Abstract:
A method and system for providing a conformable cable are described. The method and system may include disposing a conformable material along at least a portion of a cable and configuring the cable into a desired position and shape in which the shape of the cord remains unchanged.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of the following provisional applications, each of which is hereby incorporated by reference in its entirety: U.S. Provisional Application No. 60/901,296 filed Feb. 12, 2007 and U.S. Provisional Application No. 60/901,238 filed Feb. 12, 2007. 
     
    
     FIELD OF INVENTION 
       [0002]    The invention herein disclosed generally refers to cables, and specifically to conformable cables. 
       BACKGROUND 
       [0003]    Power cords and connector cables are used to connect an appliance with power outlets. These power outlets may lie behind heavy furniture, televisions and couches in furnished rooms and offices. In addition, these power outlets may be located at a very low height or in areas having limited accessibility. The power cords and connector cables are flexible which allows them to reach the limited accessible areas. 
         [0004]    The flexibility of power cords and connector cables causes them to become easily tangled and wrapped around themselves and other cords and objects. Also, these power cords and connector cables do not possess sufficient internal structural integrity to resist the pull of gravity under their own weight and fall down to the ground. In addition, these types of flexible power cords and connector cables fall back behind desks and furniture if not secured or attached. 
         [0005]    Therefore, there exists a need for a power cord or a connector cable so that the disadvantages associated with power cords or a connector cable can be overcome. 
       SUMMARY 
       [0006]    The present invention provides a method and system of a conformable cable. The method and system may include disposing a conformable material along at least a portion of a cable and configuring the cable into a desired position and shape in which the shape of the cable remains unchanged. 
         [0007]    In embodiments, the entire length of cable may be conformable. In embodiments, only a portion of the cable may be conformable. In embodiments, the portion may comprise a terminal portion. In embodiments, the portion may comprise a central portion. In embodiments, the conformable material may comprise a wire molded into the cable to confer conformability. 
         [0008]    In embodiments, the conformable material may comprise a highly ductile metal molded into the cable to confer conformability. In embodiments, the conformable material may comprise a highly ductile metal over-molded onto the cable to confer conformability. In embodiments, the conformable material may comprise a wire over-molded onto the cable to confer conformability. In embodiments, the conformable material may comprise a conformable sheath surrounding some or all of the conductors within the cable. 
         [0009]    In embodiments, the conformable material may comprise a spiral stiffening member disposed along a portion of the cable. In embodiments, the spiral stiffening member may be disposed adjacent to an insulating wrap, wherein the insulating wrap provides separation between the signal wires of the cable and the stiffening member. In embodiments, the fabrication of the spiral stiffening member may comprise winding or weaving in a pattern along the cable to facilitate supporting the cable to hold its shape. In embodiments, a protective and/or insulating sheath may be disposed on the spiral stiffening member. In embodiments, the sheath may provide one of a decorative or design benefit. 
         [0010]    In embodiments, the wire may be disposed within the signal carry wires of the cable. In embodiments, the insulating wrap may be disposed on the wire to provide separation from the signal carry wires. In embodiments, the metal may be disposed within the signal carry wires of the cable. In embodiments, the insulating wrap may be disposed on the metal to provide separation from the signal carry wires. 
         [0011]    In embodiments, over-molding may comprise a non-conductive material capturing the metal on the outer surface of the cable. 
         [0012]    In embodiments, the cable may comprise one of a power cord and a data cord. In embodiments, the power cord may comprise one of a 110 VAC high current extension cords, an extension cord, an equipment cord, an appliance cord, and a power cord for a rechargeable device. 
         [0013]    In embodiments, the data cord may comprise one of an optical cord, a fiber cord, a serial data cord, a parallel data cord, a Universal Serial Bus (“USB”) connector cord, a Firewire (IEEE 1394) connector cord, an audio connector cord, a digital player input connector cord, an RCA connector cord, a coaxial cable, a network cable, a D-shell monitor cable, a component audio cable, and a component video cable. 
         [0014]    In an aspect of the invention, a system and method of a conformable extension cord may comprise disposing a conformable material along at least a portion of the extension cord, and configuring the extension cord into a desired position and shape in which the shape of the extension cord will remain unchanged. In the system and method, the extension cord may be a 110 VAC high current extension cord. In the system and method, the entire length or only a portion of the cable may be conformable. 
         [0015]    In an aspect of the invention, a system and method of a conformable equipment cord may comprise disposing a conformable material along at least a portion of the equipment cord, and configuring the equipment cord into a desired position and shape in which the shape of the equipment cord will remain unchanged. In the system and method, the entire length or only a portion of the cord may be conformable. 
         [0016]    In an aspect of the invention, a system and method of a conformable appliance cord may comprise disposing a conformable material along at least a portion of the appliance cord, and configuring the appliance cord into a desired position and shape in which the shape of the appliance cord will remain unchanged. In the system and method, the entire length or only a portion of the cord may be conformable. 
         [0017]    In an aspect of the invention, a system and method of a conformable data cable may comprise disposing a conformable material along at least a portion of the data cable, and configuring the data cable into a desired position and shape in which the shape of the data cable will remain unchanged. In the system and method, the data cable may comprise at least one of an optical cord, a fiber cord, a serial data cord, a parallel data cord, a Universal Serial Bus (“USB”) connector cord, a Firewire (IEEE 1394) connector cord, an audio connector cord, a digital player input connector cord, an RCA connector cord, a coaxial cable, a network cable, a D-shell monitor cable, a component audio cable, and a component video cable. 
         [0018]    In an aspect of the invention, a system and method may comprise providing a consumer-salable kit, wherein the consumer-salable kit may comprise a conformable material adapted to be attached to a separately sold cable, and an instruction guide instructing a user how to attach the conformable material to the cable and how to position the cable once the conformable material has been attached. In the system and method, the cable may comprise at least one of a power cord and a data cord. The power cord may comprise at least one of a 110 VAC high current extension cords, an extension cord, an equipment cord, an appliance cord, and a power cord for a rechargeable device. The data cord may comprise at least one of an optical cord, a fiber cord, a serial data cord, a parallel data cord, a Universal Serial Bus (“USB”) connector cord, a Firewire (IEEE 1394) connector cord, an audio connector cord, a digital player input connector cord, an RCA connector cord, a coaxial cable, a network cable, a D-shell monitor cable, a component audio cable, and a component video cable. In the system and method, positioning the cable may involve positioning and shaping the cable to at least one surface of an object. In the system and method, the entire length or only a portion of the cable may be conformable. The portion may comprise a central or a terminal portion. In the system and method, the conformable material may comprise a spiral stiffening member disposed along at least a portion of the cable. The spiral stiffening member may be disposed adjacent to an insulating wrap, wherein the insulating wrap provides separation between the signal wires of the cable and the stiffening member. The spiral stiffening member may include a protective and/or insulating sheath. The sheath may provide at least one of a decorative or design benefit. In the system and method, the conformable material may comprise at least one of a highly ductile metal, a wire, and a conformable sheath surrounding some or all of the conductors within the cable. 
     
    
     
       BRIEF DESCRIPTION OF FIGURES 
         [0019]    The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention may best be understood by reference to the following description, taken in conjunction with the accompanying drawings, wherein: 
           [0020]      FIG. 1  illustrates an exemplary view of an electrical cord in accordance with an embodiment of the present invention; 
           [0021]      FIG. 2  illustrates the use of the electrical cord that stays in position to provide a connector at table height in accordance with an embodiment of the present invention; 
           [0022]      FIG. 3  illustrates the ability of a phone charger cord to maintain its position and shape to provide a connector above table height in accordance with an embodiment of the present invention; 
           [0023]      FIG. 4  illustrates the construction of a power cable mated to a connector in accordance with an embodiment of the present invention; 
           [0024]      FIG. 5  illustrates the use of a cable connector that substantially retain their shape and stay in position in accordance with an embodiment of the present invention; 
           [0025]      FIG. 6  illustrates the construction of an exemplary conformable cable  602  for a D-shell monitor in accordance with an embodiment of the present invention; 
           [0026]      FIG. 7  illustrates the construction of a conformable cable for a D-shell monitor in accordance with another embodiment of the present invention; 
           [0027]      FIG. 8  illustrates the construction of a conformable cable for a USB connection in accordance with an embodiment of the present invention; 
           [0028]      FIG. 9  illustrates the construction of a conformable cable for a USB connection in accordance with another embodiment of the present invention; 
           [0029]      FIG. 10  illustrates the construction of a conformable cable for an RJ network connection in accordance with an embodiment of the present invention; 
           [0030]      FIG. 11  illustrates the construction of a conformable cable for an RJ network connection in accordance with another embodiment of the present invention; 
           [0031]      FIG. 12  illustrates the construction of a conformable cable for an RJ network connection in accordance with another embodiment of the present invention; 
           [0032]      FIG. 13  illustrates a decorative extension cord in accordance with an embodiment of the present invention; 
           [0033]      FIG. 14  illustrates a decorative extension cord in accordance with another embodiment of the present invention; 
           [0034]      FIG. 15  illustrates a decorative extension cord in accordance with another embodiment of the present invention; and 
           [0035]      FIG. 16  illustrates a conformable portion and a flexible portion in accordance with an embodiment of the present invention. 
       
    
    
       [0036]    Those with ordinary skill in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention. 
       DETAILED DESCRIPTION 
       [0037]    While the specification concludes with the claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawings figures, in which like reference numerals are carried forward. 
         [0038]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention. 
         [0039]    The terms “a” or “an”, as used herein, are defined as one or more than one. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having” as used herein, are defined as comprising (i.e. open transition). The term “coupled” or “operatively coupled” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. 
         [0040]      FIG. 1  illustrates a perspective view of an electrical cord  102  in accordance with an embodiment of the present invention. The electrical cord  102  may substantially retain its position and shape. The electrical cord  102  may be connected to a power outlet  104  which may have limited accessibility. For example, at one end, a male plug connector  108  of the electrical cord  102  may plug into a wall mounted power outlet  104 . At the other end, a female plug connector  110  of the electrical cord  102  may be connected with an appliance. The female plug connector  110  of the electrical cord  102  may provide the power supply to the appliance from the power outlet  104 . Examples of the appliance may include, but are not limited to a mobile, a laptop, a television set or some other type of device. 
         [0041]    In embodiments, the electrical cord  102  may include a conformable portion  112  and a flexible portion  114 . For example, a portion of the electrical cord  102  at the end of the female plug connector  110  may be conformable. This conformable portion  112  of the electrical cord  102  may substantially remain in a position in which a user places it. This conformable portion  112  may resist falling or drooping due to gravity or other relatively small forces. However, the conformable portion  112  may change its shape by an external force applied by the user. Once the conformable portion  112  changes its shape, then that shape may not be changed until another external force is applied. The conformable portion  112  of the electrical cord  102  may be provided by using a stiffening material. In embodiments, the electrical cord  102  cord may be stiffened partially with the stiffening material. 
         [0042]    In addition, a portion of the electrical cord  102  at the end of the male plug connector  108  may be flexible. This flexible portion  114  of the electrical cord  102  may change its shape under the gravitational forces or relatively small forces. The length of the flexible portion  114  may depend upon the length of routing required for coiling. In embodiments, the flexible portion  114  may be coiled around a furniture, such as the leg of a table, chair. 
         [0043]    The flexible portion  114  may provide a better ability to coil, fold, stow, or tuck the bulk of the electrical cord  102 . Also, the electrical cord  102  may be less expensive if it does not require stiffening along its entire length. In embodiments, the overall weight of the electrical cord  102  may be less as the conformable portion  112  may not run along the entire length. 
         [0044]      FIG. 2  illustrates the use of the electrical cord  102  that stays in position to provide a connector at various heights and positions in accordance with an embodiment of the present invention. To describe  FIG. 2 , reference will be made to  FIG. 1 , although it is understood that the electrical cord  102  that stays in position to provide a connector at various heights and positions may be practiced in the different embodiments. 
         [0045]    As shown in  FIG. 2 , the electrical cord  102  may be used as a connector to provide power at a work surface  202 . The work surface  202  may not be located at the height of the power outlet  104 . The male plug connector  108  may plug into a power outlet  104  having limited accessibility. The electrical cord  102  may provide power at the work surface  202  through the female plug connector  110 . The flexible portion  114  or the conformable portion  112  may be wrapped around the desk leg, or around some other part to provide temporary positioning to the electrical cord  102 . 
         [0046]      FIG. 3  illustrates the ability of a phone charger cord  302  to maintain its position and shape to provide a connector above table height in accordance with an embodiment of the present invention. To describe  FIG. 3 , reference will be made to  FIG. 1  and  FIG. 2 , although it is understood that the phone charger cord  302  that stays in position to provide a connector at table height may be practiced in the different embodiments. 
         [0047]    As shown in  FIG. 3 , a device charger cord  302  may have a conformable portion  304  and a flexible portion  308 . As explained in the description of  FIG. 1 , the conformable portion  304  may retain its shape under the application of gravitational forces and the flexible portion  308  may be wrapped around any furniture and may change its shape under application of gravitational forces. The flexible portion  308  may be wrapped around a leg of the table  310 . The conformable portion  304  may be provided near a charging pin  312  of the device charger cord  302 . The device charger code  302  may also include a male plug connector  318  which may plug in to a limited accessible power outlet  320 . The device  314  may be charged by taking power from the limited accessible power outlet  320  through the phone charger cord  302 . 
         [0048]      FIG. 4  illustrates an exemplary construction of cable  402  mated to a connector plug  404  in accordance with an embodiment of the present invention. The outer cover of the cable  402  may overlay a stiffened spiral member  408 . The stiffening spiral member  408  may be enclosed within a protective and insulating sheath, which may also provide a decorative or design benefit. The stiffening spiral member  408  may be made up of various stiffening materials. In embodiments, the fabrication of the spiral stiffening member  408  may include winding or weaving in a pattern that may be helpful to supporting the cable  402  to hold its shape. 
         [0049]    A spiral wound or woven insulating wrap  410  may provide separation from the power conductors. The power conductors may comprise hot, neutral and ground wires  412 . In embodiments, the conformable segment may be constructed for the entire length of the cable  402 . In embodiments, the conformable segment may be constructed for the partial length of the cable  402 . 
         [0050]      FIG. 5  illustrates the use of a cable connector  502  that substantially retains its shape and stays in position in accordance with an embodiment of the present invention. To describe  FIG. 5 , reference will be made to  FIG. 1 , although it is understood that the cable connector  502  may be practiced in the different embodiments.  FIG. 5  shows a cable connector  502  that may be used to connect the inputs and outputs of a device  504 , such as a portable laptop computer, to its various peripherals and to the network. A conformable portion  508  of the cable connector  502  may hold its shape when formed around the leg of a table  510  or any other object that is in the local environment. In embodiments, the conformable portion  508  may extend to the entire length of the cable connector  502 . In embodiments, the conformable portion  508  may extend partially to the entire length of the cable connector  502 . 
         [0051]      FIG. 6  illustrates the construction of an exemplary conformable cable  602  for a D-shell monitor in accordance with an embodiment of the present invention. The conformable cable  602  may be mated to a connector  604  of a parallel format communication protocol. The connector  604  may utilize the D-Shell standard geometry, such as RS-232 format, for cabling computers to monitors, printers and other peripherals. The conformable cable  602  may have an RF suppression device  608  integrated to its assembly. In embodiments, a conformable cable outer cover  610  of the cable  602  may overlay a spiral spring casing  612 . The spiral spring casing  612  may include an insulating wrap  614 . The insulating wrap  614  may separate a spiral wound bundle  618  of signal carrying wires  620  from the outer wrap of conformable material. In embodiments, the construction of the conformable segment may be for the entire length of the conformable cable  602 . In embodiments, the conformable segment may be constructed for a partial length of the conformable cable  602 . 
         [0052]      FIG. 7  illustrates the construction of a conformable cable  702  for a D-shell monitor in accordance with another embodiment of the present invention. The conformable cable  702  may be mated to a connector  704  of a parallel format communication protocol. The connector  704  may utilize the D-Shell standard geometry such as RS-232 format for cabling computers to monitors, printers and other peripherals. The conformable cable  702  may include an RF suppression device  708  integrated to its assembly. In embodiments, the outer cover  710  of the cable  702  may overlay a spiral wound insulating wrap  712 . The spiral wound insulating wrap  712  may cover a spiral wound bundle  714  of signal carrying wire. The spiral wrapped bundle  714  of signal carry wires may include an insulating wrap  718  that may cover a highly ductile metal or other material wire. The highly ductile metal or some other material wire may provide conformability to the cable  702 . In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  702 . In embodiments, the conformable segment may be constructed for the partial length of the conformable cable  702 . 
         [0053]      FIG. 8  illustrates the construction of a conformable cable  802  for a USB connection in accordance with an embodiment of the present invention. The conformable cable  802  may be mated with a connector  804 . The connector  804 , such as the Universal Serial Bus (“USB”) connector, may be used for cabling computers to printers and other peripherals. The outer cover of the conformable cable  802  may overlay a spiral spring casing  808 . The spiral spring casing  808  may hold its shape after it is formed into a particular configuration. An insulating wrap  810 , which is inside the spiral spring casing  808 , may separate a coaxial braided ground jacket  812  from the signal carrying wires  814 . The insulating wrap  810  may separate the coaxial braided ground jacket  812  from the inner wrap insulator  818  and the ground wire  820 . In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  802 . In embodiments, the conformable segment may be constructed for the partial length of the conformable cable  802 . 
         [0054]      FIG. 9  illustrates the construction of a conformable cable  902  for a USB connection in accordance with another embodiment of the present invention. The conformable cable  902  may be mated with a connector  904 . The connector  904 , such as the Universal Serial Bus (“USB”) connector, may be used for cabling computers to printers and other peripherals. The outer cover of the conformable cable  902  may overlay a spiral wound insulating wrap  908  covering the coaxial braided ground jacket  910 . The coaxial braided ground jacket  910  may surround the signal carrying wires  912  and the ground wire  914 . An insulating wrap  918 , which is inside of signal carrying wires  912 , may cover a highly ductile metal or other material wire  920 . The highly ductile metal or other material wire  920  may provide conformability to the conformable cable  902 . In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  902 . In embodiments, the conformable segment may be constructed for the partial length of the conformable cable  902 . 
         [0055]      FIG. 10  illustrates the construction of a conformable cable  1002  for an RJ network connection in accordance with an embodiment of the present invention. The conformable cable  1002  may be mated with the common RJ connector  1004 . The common RJ connector  1004  may be used for cabling computers to the elements of a local area network and to the Internet. The outer cover of the conformable cable  1002  may overlay a spiral spring casing  1008 . An insulating wrap  1010 , which is internal to the spring wrap, may provide separation from the signal carrying wires  1012 . In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  1002 . In embodiments, the conformable segment may be constructed for the partial length of the conformable cable  1002 . 
         [0056]      FIG. 11  illustrates a conformable cable  1102  for an RJ network connection in accordance with another embodiment of the present invention. The conformable cable  1102  may be mated with the common RJ connector  1104 . The outer cover of the conformable cable  1102  may overlay a spiral wound insulating wrap  1108 . The spiral wound insulating wrap  1108  may provide separation from the signal carrying wires  1110 . The insulating wrap  1112 , which is internal to the signal carrying wires  1110 , may cover a highly ductile metal or other material wire  1114  which may provide conformability to the assembly. In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  1102 . In embodiments, the conformable segment may be constructed for the partial length of the conformable cable  1102 . 
         [0057]      FIG. 12  illustrates a conformable cable  1202  for an RJ network connection in accordance with another embodiment of the present invention. The conformable cable  1202  may be mated with the common RJ connector  1204 . The outer cover of the conformable cable  1202  may be over-molded with a compatible plastic material  1210  or other suitable over-molding material capturing a highly ductile metal or other material wire  1208  on the outer surface. The internal construction of the conformable cable  1202  may have an insulating wrap  1212 . In embodiments, the internal construction of the conformable cable  1202  may vary with the communication standard employed. The insulating wrap  1212  may provide separation from the signal carrying wires  1214 . In embodiments, the conformable segment may be constructed for the entire length of the conformable cable  1202 . In embodiments, the conformable segment may be constructed for a partial length of the conformable cable  1202 . 
         [0058]      FIG. 13  illustrates a decorative extension cord  1302  in accordance with an embodiment of the present invention. The decorative extension cord  1302  may stay in position to provide a connector at various heights and/or positions and may be designed to be attractive, display a certain set of features and/or patterns, blend into or enhance an environment, and the like. For example, the decorative extension cord  1302  may look like a vine  1304  with flowers or other types of living plants. The visual aspects of the decorative extension cord  1302  may be manufactured by over-molding plastic or other materials onto a standard power cord. The visual aspects of the decorative extension cord  1302  may be made by incorporating the conductors into the plastic and/or other materials that are utilized by the faux plant and flower manufacturers to create a look that imitates a living plant. In the example, the decorative extension cord  1302  may utilize a standard female outlet  1308  configuration disguised within a flower  1310 . In embodiments, as shown in  FIG. 14 , the decorative extension cord  1302  may utilize a standard female outlet  1308  configuration disguised in a snake&#39;s mouth. In embodiments, as shown in  FIG. 15 , the decorative extension cord  1302  may utilize a standard female outlet  1308  configuration disguised in a fictional pattern  1502 . 
         [0059]    The decorative extension cord  1302  may include a standard male power connection  1310 . The standard male power connection  1310  may be plugged into a power outlet  1312 . A length or a portion of the decorative extension cord  1302  may be conformable. The remaining length of the decorative extension cord  1302  may be flexible depending upon the overall length of the decorative extension cord  1302 . 
         [0060]      FIG. 16  illustrates an exemplary conformable portion  1602  and an exemplary flexible portion in accordance with an embodiment of the present invention. The conformable portion  1602 , as explained in the description of  FIG. 1 , may resist falling or drooping due to gravity or other relatively small forces. However, the conformable portion  1602  may change its shape by an external force applied by the user. As shown, the conformable portion  1602  may have a bundle of signal carrying wires  1608 . The flexible portion  1604  may change its shape under the gravitational forces or relatively small forces. 
         [0061]    While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law. 
         [0062]    All documents referenced herein are hereby incorporated by reference.