cord reel, and winding said second cable portion on a spool of the retractable cord reel.

28. A method of making a flat-round cable for a cord reel, comprising the steps of:

(a) pulling plural conductive members for a predetermined first length, said conductive members being parallel and side-by-side relative to one another to form a substantially flat first portion;

(b) continuing to pull said plural conductive members for a second length;

(c) twisting said second length of conductive members to form a substantially round second portion; and

(d) applying a continuous jacket over said first and second portions to hold said first portion in a substantially flat configuration and to hold said second portion in a substantially round configuration.

29. A method as in claim 28 wherein said continuous jacket is braided.

30. A method as in claim 28 further comprising the steps installing said first cable portion in an expansion chamber of a retractable cord reel, and winding said second cable portion on a spool of the retractable cord reel.

31. A method of making a flat-round cable, comprising the steps of:

providing a first length of plural conductive members;

weaving said first length of conductive members to each other in a parallel, side-by-side relationship to form a flat first portion;

providing a second length of plural conductive members, said second length being continuous and seamless with said first length;

twisting said second length of conductive members to form a substantially round second portion.