Abstract:
Methods and systems for assembling customizable solderless cables for direct current (DC) transmission of electricity to an electronic device. The systems and methods utilize shielded co-axial cable defining first and second opposed ends which may be cut to a desired length as selected by the user. Connectors, which may have a conventional 2.1 mm×5.5 mm DC plug design, include a barrel portion defining a threaded axial passageway. In use, the threaded passageway of the plug is twisted upon a respective end of the cable such that the end of the cable becomes threadedly seated thereinto and in electrical contact with the plug to form two dedicated electrical connections. A respective other plug is mounted on the other respective end of the cable in the same manner to thus define the customizable cable. A single length of cable or a plurality of wire segments and plugs may be sold as a pre-packaged unit for use in making a plurality of customizable DC cables.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/321,836, entitled DC SOLDERLESS CONNECTOR, filed Apr. 13, 2016, and U.S. Provisional Patent Application Ser. No. 62/378,802, entitled DC SOLDERLESS CONNECTOR filed Aug. 24, 2016, the teachings of all of which are specifically incorporated herein by reference. 
     
    
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND 
       [0003]    The present invention relates to methods and kits for forming customized solderless cables for transmitting direct current (DC) electricity. The present invention further relates to the cables produced by such methods. 
         [0004]    As is well-known in the art, electricity is typically transmitted via alternating current (AC) or direct current (DC). DC works by supplying a constant electric voltage, from which most devices will draw a constant electric current. Along those lines, most modern electronics require direct current in order to operate. 
         [0005]    In many instances, electronic devices requiring DC are adapted to draw power from a battery—a common source of direct current—or otherwise receive DC transmission from a source operative to convert AC to DC. The latter approach is considered far more favorable as AC power is the predominant form of electricity transmission made publicly accessible and further, eliminates the need to rely upon batteries as the DC power source, which would otherwise require frequent replacement or recharging on a routine basis. 
         [0006]    To facilitate the ability to transmit DC to an electronic device, numerous standardized cables have been developed. Perhaps the most common of such cables is the 2.1 mm×5.5 mm DC cable operative to interconnect with male and female plugs/sockets. Such cables come in a wide variety of lengths and are typically provided with either a straight or right-angle plug configuration. 
         [0007]    Despite the widespread availability of such cables, however, there is not yet presently available any type of system and method by which customized DC cables can be easily and readily created, as well as created in a manner that results in an exceptionally durable cable that is structurally robust, capable of long product life and is designed to deliver a maximum degree of current transmission. There is particularly lacking such a system and method for creating a DC cable that dispenses with the need to form a solder connection between the respective plugs formed on the end of such cable and the cable through which electricity is transmitted. 
         [0008]    Due to the lack of any systems and methods for forming such DC cables, numerous difficulties have arisen in a number of applications. Exemplary of the difficulties associated with using standardized DC cables include the supply of power to multiple guitar effects pedals operatively combined with one another as part of an effects pedalboard. As is well-known to those skilled in the art, guitar effects pedals are utilized extensively in connection with electric guitar amplification and are operative to modify the signal transmitted from the electric guitar to a guitar amplifier. Such pedals are designed to impart effects such as distortion, chorus, delay, flange and numerous others as can be selectively chosen by the player. Typically, each pedal is responsible for a single effect, and a plurality of pedals are arranged in a particular sequence upon a pedalboard, which can take countless different forms, spatial arrangements, different types of pedals of different sizes made by a variety of manufacturers that are all dependent upon the particular tastes of the guitarist (and often times the guitarist&#39;s guitar tech). 
         [0009]    Given the drastic variation in the layout and configuration of the specific guitar effects pedals upon a pedalboard, substantial difficulty arises in supplying power to each specific effects pedal. As discussed above, the use of batteries is completely impractical as it is far too labor intensive and time consuming to continuously monitor and replace the numerous number of batteries that would be used in connection with such pedals. The use of standard DC cables to run power from an AC to DC conversion electricity source is likewise problematic insofar as the spatial arrangement of the effects pedals, as discussed above, can vary greatly and standardized cables provide no means whatsoever to customize the same to a specific length as would be desirable for such applications. 
         [0010]    While the ability to make custom DC cables can be readily accomplished, such task typically involves the step of soldering the plugs to the respective ends of the wire forming the cable. Such process, however, is time consuming, requires soldering equipment, skill in knowing how to properly solder and carries risk of injury given the heat and melting of solder needed to form an ideal electrical connection. 
         [0011]    Accordingly, there is a substantial need in the art for systems and methods that enable a customized DC cable to be easily and readily fabricated. There is likewise a need in the art for such systems and methods that rely on a simple, easily understood construction, fast and exceedingly simple to assemble, capable of being precisely customized to exact specifications, and operative to produce cables that are exceptionally durable and capable of maximizing current flow therethrough and without the need for soldering. 
       BRIEF SUMMARY 
       [0012]    The present invention specifically addresses and alleviates the above-identified deficiencies in the art. In this regard, the present invention is directed to methods and kits for forming solderless DC cables for delivering a direct electrical current via conventional wiring connections, and in particular through conventional plugs and sockets per conventional male/female fittings. Advantageously, the methods and kits of the present invention enable such cables to be formed to selectively chosen lengths and further, result in DC cables that are exceptionally durable and maximize transmission of DC electricity without having to form solder connections. 
         [0013]    According to a preferred embodiment, the methods and kits deploy sheathed electrical cable for transmitting DC electricity and possess a specified length defining first and second opposed ends. Per conventional sheathed wire, such cable will comprise a coaxial cable consisting of an inner conductive core, a core insulator wrapped thereabout, a metal conductive shield extending about the core insulator, and an outer shearable sheath. As the outer layer suggests, the shearable sheath is selectively chosen to be shearable in nature so as to expose the metal conductive layer underneath, as discussed herein. 
         [0014]    Attachable to the respective ends of the cable are connectors or plugs designed to have a conventional fitting formed thereon. According to a preferred embodiment particularly well suited for the formation of cables for use with guitar effects pedalboards, the plugs will take the form of a conventional 2.1 mm plug. Such plug, which will typically take the form of a male plug portion, will be configured to have a proximal barrel portion operative to receive and interconnect with a respective one of the opposed ends of the cable and an exterior male distal end or sleeve extending therefrom forming the conventional plug portion. The proximal barrel portion further has a threaded axial passageway disposed therein. 
         [0015]    Within the distal interior of the axial passageway is a pin assembly having a registry pin for forming an electrical connection with the wiring encased within the inner core of the cable that is operative to transmit the current through an internal sleeve or male end of the plug (i.e., the “hot” tip) per conventional electrical interconnections. An annular non-conductive sleeve is interposed between the outer sleeve portion extending from the barrel portion and the internal sleeve of the internal pin assembly to thus enable the transmission of two separate currents, as will be understood by those skilled in the art. 
         [0016]    In use, a respective one of the ends of the cable is introduced within the axial passageway of the barrel portion of the plug with the plug thereafter being rotated clockwise thereupon such that the threads within the axial passageway shear through the shearable outer sheath and expose the metal conductive shield about the distal end of the cable. Through such process, the inner core within the end of the cable is caused to securely contact and form an electrical connection with pin extending thereinto from the distal end of the interior pin assembly. The shearing force of the threads against the sheath of the cable ensures that the inner core wiring will ideally interconnect with the pin. Moreover, due to the actual positioning of the pin within the passageway, an optimal electrical connection is thus formed. Still further, by virtue of the threaded engagement between the threads of the axial passageway and the metal conductive shield about the distal end of the cable, a second electrical connection is established to allow for a second dedicated current flow. In this regard, the shearing action of the threads is operative to only form an electrical connection between the threads of the axial passageway and the metal conductive shield lying there underneath and does not extend past the core insulator wrapped about the conductive inner core. Moreover, such threaded engagement causes the interconnection between the distal end of the cable and the interior of the barrel portion of the plug to become extremely secure and durable, and dispenses with the need to form a solder connection. 
         [0017]    To the extent the cable assumes the desired length, the same process is repeated with respect to another like plug as attached to the respect other end of the cable. Alternatively, once a plug is securely attached to a respective end of the cable, the cable may be cut to a desired length and then a second like plug may be attached, with the end result being a DC solderless cable having conventional plugs securely attached at the ends thereof with the cable having a length as specified by the user. Such cable may then be utilized per conventional DC electricity transmission applications, and in particular for use in transmitting energy from an AC to DC power source into a DC electronic device, such as a guitar effects pedal. To the extent desired, plugs may be used that form either straight or right angle connections. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which: 
           [0019]      FIG. 1  is a perspective view of a solderless DC cable having conventional 2.1 mm male plugs formed on the respective ends thereof as assembled by the methods and kits of the present invention; 
           [0020]      FIG. 2  is an exploded view, partially in cross-section, of a respective plug as attached to a respective end of a cable as taken along line  2 - 2  of  FIG. 1 ; 
           [0021]      FIG. 3  is a view taken along line  3 - 3  of  FIG. 1 , partially in cross-section, showing the assembly procedure for assembling a plug to a respective end of the cable; and 
           [0022]      FIG. 4  is an exploded view of the components of the plug assembly for forming the DC solderless cables of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    The detailed description set forth below is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form in which the present invention may be implemented or performed. The description sets forth the functions and sequences of steps for practicing the invention. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments and that they are also intended to be encompassed within the scope of the invention. 
         [0024]    Referring now to the figures, and initially to  FIG. 1 , there is shown a DC cable  10  as constructed in accordance with a preferred embodiment of the present invention. As illustrated, the cable  10  assumes the configuration of a conventional 2.1 mm DC cable having an intermediate cable portion  12  with 2.1 mm plugs  14  and  16  fitted on the opposed ends thereof. Per conventional 2.1 mm plugs, plugs  14 , 16  include barrel portions  18 ,  20  respectively, as well as male pin portions  22 ,  24 , respectively. Such cables as  10  are utilized in a conventional manner to transmit DC electricity therethrough via the use of conventionally sized fittings such as  14 , 16 . Advantageously, however, the cables  10  of the present invention are operative to be easily and readily fabricated such that the cable portion  12  may have a desired length and further, plugs  14 , 16  may be easily, readily and securely attached to cable  12  at the opposed ends thereof without the need of forming a soldered connection. 
         [0025]    To accomplish that end, the DC cable  10  of the present invention are assembled via the interconnection of the respective plugs  14 , 16  to the opposed ends of cable  12  in the manner depicted in  FIGS. 2 and 3 . As shown, cable  12  comprises a coaxial cable operative to facilitate the transmission of two signals. Specifically, a first current is transmissable via a conductive inner core  32 , about which is wrapped a core insulator  31   a . Axially encased about the core insulator  31   a  is a metal conductive shield  31 , which is thus electrically isolated from the inner core  32  and operative to facilitate the transmission of the second separate, independent signal. Wrapped about the metal conductive shield  31  is a shearable outer layer  30 , which is operative to electrically insulate the metal conductive shield  31  unless otherwise selectively sheared or shred therefrom to enable an electrical connection to be made, as discussed more fully below. 
         [0026]    The opposed ends of the cable  12  are designed to interconnect and form an electrical connection with a respective plug, such as  14  as shown in  FIG. 2 , as well as exploded view of  FIG. 4 . With respect to the latter, plug  14  includes an outer barrel portion  18  with male sleeve portion  22  extending therefrom. Such plug  14  is designed to have a conventional 2.1 mm configuration whereby external sleeve portion  22  is operative to interconnect with and transmit DC electricity per conventional fittings well-known in the art. To accomplish that end, plug  14  is configured such that the barrel portion  18  has an axial passageway  24  extending therewithin from the proximal side thereof. Such axial passageway  24  is defined by a periphery of threads  26  that are operative to be twisted or rotatably mounted upon the end of the cable  12  to which the plug  14  is attached. Plug  14  further includes an internal pin assembly that comprises conductive sleeve  36  having a pin  28  extending rearwardly therefrom and into the axial passageway  24  of barrel  18 . Insulating sleeve  34  is further provided so as to prevent current transmitted through sleeve  36  to anything than the socket to which the plug  14  is connected, including outer sleeve portion  22 . Such plugs  14  have recently become commercially available from 3 Monkeys Amps, of Raleigh, N.C. Also, although depicted in the figures as having a straight or 180° linear configuration, it will be readily understood by those skilled in the art that plugs  14 , 16  may also be formed to have a right angle or 90° orientation as may be desired for a particular application. 
         [0027]    Referring now to  FIG. 3 , there is shown the manner by which an end of cable  12  is interconnected with plug  14  as shown in  FIG. 2 . As illustrated, plug  14  is rotated in a clockwise fashion as indicated by the letter “A” such that threads  26  are caused to compress against and shear through sheath  30  as the end of the cable  12  is advanced into the axial passageway. By virtue of the concentric orientation of pin  28  within axial passageway  24 , the threads  26  thus cause interior wiring  32  to concentrically encase pin  28  to thus establish an optimal degree of electricity transmission. In this regard, by maintaining a concentric relationship between core wiring  32  and pin  28 , a secure connection is easily and readily established that further dispenses with the need of having to strip coaxial cable. 
         [0028]    At the same time, a second, independent electrical connection is established by virtue of threads  26  that have sheared through outer layer  30  and subsequently brought into contact with metal conductive shield  31 . In this regard, the threads  26  are operative to only shear through outer layer  30  and form an electrical contact with metal conductive shield  31  but not shear through core insulator  31   a , which in turn maintains an electrically insulated covering about inner core  32 . As a consequence, electrical signal pathways are established both by inner core  32  with pin  28  and ultimately internal male pin portion  36 , in one direction, and separately through outer sleeve portion  22 , which in integrally formed as part of barrel portion  18  and threaded portion  26  thereof with metal conductive shield  31 . 
         [0029]    Such interconnection advantageously dispenses with the need to form any type of soldering connection, as discussed above, as well as dispenses with the need of any type of screws that are frequently deployed to secure plugs to the cables with which they are connected that are widely recognized in the art as being exceptionally problematic. In this regard, the user need only make a clean, straight cut of the cable  12  using a utility knife with a sharp blade in order to form a connection between the end of the cable  12  and a connector  14 . Such clockwise twisting is performed to the point to where the end of the cable  12  is fully nested within the axial passageway formed within bore  18 , a point that is reached when the plug  14  is “finger tight” or cannot be advanced further without applying excessive force. 
         [0030]    As will be appreciated by those skilled in the art, the sheath or jacket  30  formed about metal conductive shield  31  of cable  12  should be selectively chosen to shear when contacted with threads  26 . Exemplary of commercial wiring suitable for the practice of the present invention including a cable jacket  30  capable of shearing includes Part No. 8 1C16-1430SB, produced by Anixter, Inc. of Glenview, Ill. Cables  12  that do not include a shearable jacket will not be ideal for the practice of the present invention. 
         [0031]    As discussed above, the spiral shearing accomplished by threads  26  are operative to facilitate the electrical connection between threads  26  and metal conductive shield  31 , on one hand, and interior wiring  32  and pin  28 , on the other. Such action also causes the end of the cable  12  to become securely seated and permanently nested within the axial passageway of bore  18 . In this regard, the compressive force by thread  26  forms a 360° interconnection that forms a nearly perfect concentric relationship between threads  26  and shield  30  and the core of the cable  32  and the pin  28 , especially insofar as the pin  28  is driven into the core wiring  32  that, in turn, maximizes the contact between such elements and eliminates the need for a solder-like connection. 
         [0032]    In order to cause the DC solderless cables of the present invention to assume the desired length, the cable  12  may be cut to have a pre-determined length prior to the attachment of the plugs  14 , 16  on the opposed ends thereof or, alternatively, a first plug  14  may be mounted on a respective end of the cable  12 , and thereafter the length of cable  12  measured to a desired length and subsequently cut to define the other end of the cable to which the respective other plug  16  may be attached. In this regard, the attachment of second plug  16 , not shown, is identical to that as discussed above with respect to plug  14 . Advantageously, because each respective plug  14 , 16  is threadably mounted upon the respective opposed ends of cable  12  via clockwise threaded engagement, such plugs  14 , 16  are consequently caused to assume a more secure attachment to the respective ends of cable  12  insofar as to remove a respective  14 , 16  would require the same be rotated counterclockwise relative the cable  12 , which consequently has an opposite effect on the opposite end of cable  12  and plug to which it is attached. A more secure attachment to the opposed end is thus created by virtue of the torsional system by which the respective plugs  14 , 16  are attached to cable  12 . Indeed, such interconnection is so secure, that any type of conventional locking material or mechanism, such as screws, glue and the like, are completely unnecessary. 
         [0033]    In order to more easily and readily practice the methods of the present invention, it is contemplated that a plurality of cable segments  12  and plugs  14 , 16  may be pre-packaged and sold as a kit to thus enable a plurality of cables of the present invention  10  to be performed. To that end, it is contemplated that two plugs  14 , 16  will be provided for each segment of cable  12  or, alternatively, a certain number of pairs of plugs  14 , 16  may be sold in connection with a single length of cable  12 , the latter may be cut to specific lengths as may be selectively chosen by the user. For example, it is contemplated that a kit may include ten plugs (i.e.,  5  pairs) in combination with ten feet of cable  12 , the latter of which being cut to specific lengths and used with a respective pair of plugs  14 , 16  as may be desired. 
         [0034]    Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. For example, while discussed herein for the creation of DC cables, it is expressly contemplated that the methods of the present invention and the cables formed thereby may also include any bi-filler (i.e., bi-polar) connection, such as for AC applications and the transmission of audio signals. Thus, the particular combination of parts and steps described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices and methods within the spirit and scope of the invention.