Abstract:
In general, a cordage fixture and insertion tool provides a system and method of stabilizing wires of a cordage so that echo properties of telecommunication cords, created by use of the tool, are similar and may be effectively cancelled by a modular device to which the cord is attached. The tool comprises an elongated body having a longitudinal concave portion therein, which extends through the length of the tool. The width of the longitudinal concave portion is shaped in accordance with the size of the cord for which the tool is created. An elongated member extends from one end of the elongated body in a manner axially adjacent to the central axis of the longitudinal concave portion, and is capable of receiving a crimp ring, located on the cord so as to stabilize the cord during insertion of a plug subassembly into a housing.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to telecommunications. More specifically, the invention is related to a telecommunication cordage fixture and insertion tool for holding cordage during wire management and assisting in the insertion of a plug subassembly into an outer housing of a communication modular plug, while ensuring minimal wire shift. 
     BACKGROUND OF THE INVENTION 
     Modular telecommunication cords are used in the field of telecommunications for connecting between modular telecommunication devices. These cords hold cordage, which is comprised of a series of wires, within an outer jacket which, in turn, protects the cordage. Generally, a communication modular plug is located on the ends of the modular telecommunication cord, for connecting to modular telecommunication devices. 
     In accordance with the latest modular telecommunication cord design, one end of a sled is inserted into the outer jacket of the telecommunication cord, thereby providing a means of externally arranging the series of wires in the cordage. Wire arrangement is usually performed according to the polarity of the wires, although wire arrangement may be performed for other reasons. A metal crimp ring is also used to provide strain relief on the outside of the outer jacket. 
     Unfortunately, the cordage is difficult to hold while manipulating the wires for purposes such as arranging and inserting the wires into the sled, and inserting into a housing. To accommodate this difficulty, production operators generally have a tendency of wrapping the cordage around their fingers, thereby providing a better grip of the cordage during manipulation. This generally used technique causes the length of the wires to be uneven within the outer jacket of the cordage. Finally, when the wires are situated in the sled, they are trimmed. 
     Production of the finished modular telecommunication cord requires insertion of the wired sled into a housing, which, in combination with the sled, provides a means of connecting the modular telecommunication cord to modular telecommunication devices. Unfortunately, insertion of the wired sled into the housing, by holding the cordage, provides a further strain on the wires of the cordage, and additional shifting of the wires. 
     During the transmission and reception process of a telecommunication device, a receive signal, received from a first transmission line, can be corrupted by a transmit signal located on a second transmission line. This corruption is oftentimes referred to as an “echo” in that the corruption is substantially similar to the transmit signal, although attenuated in amplitude and delayed in phase in comparison. As such, each modular telecommunication cord has its own echo. One source of this echo in the cord is attributed to the length of wires in the outer jacket of the cordage. This “echo” is generally cancelled by the modular device to which the cord is attached. If however, numerous cords are attached to the modular device, via modular plugs, it is difficult, if not impossible, for the modular device to provide “echo cancellation” for all cords attached. Different lengths of wires within the outer jacket of the cordage provide different “echoes,” thereby making it difficult for the modular device to provide accurate echo cancellation for all modular telecommunication cords attached thereto, without excessive cost for additional echo cancellation devices. 
     Therefore, it is desirable to provide a system and method for creating modular telecommunication cords having similar echo properties. 
     SUMMARY OF THE INVENTION 
     Briefly described, the invention provides a cordage fixture and insertion tool for assisting in the creation of modular telecommunication cords, while assuring that the modular telecommunication cords have similar echo properties. 
     Generally, the tool supplies a means of securing a modular telecommunication cord, having a sled attached thereto and wired to wires within the cord, before insertion of the wired sled into a housing. Securing of the cord prevents the creation of different lengths of wires within the cord after clipping of the wires. This assures that cords created with use of the tool will have similar wire length, thereby assuring that proper echo cancellation may be provided by a modular device, to which the cord is attached. 
     The tool comprises an elongated body having a longitudinal concave portion therein, which extends through the length of the tool. The width of the longitudinal concave portion is shaped in accordance with the size of the cord for which the tool is created. An elongated member extends from one end of the elongated body in a manner axially adjacent to the central axis of the longitudinal concave portion, and is capable of receiving a crimp ring, located on the cord. 
     An alternative embodiment provides for the elongated member to be removably attachable to the elongated body. 
     The invention has numerous advantages, a few of which are delineated hereafter as examples. Note that the embodiments of the invention which are described herein possess one or more, but not necessarily all, of the advantages set out hereafter. 
     One advantage of the invention is that, it provides a means of assuring that the echo properties of multiple modular telecommunication cords are similar so that the modular device, to which the cords are attached, may provide effective echo cancellation. 
     Other features and advantages of the invention will become apparent to one of reasonable skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional features and advantages be included herein within the scope of the present invention, as defined by the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will be more fully understood from the detailed description given below and from the accompanying drawings of the preferred embodiments of the invention, which however, should not be taken to limit the invention to the specific embodiment, but are for explanation and for better understanding. Furthermore, the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. Finally, like reference numerals in the figures designate corresponding parts throughout the several drawings. 
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a plug assembly used by the telecommunication cord of the present invention. 
     FIG. 2 further illustrates the plug assembly of FIG. 1 having wires therein. 
     FIG. 3 illustrates a modular telecommunication cord having a sled, cover, and crimp ring attached. 
     FIG. 4 illustrated the cordage fixture and insertion tool in accordance with the preferred embodiment of the invention. 
     FIG. 5 illustrates the cordage fixture and insertion tool of FIG. 4, during the first step of constructing the modular telecommunication cord of FIG.  3 . 
     FIG. 6 further illustrates the process of making the modular telecommunication cord of FIG. 3, wherein the crimp ring is held by said tool. 
     FIG. 7 illustrates the modular telecommunication cord of FIG. 6, after the wires have been clipped. 
     FIG. 8 illustrates the modular telecommunication cord of FIG. 7, after the cord, with the sled, cover, and crimp ring attached, has been connected to a housing. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof is shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives, following within the spirit and scope of the invention as defined by the claims. 
     The present invention will be described hereafter by way of example with respect to a modular telecommunication cord. The skilled artisan will nevertheless appreciate that the teachings disclosed herein can be applied to other types of cables wherein during assembly of such cables, there is a need to keep the wires therein in a stationary position. 
     Turning now to the drawings, wherein like reference numerals designate corresponding parts throughout the drawings, FIG. 1 illustrates a plug assembly  2  which may be used in conjunction with the cordage fixture and insertion tool in the making of a modular telecommunication cord. A possible implementation of the plug assembly  2  is described in the copending, commonly assigned application entitled, “Communication Cable Terminating Plug, filed Dec. 16, 1998, and having Ser. No. 09/212,889, the disclosure of which is incorporated herein by reference. 
     In accordance with FIG. 1, a sled  4  having a proximate  6  and a distal portion  8  is illustrated. The proximate portion  6  of the sled  4  contains a divider  10 , central to the proximate portion  6 , which extends into the sled  4  for purposes of dividing wires  5 , from a cordage  9 , into groups during insertion into the sled  4 , as shown by FIG.  2 . Dividing of the wires  5  may be performed for such reasons as differentiating between wire polarity. Preferably, a proximate end  12  of the proximate portion  6  of the sled  4  is shaped in a cylindrical fashion so as to fit into a cord outer jacket  7  (FIG.  2 ). While the proximate end  12  is preferably shaped cylindrically, one of reasonable skill in the art will appreciate that any shape which provides an opening in which the wires  5  (FIG. 2) may be inserted, and which allows the proximate portion  6  of the sled  4  to be inserted into the outer jacket  7  (FIG. 2) of the cord, may be used. 
     The proximate portion  6  of the sled  4  is inserted into the outer jacket  7  (FIG. 2) of the cord, thereby exposing the wires  5  (FIG. 2) over the distal portion  8  of the sled  4 . The distal portion  8  of the sled  4  provides grooves  14  for supporting the wires in a uniform fashion. Preferably, the number of grooves  14  located within the distal portion  8  is equivalent to the number of wires  5  in the cordage  9 , although this is not required. A crimp ring  16  is used to provide strain relief on the outside of the outer jacket  7 . The crimp ring  16  may be made of any solid or semi solid material, which will provide appropriate strain relief on the outside of the outer jacket  7 . A cover  18  is provided for protecting the proximate portion  6  of the sled  4  and aligning the wires  5 , which have been sorted by the divider  10 . FIG. 3 illustrates the modular telecommunication cord  40  after the sled  4 , cover  18 , and crimp ring  16  have been attached. 
     Referring back to FIG. 1, a housing  20  is provided having a proximate  22  and distal portion  24 , and a top  26  and a bottom portion  28 . A proximate end  30  of the proximate portion  22  contains an opening  32  into which the sled  4  may be inserted, with the attached cover  18 . The top distal portion of the housing  20  contains a series of slits  34  wherein blades  36  may be inserted into the slits  34  when the sled  4  and cover  18  have been inserted into the housing  20  and are situated below the slits  34 . When the blades  36  are inserted, they cut through wire insulation, thereby exposing the wires  5  to the blades  36  and, in turn, exposing the conductance of the wires  5  through the top distal portion of the housing  20 . 
     FIG. 4 illustrates the cordage fixture and insertion tool  100  in accordance with the preferred embodiment of the invention. An explanation of use of the cordage fixture and insertion tool  100  shall be provided in accordance with FIGS. 5-8. With reference to FIG. 4, an elongated body  102  is provided having a longitudinal concave portion  104 , which extends through the length of the tool  100 . The elongated body  102  is preferably in a rectangular shape, so as to provide ease of handling. However, the elongated body  102  need not be limited to a rectangular shape, but instead may have any shape which provides ease of handling, while maintaining the width of the longitudinal concave portion  104  as described below. The width of the longitudinal concave portion  104  is set in accordance with the width of the modular telecommunication cord  40  for which the cordage fixture and insertion tool  100  will be used, such that the longitudinal concave portion  104  of the cordage fixture and insertion tool  100  is capable of receiving the modular telecommunication cord  40 . As such, the width of the longitudinal concave portion  104  may be different in accordance with the type of cord used. As an example, a modular telecommunication cord  40  which uses a four twisted pair wire would be significantly larger than a telecommunication cord  40  which uses a two twisted pair wire. 
     A proximate portion  106  of the elongated body  102  contains an elongated member  108 , which extends from the proximate portion  106  of the body  102  in a manner axially adjacent to the central axis of the longitudinal concave portion  104 . The elongated member  108  is capable of receiving the crimp ring  16  of the plug assembly  2 , such that when the modular telecommunication cord  40  is inserted into the cordage fixture and insertion tool  100 , the ring  16  is flush with a central portion  110  of the elongated member  108 . In accordance with the preferred embodiment of the invention, the crimp ring  16 , when pressed onto the outer jacket  7  of the modular telecommunication cord  40 , is shaped in a manner similar to the central portion  110  of the elongated member  108 . 
     Preferably, the elongated member  108  is comprised of two separate fingers  112 A- 112 B which each extend outward from the proximate portion  106  of the body  102 . The fingers  112 A- 112 B extend parallel to each other wherein the central portion of the first finger  112 A is facing the central portion of the second finger  112 B. The central portions of the fingers  112 A- 112 B are shaped in a concave manner so as to be capable of holding the crimp ring  16  during wire manipulation. Preferably, the central portion of the first finger  112 A is shaped in the form of a V, as is the central portion of the second finger  112 B, thereby providing two grooves wherein the compressed crimp ring  16  may be slidably inserted. The crimp ring  16  is shaped as a hexagon such that two outer edges of the hexagon may be supported by the central portion of the fingers  112 A- 112 B. 
     FIG. 5 represents the first step taken in the construction of a modular telecommunication cord  40 , while using the cordage fixture and insertion tool  100 . The sled  4  is first inserted into the cord jacket, after which the crimp ring  16  is compressed onto the outer jacket  7  of the cord  40 . The cover  18  is then attached to the sled  4  as described with reference to FIG.  1 . The modular telecommunication cord  40 , without the housing  20  and blades  36  attached, is then pushed into the longitudinal concave portion  104  of the tool  100  with the crimp ring  16  situated outside of the fingers  112 A- 112 B. The cord  40  may then be pushed into the proximate portion  106  of the elongated body  102 , thereby fitting the crimp ring  16  into the elongated member  108  and providing a firm holding for the crimp ring  16 , as illustrated by FIG.  6 . Alternatively, the cord  40  may be pulled at a distal end  114  of the elongated body  102 . 
     With the modular telecommunication cord  40  secured in the tool  100 , the previously arranged wires  5 , after being divided by the divider  10 , and arranged in the sled  4 , may then be clipped along the distal portion  8  of the sled  4 , such that the ends of the wires  5  are even. After the wires  5  are properly arranged and clipped, as shown by FIG. 7, the cordage fixture and insertion tool  100  may then be used to push the modular telecommunication cord  40 , with the sled  4 , cover  18 , and crimp ring  16  attached, into the housing  20 , as shown by FIG.  8 . The tool  100  thereby forces the modular telecommunication cord  40 , and the wires therein, to remain straight during insertion of the sled  4  into the housing  20 , thereby producing a modular telecommunication cord  40  having a stable echo. 
     While described as a tool  100  being a single solid unit, the cordage fixture and insertion tool  100  may be constructed of more than a single part. As an example, in an alternative embodiment, the elongated member  108 , which, in accordance with FIG. 4, extends from the proximate portion  106  of the elongated body  102 , may be a separate portion, hereafter referred to as a tip, which is attached to the proximate portion  106  of the elongated body  102 , either in a permanent or temporary manner. As such, the tip contains the fingers  112 A- 112 B at a proximate end of the tip and a flat portion at a distal end of the tip, which may be attached to the proximate portion  106  of the elongated body. 
     The tip, having fingers  112 A- 112 B thereupon, may be attached to the proximate portion  106  of the elongated body  102  by using such means as an adhesive, a fixing means such as a screw, or an alternative attachment means. It should be noted, that although the tip may be separated from the elongated body  102 , when the tip is attached, the longitudinal concave portion  104  of the body  102  aligns with the central portion of the fingers  112 A- 112 B, thereby still providing a means for the modular telecommunication cord  40  to be pushed into the longitudinal concave portion  104  of the body  102 , with the crimp ring  16  still outside of the tool  100 . 
     In accordance with the preferred embodiment of the invention, the tool  100  is made entirely of plastic. Alternatively, in accordance with an alternative embodiment of the invention, the elongated body  102  may be made of plastic with the tip made of aluminum or steel. 
     The foregoing has been illustrative of the features and the principles of the present invention. Various changes or modifications to the invention may be apparent to those skilled in the art without departure from the spirit and scope of the invention. All such changes or modifications are intended to be included herein and within the scope of the invention.