Abstract:
A tool for installing and removing flexible flat cable with respect to a protective sleeve has a groove for receiving the cable. The cable slides into and is formed into an arc by the groove and is supported evenly on both sides of the cable. With the full width of the cable in the groove, the tool slides down the length of the cable into the sleeve for the cable to be removed. As the tool slides into the sleeve, there is a smooth transition of the cable from flat to curved, and the cable and sleeve separate. The tool is slid through the sleeve as far as necessary for the needed action. After alternations to the sleeve or cable are complete, the tool is used to replace the cable back into the sleeve by reversing these steps.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates in general to an improved tool for handling flat cable and, in particular, to an improved system, method, and apparatus for installing and removing flexible flat cable into and out of, respectively, a protective sleeve or track for dynamic applications. 
   2. Description of the Related Art 
   Flexible flat cables have a plurality of electrical conductors that are molded inside a flexible, electrically insulative material or conduit. The conductors, which may be round or flat in cross-section, typically have very small dimensions and are spaced apart in a parallel configuration on narrow center-to-center spacings. These small dimensions place significant importance on handling or working with flat cables because the fragile conductors they contain are easily damaged. Because of the high cost of such flat cables, there must be assurance that the flat cable is not folded or crimped when it is handled during maintenance operations. 
   In some dynamic applications, such as high-speed robotic library pickers, flat cables are required to flex for millions of cycles without an electrical continuity failure or interruption. Under such conditions, the flat cables may be placed inside an elongated flexible sleeve or track in order to protect and extend the life of the flat cable. The sleeve typically has a rectangular cross-sectional profile that is similar to the shape of the flat cable. The sleeve controls the direction in which the flat cable can flex and the radius of curvature of the bend in the flat cable. Thus, the sleeve acts as an exoskeleton that further protects the flat cable. 
   Some sleeves do not fully envelop the flat cable, but are open on one side to permit the flat cable to be mounted in and removed from the sleeve. However, the small, fragile conductors in the flat cable can be damaged easily when the flat cable is placed in or taken out of the sleeve if the handling procedures are not performed carefully. Unfortunately, there are relatively frequent occasions in which handling of the flat cable is required after the flat cable is already installed in the sleeve. For example, the length of the flat cable and the sleeve may need to be altered, or a portion of the flat cable may need to be removed from the sleeve in order to change mounting hardware on the sleeve and/or flat cable. In addition, if only a small change is needed, or a change in only one end of the mounting hardware, it is laborious to completely remove all of the hardware from the flat cable and slide the entire flat cable out of the sleeve. For particularly long flat cables, this requires a significant amount of time and floor space to stretch out the entire flat cable. Thus, an improved system, method, and apparatus for installing and removing flexible flat cable into and/or out of a protective sleeve for dynamic applications is needed. 
   SUMMARY OF THE INVENTION 
   One embodiment of a system, method, and apparatus for installing and removing flexible flat cable into and out of a protective sleeve utilizes a tool having a single part that is snapped over the flat cable to allow the flat cable to smoothly slide into and out of the sleeve. The tool can partially remove the flat cable from the sleeve while protecting the flat cable from being damaged. After removal, the tool can also be used to easily and protectively return the flat cable into the sleeve. In addition, the tool does not require the entire flat cable to be removed from the sleeve. Moreover, existing hardware at an unaltered end of the flat cable assembly can be left in place. In addition, the tool can be used while a majority of the flat cable is rolled up. Furthermore, the tool can initially be applied to and engage any portion of the flat cable located outside of the sleeve. Thus, the tool does not need to start at the terminal ends of the flat cable in order to be utilized. 
   The tool is designed to work in conjunction with the protective sleeve, which fully contains the flat cable but has an opening that aids in the sleeve being able to flex. The flat cable generally fills the entire width of the sleeve when installed. Using the tool, the flat cable can be removed through the opening in the sleeve. The tool works by sliding part of the flat cable that is not in the sleeve into a groove that is formed in the tool. The groove forms the flat cable into an arcuate shape, giving it a smooth radius by supporting it evenly on both sides of the flat cable. The flat cable does not get creased or folded. With the full width of the flat cable located in the groove of the tool, the tool can slide down the longitudinal length of the flat cable and into the sleeve in order to remove the flat cable. As the tool slides into the sleeve, there is a smooth transition of the flat cable from a flat shape to a curved shape. As the tool moves into the sleeve, the flat cable and sleeve separate because of the interaction between the flat cable and the tool. The tool slides through the sleeve as far as necessary for the needed action. After the alterations to the sleeve and/or flat cable are complete, the tool can be used to replace the flat cable back into the sleeve by sliding the tool back through the sleeve in a smooth, safe motion. Finally, the tool is removed from the flat cable by sliding the flat cable back out of the groove in the tool. 
   Another aspect of the tool of the present invention is that an outside wall of the tool (i.e., the portion located radially outside of the groove) is flexible to aid in allowing the flat cable to easily enter and exit the groove. In addition, the edges of the tool along the groove are very smooth so as to not catch or shave the flat cable. In contrast, prior art solutions required removal of the entire flat cable from the sleeve, or removal of the hardware from both ends of the flat cable assembly, and for the entire flat cable to be removed from the sleeve. 
   The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the preferred embodiment of the present invention, taken in conjunction with the appended claims and the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     So that the manner in which the features and advantages of the invention, as well as others which will become apparent are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only an embodiment of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments. 
       FIG. 1  is an isometric view of a flat cable insertion and removal tool constructed in accordance with the present invention. 
       FIG. 2  is a sectional front view of the tool of  FIG. 1 . 
       FIG. 3  is a sectional front view of a flat cable located in a protective sleeve/track. 
       FIG. 4  is an isometric view of the tool of  FIG. 1  prior to removing the flat cable from the sleeve of  FIG. 3 . 
       FIG. 5  is an isometric view of the tool of  FIG. 1  at an initial stage of removing the flat cable from the sleeve, after the stage of  FIG. 4 . 
       FIG. 6  is an isometric view of the tool of  FIG. 1  at a subsequent stage of removing the flat cable from the sleeve, after the stage of  FIG. 5 . 
       FIG. 7  is an isometric view of the tool of  FIG. 1  at a subsequent stage of removing the flat cable from the sleeve, after the stage of  FIG. 6 . 
       FIG. 8  is an isometric view of the tool of  FIG. 1  at a subsequent stage of removing the flat cable from the sleeve, after the stage of  FIG. 7 . 
       FIG. 9  is a sectional front view of the flexible flat cable located in the tool of  FIG. 1  during removal and/or installation with respect to the protective sleeve. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIGS. 1 and 2 , one embodiment of an apparatus or tool  11  for installing and removing a flexible flat cable  13  ( FIG. 3 ) with respect to a protective sleeve  15  is shown. The flexible flat cable  13  has a plurality of electrical conductors  14  that are molded or laminated inside a flexible, electrically insulative material or conduit  16 . The conductors  14 , which may be round or flat in cross-section, typically have very small dimensions and are spaced apart in a parallel configuration on narrow center-to-center spacings. Although only one cable  13  is shown inside the sleeve  15 , the sleeve  15  is capable of supporting more than one cable  13  when the cables  13  are stacked flat against each other. 
   The tool  11  comprises a body  21  having a flat lower surface  22  and a curved upper surface  24 . The body  21  also has a longitudinal axis  23  ( FIG. 2 ) and a slot  25  formed in the body  21 . The slot  25  extends longitudinally through the body  21  about the axis  23 . The slot  25  has a generally arcuate shape with a closed end  27  on one side of the body  21 , and an open end  29  on an opposite side of the body  21 . The open end  29  forms a receptacle that is allows lateral ingress and egress of the flexible flat cable  13  ( FIG. 5 ). 
   The tool  11  also has a shelf  31  that is formed in the body  21  adjacent to the open end  29  of the slot  25 . The shelf  31  captures a side edge  17  of the flexible flat cable  13  ( FIG. 9 ) in order to retain the flexible flat cable  13  in the body  21  when the flexible flat cable  13  is located in the slot  25 . The arcuate shape of the slot  25  is, in the embodiment shown, semi-circular, and spans an arc  28  of approximately 180 degrees ( FIG. 2 ). The slot  25  supports an entire lateral width  32  of the flexible flat cable  21  ( FIGS. 9 ,  2 , and  3 ), such that the slot  25  has a circumferential length extending from the closed end  27  to the shelf  31  that is approximately equal to the lateral width of the flexible flat cable  13 . The slot  25  also defines an inner wall  33  having an inner radius  35 , and an outer wall  37  having an outer radius  39 . The outer radius  39  is greater than the inner radius  35 , and the shelf  31  is formed at a shelf radius  41  that is greater than a radius  43  of the open end  29 . 
   The slot  25  also segments the body  21  into a lower portion  45  ( FIG. 2 ) and an upper portion  47 . In the embodiment shown, the upper portion  47  is cantilevered and flexible relative to the lower portion  45 . The lower and upper portions  45 ,  47  of the body  21  have edges  49  ( FIG. 1 ) that are very smooth and beveled or polished in order to avoid scuffing the surfaces of the flexible flat cable  13 . All edges  49  on body  21  (on both longitudinal ends) are smooth. The shelf ( 31 ) is positioned on the upper portion ( 47 ) such that it lies in a longitudinal plane with the bottom surface of the lower portion ( 45 ). 
   In operation ( FIGS. 4–9 ), the present invention also comprises a system and method of using the tool  11  to install and/or remove the flexible flat cable  13  with respect to the protective sleeve  15 . As best shown in  FIG. 3 , the protective sleeve  15  has a base  51 , side walls  53 , and a longitudinal opening  55  defined between the side walls  53 . The flexible flat cable  13  is positioned in the protective sleeve  15  and extends laterally between the side walls  53 . The flexible flat cable  13  has an exposed portion  61  ( FIG. 4 ) that is not located in the protective sleeve  15 . Although the exposed portion  61  is shown at the longitudinal end  65  of the flexible flat cable  15 , the exposed portion  61  may be located anywhere along the longitudinal length of the flexible flat cable  13  and/or protective sleeve  15 . 
   The method of removing the flexible flat cable  13  from the protective sleeve  15  comprises inserting the side edge  17  ( FIG. 5 ) of the exposed portion  61  of the flexible flat cable  13  into the open end  29  of the tool  11 . The flexible flat cable  13  is guided through the slot  25  in the tool  11 , such that a longitudinal segment  63  ( FIG. 6 ) of the flexible flat cable  13  is formed into an arcuate shape with a smooth radius that protects the integrity of the flexible flat cable  13 . The tool  11  is moved longitudinally with respect to and along a length of the flexible flat cable  13  such that the longitudinal segment  63  of the flexible flat cable  13  in the arcuate shape transitions and moves smoothly with the tool  11  as the flexible flat cable  13  passes through the tool  11 , while other portions  67 ,  69  ( FIG. 7 ) of the flexible flat cable  13  on either longitudinal side of the longitudinal segment  53  transition to a flat shape. As the tool  11  moves into contact with the protective sleeve  15  ( FIGS. 7–9 ), the flexible flat cable  13  is extracted from the longitudinal opening  55  of the protective sleeve  15 . 
   The method also comprises installing the flexible flat cable  13  in the protective sleeve  15  by simply reversing these steps. By doing so, the flexible flat cable  13  flattens out from the arcuate shape and into the longitudinal opening  55  in the protective sleeve  15  between the side walls  53  as the tool  11  is moved away from the protective sleeve  15  (see, in order,  FIG. 8 , then  FIG. 7 , then  FIG. 6 ). 
   During operation, the longitudinal segment  63  ( FIG. 7 ) of the flexible flat cable  13  defines a chord  71  ( FIG. 9 ) having a dimension that is less than a lateral dimension  73  of the longitudinal opening  55  in the protective sleeve  15 . As a result, the flexible flat cable  13  can be removed from the protective sleeve  15  with the tool  11 . The tool  11  can be used while a majority of the flexible flat cable  13  and/or protective sleeve  15  is rolled up ( FIG. 8 ). Moreover, only that portion of the flexible flat cable  13  in need of attention (e.g., exposed portion  61 ;  FIG. 5 ) need be removed from the protective sleeve  15 . In other words, the tool  11  can be applied to and engage the longitudinal portion or segment  63  of the flexible flat cable  13  located in the protective sleeve  15  such that the entire flexible flat cable  13  need not be removed from the protective sleeve  15 . As a result, the flexible flat cable  13  is not creased or folded by the tool  11 . 
   The present invention has several advantages, including the ability to install and remove flexible flat cable into and out of a protective sleeve. The invention utilizes a tool having a single part that is snapped over the flat cable to allow the flat cable to smoothly slide into and out of the sleeve. The tool can partially remove the flat cable from the sleeve while protecting the flat cable from being damaged. After removal, the tool can also be used to easily and protectively return the flat cable into the sleeve. In addition, the tool does not require the entire flat cable to be removed from the sleeve. Moreover, existing hardware at an unaltered end of the flat cable assembly can be left in place. In addition, the tool can be used while a majority of the flat cable is rolled up. Furthermore, the tool can initially be applied to and engage any portion of the flat cable located outside of the sleeve. Thus, the tool does not need to start at the terminal ends of the flat cable in order to be utilized. 
   The tool is designed to work in conjunction with the protective sleeve, which fully contains the flat cable but has an opening that aids in the sleeve being able to flex. The flat cable generally fills the entire width of the sleeve when installed. Using the tool, the flat cable can be removed through the opening in the sleeve. A groove in the tool forms the flat cable into an arcuate shape, giving it a smooth radius by supporting it evenly on both sides of the flat cable so that the flat cable does not get creased or folded. The tool also can be used to replace the flat cable back into the sleeve by sliding the tool back through the sleeve in a smooth, safe motion. The edges of the tool along the groove are very smooth so as to not catch or shave the flat cable. 
   While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.