Patent Publication Number: US-2006000517-A1

Title: Wire and separation prep-tool

Description:
REFERENCES CITED: [REFERENCED BY] 
     
       
         
           
               
               
               
               
             
               
                   
               
               
                   
               
             
            
               
                 3906561 
                 September, 1975 
                 Bawa 
                  7/5 
               
               
                 4025998 
                 May 1977 
                 Eppler 
                  29/566 
               
               
                 4444228 
                 April, 1984 
                 Demirjian 
                 140/23 
               
               
                 4620573 
                 November, 1986 
                 Meder. 
                 140/123 
               
               
                 4713874 
                 December 1987 
                 Shwartz 
                  29/566 
               
               
                 4797988 
                 January, 1987 
                 Bowden Jr. 
                  29/566.4 
               
               
                 5771945 
                 June, 1998 
                 Jenner, et al. 
                 140/123 
               
               
                 6584670 
                 July, 2003 
                 Costa 
                  29/564.7 
               
               
                 6601615 
                 August, 2003 
                 Hammond 
                 140/23 
               
               
                 6604268 
                 August, 2003 
                 Fujita, et al. 
                  29/33F 
               
               
                   
               
            
           
         
       
     
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
      “Not Applicable” 
     STATEMENT TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX  
      “Not Applicable” 
     DESCRIPTION  
      1. Technical Field  
      The present invention relates to a twisted wire preparation tool and more particularly to a hand held, inexpensive, compact, prolate, lightweight, multiple-tasks performer, labor-saving, and simple-to-use tool which enables the tool-operator&#39;s maneuverability, and ability to properly separate, straighten and align single and plural wires for two different types of RJ-45 connectors, female plugs and male jacks, without inflicting harm to the jacket sheath, wire or wire insulation.  
      2. Background of the Invention  
      In the telecommunications, electronics and computer industries, shielded (STP) and unshielded twisted pair (UTP) wires have been the faster performance replacement wire for coaxial cable, not only used for networking but also for the traditional telephone. There are 10 different types of STP/UTP categories and, depending on what you want to achieve, you would need the appropriate type of cable. Yet all sheathed/unsheathed jacket cables and their twisted pair wires in these categories can be separated, straightened and aligned with this new tool invention. Here are UTP Categories 1-6 that serve most applications worldwide at this time.  
     The Different UTP/STP Twisted Pair Wire Categories  
     
         
          Cat. 1 Data rate up to 1 Mbps Traditional telephone ISDN (one wire)  
          Cat. 2 Data rate up to 4 Mbps Token Ring  
          Cat. 3 Data rate up to 10 Mbps Token Ring and 10 BASE-T  
          Cat. 4 Data rate up to 16 Mbps Token Ring  
          Cat. 5 Data rate up to 100 Mbps Ethernet  
          Cat. 6 Data rate up to 16 MMbps Fast Ethernet and Token Ring  
          Cat. 5e Data rate up to 1000 Mbps Gigabit Ethernet  
          Cat. 6 Data rate up to 1000 Mbps Gigabit Ethernet  
          Cat. 7-10 Data rate up to 10,000 Mbps Shielded Twisted Pairs in Research and Military  
       
    
      The number identified in each category (example: Cat. 2), where the number two refers to the number of twists per inch inside the wire sheath (and the quality of a connection in a jack). The “twist” effect of each pair in the cables will cause any interference presented/picked up on one cable to be cancelled out by the cable&#39;s partner which twist around the initial cable. Please note that Cat. 1 is only a single wire, yet may be serviced by this tool also.  
      In general, the number of twisted wires, wire length, wire type, and physical separators also dictate the performance of twisted wire pairs. Cat. 2, Cat. 3, Cat. 4 Cat. 5 and Cat. 6 are network wire specifications. Cat. 5 and Cat. 6 have become today&#39;s standards and most widely used with four twisted wire pairs per sheathed cable due to the growth and continued demand for faster data transmission speeds for private, public and governmental entities.  
      Lastly, STP/UTP wire cables are terminated with standard connectors, jacks, plugs and punchdowns. The standard jack/plug is often referred to as a RJ-45, but that is really a telco designation for the “modular 8-10 pin connector” terminated with a UPOC pinout used for telephones. The male plug on the end of a patchcord is called a “plug” and the female receptacle on the wall outlet is a “jack”. These may connect into the hub or computer&#39;s network card.  
      This Wire And Separation Prep-Tool invention prepares twisted wire pairs in two general ways with convenient 5 subparts, so to be inserted into either a plug or jack. In addition, this hand tool invention reduces the harm and damage inflicted when compared to wires that are frequently separated with a knife, screwdriver or other nonconforming items. Nicks, cuts and other damage causes significant amount of undesirable Radio Frequency (RF) transmissions. Plus, this combination tool reduces the time and effort to straighten and untwist the twisted pair wires when compared to “hand &amp; fingers” which is still the predominant standard in the industries, and since it has 5 specific subpart tool instruments per this one tool invention, it reduces the amount of tools required by the operator and the amounts thereby expensed.  
      Therefore, it will be appreciated that there is a big need for a multi-task tool which enhances the practicability of terminating Categories 1-10, RJ-45 connectors, by properly separating, straightening, and aligning any twisted wire pair so to match the plug or jack requirements quickly and economically.  
     SUMMARY OF THE INVENTION  
      It is therefore an object of the present invention to provide an improved twisted wire preparation tool that has 5 multiple task subpart tool functions to perform six distinct tasks.  
      It is a further object of the present invention to provide a twisted wire preparation tool which appreciably enhances termination of RJ-45 connectors in STP/UTP Categories 1-10 in the field for new wire and receptacle installation, repair, maintenance and/or new wire installation on a new product at it&#39;s manufacturing plant.  
      It is a still further object of the present invention to provide a compact, lightweight, inexpensive, and multi-task time reducing twisted wire preparation tool that penetrates and separates twisted wire pairs safely, quickly straightens single wire, aligns single and plural wires correctly for proper insertion into RJ-45 jacks, and narrows and flattens single and plural wires for proper insertion into RJ-45 plugs.  
      It is a still further object of the present invention to provide a unique twisted wire multi-preparation tool which has multiple task functions that minimizes the time for labor &amp; organization while minimizing overall tool expense.  
      In general, this is a solid prolate cylindrical shaped rod shaft that has two ends; the first end being a conically narrowed round dull pointer for safely penetrating twisted wire pairs; adjacent is the overall expanding conical shape shaft which assists with it&#39;s inherent expanding diameter wall slope to increase the distance of separation space between the two twisted wires, as they are continually penetrated with the tool, until the two wires are caught by and semi-held into opposing groove channels at the top by the first diametrical cut circular groove. Thus by the operator pushing the tool&#39;s pointed tip about an inch forward in between the wires until they rest in the first diametrical cut circular groove, this allows the wires preformed compression to assist in adhering to the tool&#39;s first concentric groove&#39;s walls just long enough to allow the operator, by hand, to pull up horizontal and leverage the longitudal rod shaft base tool to forcefully continue separating several inches (1-7 inches) in length of the twisted pair wire&#39;s ends entirely apart into two single wires without harm.  
      Then the operator replaces one of the same wires back into the groove and applies thumb holding pressure to the wire and uses the same single diametrical cut circular groove to continuously rub the wire into . . . stroke the single wire up and down and allow this repetitive motion in this groove helps re-mold and straighten the wire with this procedure. Once each wire has been straightened in such a manner, then the wires are ready for the next of one of two steps depending on which RJ-45 connector is the require target.  
      For the RJ-45 “jack”, place the wires in proper order according to the schematics and insert the straightened five single wires, each one into one of the five evenly-spaced diametrically cut circular grooves, traverse and horizontal to the tool&#39;s longer longitudal shaft, thereby pre-aligning all 5 wires (10 wires total: two sets of five) into the specifically spaced grooves matching the same wire pattern as this proposed connector. Once the wires are ready, insert in the jack and lock down with a standard crimp tool.  
      For the RJ-45 “plug”, it&#39;s different. First, position the straightened wires into the order prescribed by the schematics. Then, find the rectangular notch centered into the longitudal and horizontal axis at the flat end of the second end to push the connecting wires&#39; ends sideways into this notch. This notch will narrow and pre-align these wires into a specific sized pattern exactly like that of the target RJ-45 plug. If needed, trim the wires for either the RJ-45 plug or jack wire placement prior to actual wire insertion in either the notch or five grooves, respectfully, for immediate final crimping of the wires into the plug or jack.  
      Located 360 degrees around the entire outside diameter of only the middle section of the prolate cylindrical rod shaft is an insulating tubular hand grip. It lies, by, and between the single wider sheath groove on one side and the inner and closest of the 5 plural wire diametrically circular grooves on the other side. It enhances grip while minimizing low-voltage shock of any live electrical wires.  
      This lightweight hand tool may fit in a top shirt pocket, pants pocket, briefcase or tool pouch just like a similar sized fountain pen. This gives it a compact status and is further significant because this one tool invention has 5 tool subparts that technically perform the job of 6 tools as described here within.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  identifies the REFERENCES of all major subpart components and illustrates the Side View of the entire WIRE AND SEPARATION PREP-TOOL, including all particular subpart components in accordance with the present invention.  
       FIG. 2  is a Top View of the entire WIRE AND SEPARATION PREP-TOOL in accordance with the present invention.  
       FIG. 3  is a First End View of the round tip, diametrical shaft, and concentric hand grip.  
       FIG. 4  is a Second End View of the centered notch, diametrical shaft and concentric hand grip.  
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      With reference to  FIG. 1 , a prolate cylindrical rod shaft tool having two opposing ends longitudal, one conically narrowed to a small dull pointed round mammilated end (see REF.  1 ), the other end perpendicularly blunt yet notched (see REF.  7 ). Located in between the two opposing ends is a strategic series of diametrically cut circular grooves of various depths and widths along the longitudal base shaft for specific tasks and applications (see REF.  3 ,  4 ,  6 ), along with an adhering concentric insulating tubular hand grip located in the middle section (see REF.  5 ).  
      This tool is a hand tool. The tool&#39;s length is 5.1″ (″=inches) and has a maximum diameter of 0.25″ except less where strategically grooved diametrically. Also with reference to  FIG. 1 , REF.  1 ,  2 ,  3 ,  4 ,  6 , the prolate cylindrical rod shaft longitudal tool has five (5) subparts described below able to collectively perform six (6) distinct and different tasks.  
                                       SUBPART   FIG./REF.   TASK                  Subpart 1:     FIG. 1 , REF. 1:   First End for Wire Separation and               Conical Shaft Spreader       Subpart 2:     FIG. 1 , REF. 3:   Single Wire Grooves for Holding and               Separating TWP                     (second Subpart 2 task):   Single Wire Groove for Holding and           Straightening 1 wire                         Subpart 3:     FIG. 1 , REF. 4:   Widest Groove for Smoothing Cable               Jacket Sheath       Subpart 4:     FIG. 1 , REF. 6:   5 Wire Grooves for pre-aligning               wires into RJ-45 jack       Subpart 5:     FIG. 1 , REF. 7:   Second End Notch for pre-aligning               5 wires into RJ-45 plug                  
 
      This hand tool is similar to the size, weight of 250 grams, and, even, the prolate shape of a solid fountain pen. It&#39;s convenient and compact size allows it to be carried in a shirt or pant&#39;s pocket, tool pouch or briefcase. A number of materials are suitable for the cylindrical rod shaft tool, as well as for the insulating tubular hand grip. The first subpart of this tool invention is a dull pointed mammilated end of 0.05″ diameter and 0.1″ long for penetrating twisted wires as seen in  FIGS. 1-3 , REF.  1 . This point must be a rounded yet have a dull point so not to break, cut, scrape, inflict nor harm an individual wire&#39;s outer insulated coating. The connecting shaft from the first end&#39;s point must be a narrowed shape of 0.04″ diameter and 0.07″ length to enter between, catch and hold the two twisted flexible wires. Once the space between the twisted wires is penetrated, the next 0.355″ of overall conical base shaft shape progressively assists in separating the wires with it&#39;s inherent expanding diameter from 0.04″ to 0.23″, and 50 degree increasing slope as it leads away from the first end. As the wire is manually pushed up the conical shape for about an inch, the increasing diameter increases the distance of separation between said twisted two wires, until the two wires are automatically caught by, and semi-held into an adjacent position by the first diametrical cut circular groove (described more below as “second subpart”), where then the operator may pull on the tool outward and thereby separate up to seven inches of the two wires ends entirely. Now the wires are ready for straightening and trimming, as required.  
      The second subpart of this tool invention is the first end&#39;s first singular diametrical cut circular groove around the rod shaft located proximal down shaft of the greatest diameter of the conical shape as seen in  FIGS. 1-2 , REF.  3 , and 0.605″ from the first end. The single groove&#39;s walls are diametrically concentric, convex to the horizontal axis, and planar back face which provides an excellent guide surface with which to hold and realign wire. The groove&#39;s floor is convex and assists in holding the wire. Upon penetrating, dividing, and widening the two wires of the twisted wire pair with the tool as described, the operator can now begin to apply hand force to be able to pull or push the tool horizontally up the wire&#39;s longitudal axis in the same direction as the wires twist pattern and separate this pair into two single wires. Again, at this time, a common commercial wire cutting apparatus may be needed in the procedure to trim the length and/or the insulated plastic coating, and/or the outer loose jacket sheath, if needed.  
      The third subpart referenced herein includes a wider singular diametrically cut circular groove of 0.19″ diameter and 0.2″ length with obtuse walls of 140 degrees angled outward, as seen in  FIGS. 1-2 , REF.  4 . The groove&#39;s floor channel is concave. These wall and floor channel angles allow for safely rubbing this groove part of the tool back and forth on the plastic protecting jacket sheath on the ending 2 or 3 inches that surrounds a group of twisted wire pairs. The result here is to smooth kinks and ridges protruding from the loose jacket sheath and to assist in aligning and preparing twisted wire pairs for the following procedures, outlined herein, and finally, for plural wire termination into a RJ-45 plug or jack. This diametrical groove is located in between and proximal 0.35″ from the aforementioned single narrower groove and 0.24″ from the tubular grip adhered to the base tool shaft described here below.  
      The fourth subpart of this tool invention is the series of five evenly and strategically spaced, diametrically cut circular grooves in and around into the cylindrical shaft rod that assist to hold and pre-align up to five wires to then be fitted directly into a R-45 jack.  FIGS. 1-2 , REF.  6  illustrates these five diametrical grooves that have an individual length of 0.032″, a combined total length of 0.61″ from the first to the fifth, individual diameters of 0.16″, and are evenly spaced at 0.112″ apart. The grooves&#39; walls are convex and 90 degrees perpendicular to the longitudal axis to assist in holding the wires in place for alignment. The grooves floor is flat and deep enough to assist in holding the wires in place for alignment. Once the wires straightened and pre-aligned, they are removed from the tool and placed into the RJ-45 jack receptacle and an acceptable industry punch-down tool is used to push lock the pre-aligned wires into a permanent connection.  
      The fifth subpart of this tool invention is the centered rectangular notch, 0.04″ height by 0.25″ width by 0.48″ length, located at and thru the second end of the longitudal shaft rod as shown in  FIGS. 1 and 4 , REF.  7 . The purpose of this centered longitudal rectangular notch is to allow easy placing, arrangement, narrowing, and pre-aligning of the separated and straightened plural wires, of Category 1-10 twisted wire pairs, for insertion into a RJ-45 plug receptacle. Upon proper plural wire arrangement and alignment and the actual wire insertion into a RJ-45 plug, an acceptable industry crimper is used to lock down the wires in their precise connector position.  
      As stated above, this hand tool also features an insulating concentric tubular hand grip made from plastic, rubber or other material that surrounds and tightly adheres to the outer cylindrical tool shaft in the middle area so to not slip as seen in  FIGS. 1-4 , REF.  5 . The grip&#39;s dimensions are 2.3″ length and 0.005″ thick, 0.265″ outside diameter, and located 1.64″ from the end of the first end and 1.63″ from the second end. The hand grip gives the operator&#39;s hand a more secure surface to grasp and provides an insulated protecting material in case the wire is live and low voltage shock is a potential threat. The color of said grip may be produced black or any other color.  
      This hand tool contains five referenced subpart tool functions that perform a total of six tasks. This hand tool is a weight-saving alternative to carrying and operating six tools; a cost saving alternative—inexpensive option to purchasing six different tools; and, a time saving alternative that will reduce the organization and actual labor time of handling six different tools for the same job.  
      Alternatively, this hand tool&#39;s length may be manufactured several inches shorter or longer. This hand tool&#39;s diameter may be manufactured larger or smaller. This hand tool&#39;s singular and plural grooves may be manufactured deeper or shallower or increased in quantity should Industry Standards dictate so for more wires in a receptacle. This hand tool&#39;s concentric tubular hand grip may be manufactured in various lengths, colors, and from various materials, including, but not limited to, plastic, rubber or synthetic materials. This hand tool&#39;s cylindrical base shaft may be manufactured from many types of materials, including, but not limited to, plastic, carbon fiber, metal, alloys, wood, rubber, or any mix hereof, and in various colors or finishes. Thus, this hand tool&#39;s weight may change due to the compositions and/or mixes made thereof.