Abstract:
A cable repair system having a splicing member. The splicing member includes at least two conductor pairs and an insulation member disposed intermediate to the at least two conductor pairs. The insulation member is configured to shield the conductor pairs from electrical interference from adjacent conductor pairs. The conductor pairs and insulation member are configured to permit splicing of two more cable segments. A method for splicing a data cable and a repaired cable are also disclosed.

Description:
FIELD OF THE INVENTION 
     This disclosure relates to wire or cable repair and connection methods and systems. 
     BACKGROUND OF THE INVENTION 
     Known cable or wire splicing methods include direct wire contact with crimping, soldering or similar connection methods. Known methods are generally unsuitable for high speed data type connections or repairs due to crosstalk and interference at the point of connection 
     What is needed is a system and method for repair of high-speed data wires or cables that does not suffer from the drawbacks of known splicing methods. 
     SUMMARY OF THE INVENTION 
     One aspect of the present disclosure includes a cable repair system having a splicing member. The splicing member includes at least two conductor pairs and an insulation member disposed intermediate to the at least two conductor pairs. The insulation member is configured to shield the conductor pairs from electrical interference from adjacent conductor pairs. The conductor pairs and insulation member are configured to permit splicing of two more cable segments. 
     Another aspect of the present disclosure includes a method for splicing a data cable. The method includes providing a first cable segment having at least two conductor pairs and a second cable segment having at least two conductor pairs. A splicing member having at least two conductor pairs and an insulation member disposed intermediate to the at least two conductor pairs is provided. The insulation member is configured to shield the conductor pairs from electrical interference from adjacent conductor pairs. The at least two conductor pairs of the first cable segment are connected to the at least two conductor pairs of the splicing member. The at least two conductor pairs of the second cable segment are connected to the at least two conductor pairs of the splicing member. 
     Still another aspect of the present disclosure is a repaired cable having a first cable segment having at least two conductor pairs and a second cable segment having at least two conductor pairs. The repaired cable also includes a splicing member having at least two conductor pairs in electrical communication with the conductor pairs of the first cable segment and the conductor pairs of the second cable segment and an insulation member disposed between the at least two conductor pairs, the insulation member being configured to shield the conductor pairs from electrical interference from adjacent conductor pairs. 
     An advantage of the method and system for the present disclosure includes a splice having no or minimal electrical data transmission loss with reduced or eliminated crosstalk between conductor pairs. 
     Another advantage of the method and system of the present disclosure includes a portable system that is capable of use in the field or in rugged environments. 
     Still another advantage is that the splice system provides an environmentally sealed barrier suitable for a wide variety of environments. 
     Still another advantage is that the splice system is scalable from, for example, a two pair conductor pair system to a system having tens or hundreds of conductor pairs. 
     Still another advantage includes a low profile geometry that does not significantly increase the overall diameter of the cable, allowing the repaired cable to be pulled or installed according to conventional conductor installation methods. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a cable repair system  100  according to an embodiment of the present disclosure 
         FIG. 2  shows a cross-sectional view of cable splice of  FIG. 1  taken in direction  2 - 2 . 
         FIG. 3  shows a perspective view of a cable splice according to an embodiment of the present disclosure. 
         FIG. 4  shows an alternate arrangement of the insulation member. 
         FIG. 5  shows the insulation member of  FIG. 4  in a cable splice according to an embodiment of the present disclosure 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. 
       FIG. 1  shows a cable repair system  100  according to an embodiment of the present disclosure. The system includes a cable splice  101  electrically connecting a first cable segment  103  to a second cable segment  105 . The first and second cable segments  103 ,  105  are preferably wires capable of transferring signals or data. “Cable” as utilized herein, is a configuration of conductors, such as wires, capable of transmitting signals, data or information and may include combinations of conductors for varied electrical polarities or ground. “Conductor” as utilized herein, is an electrically conductive component, such as a wire, connector terminal, pin, socket, tab or any other component formed from an electrically conductive material. For example, the first and second cable segments  103 ,  105  are preferably made up of conductor pairs  201  (see e.g.  FIG. 2 ) and configured to transfer data at high rates. The conductor pairs  201  are made up of a plurality of conductors  203  (see e.g.,  FIG. 2 ). 
     The cable splice  101  includes an insulation member  107  disposed intermediate to conductor pairs  201 . Being “intermediate to”, as utilized herein, is intended to mean that the insulation member  107  is physically disposed between the individual sets of conductor pairs  201  and provides sufficient shielding to reduce or eliminate cross-talk or other interference between adjacent conductor pairs  201 . “Adjacent”, as utilized herein includes close proximity between conductor pairs  201  sufficient to, if uninsulated, to have electrical interference or cross-talk. The system further includes a sealing member  109  at each end of splicing member  101 . The sealing member  109  is preferably fabricated from a material substantially impermeable to moisture and to environmental conditions. For example, the sealing member  109  may be fabricated from a heat recoverable polymeric material that is heated to shrink fit and seal the junction between the first cable segment  103  and the cable splice  101  and the second cable segment  105  and the cable splice  101 . In addition to sealing the cable splice  101  to the first and second cable segments  103 , 105 , the sealing member  109  may also provide strain relief for the cable repair system  100 . The insulation member  107  and conductor pairs  201  are disposed in a housing  111 . The housing  111  may include any suitable electrically insulative material. For example, while not so limited, the housing may be fabricated from acrylonitrile butadiene styrene (ABS) or other electrically insulative polymer material. 
       FIG. 2  shows a cross-sectional view of cable splice  101  taken in direction  2 - 2 , as shown in  FIG. 1 . The configuration shows  FIG. 2  includes four conductor pairs  201  wherein the insulation member  107  includes a plus-sign geometry. The geometry of the insulation member  107  includes four shielded areas corresponding to the areas in which the conductor pairs  201  are disposed. 
       FIG. 3  shows a perspective view of a cable splice  101  with housing  111  removed. Conductor pairs  201  are disposed in electrically shielded areas formed by insulation member  107 . The conductors  203  include a terminal  301 . The terminal  301  includes any suitable electrically connectable structure. For example, terminal  301  may include a crimp, screw terminal, insulation displacement connector (IDC), poke-in terminal or any other structure known for connecting conductors. The insulation member  107  is sufficiently long to provide electrical shielding for the conductor  203 , including the terminal  301 . In certain embodiments of the present disclosure, the insulation member  107  includes electrical communication to a ground source and/or provide a ground pass-through within the cable splice  101 . The electrical grounding of the insulation member  107  reduces or eliminates escapement of electrical interference. In addition, the grounding of the insulation member  107  may reduce or eliminate exterior or environmental electrical noise from entering the splice and further isolates each conductor pair from adjacent pairs  201 . 
       FIG. 4  shows an alternate arrangement of the insulation member  107 , corresponding to two positions for conductor pairs  201 . The insulation member  107  includes a substantially planar configuration. 
       FIG. 5  shows the insulation member  107  of  FIG. 4  in a cable splice  101  according to an embodiment of the present disclosure with housing  111  removed. As shown, insulation member  107  is arranged such that conductors  203 , including terminals  301  are insulated from electrical interference. Specifically, the insulation member  107  preferably is sufficiently long to extend for a distance greater than conductors  203  within cable splice  101 . 
     While the above has been shown and described with respect to a two conductor pair  201  arrangement and for conductor pair  201  arrangement, the disclosure is not so limited. Any number of conductor pairs  201  may be present in cable splice  101 . In addition, the insulation member  107  is not limited to the geometry shown and may include any configuration or geometry that provides area in which conductor pairs  201  may be disposed. In addition, the conductor pairs  201  may be partially or fully surrounded by insulation member in areas not adjacent to conductor pairs  201  to provide additional interference shielding. 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.