Patent ID: 12224083

DETAILED DESCRIPTION

Embodiments may be configured to optimize wiring operations. Embodiments may include one or more devices, systems, and methods, any of which may be interchangeably referred to as a “tool” or “untwist tool” for purposes of this disclosure.

The tool may provide a variety of advantages and improvements over existing tools. This may include easier and faster wiring operations such as wire termination. The tool may improve protection for and minimize injury to the user (e.g., hands and fingers). The tool may be configured to improve the speed and efficiency of wiring operations. The tool provides advantages and improvements over typical data, network, audio/video, cable, and telecommunications technologies and associated tools and equipment.

The tool may include a wire tool configured as a wire bit. The tool may be configured to streamline wiring operations on any type of wire and/or connector. The tool may be configured for wiring operations on any type of wire or connector, e.g., for network cables and twisted-pair wire. Exemplary wires and/or connectors may be category 3 through 8 (Cat3 to Cat8), shielded twisted-pair (STP), and/or unshielded twisted-pair UTP. Embodiments may also be configured for RJ 45 (e.g., EZ-RJ 45) connectors.

Embodiments may be configured for any wiring operations such as twisting, untwisting, cutting, decoupling, crimping, or connecting operations or a combination thereof. The tool may include a tool body and a shaft. The tool body may include a socket along the rotational axis of the tool body, e.g., configured to receive the shaft. The shaft and socket may include corresponding male and female connections, e.g., a hex and/or microwire tool. An exemplary connection may include 5/32″ (4 mm) hex-sized.

An exemplary tool may include a tool body and a shaft. The tool body may include an outer shell, a distribution hub, one or more radial walls, a rotational axis, a radial axis, and leading and trailing ends. The radial walls may extend all or any part of the tool body, form respective channels therebetween, receive a wire between the outer shell and distribution hub, and/or split the wire into wire strands along respective channels that expand radially outward to capture and separate each wire strand. The outer shell may include an outer edge (e.g., a rounded tip). The distribution hub may include an inner edge (e.g., pointed, angled, and/or star-structured tip). The tool may be configured to receive and direct the wire at the leading end, separate the wire into respective strands along the distribution hub, and discharge the separated wire strands at the trailing end.

An exemplary system may be configured for powered or mechanically assisted wire operations. The system may include a wire tool and a drive device operatively connected to the drive device. The wire tool may include a tool body having a rotational axis. The tool body may include an outer shell, a distribution hub, one or more radial walls extending between the distribution hub and the outer shell, and respective channels formed by the outer shell, the distribution hub, and one or more radial walls.

Methods are contemplated. A method may include providing a tool body having a rotational axis. The method may include providing the tool body having an outer shell, a distribution hub, one or more radial walls extending between the distribution hub and the outer shell, and respective channels formed by the outer shell, the distribution hub, and one or more radial walls. The method may include providing a shaft configured to be positioned in the tool body and along the rotational axis and receiving a wire between the outer shell and distribution hub to split the wire into the respective channels.

Embodiments may be optimized for ergonomics. An exemplary tool may be configured to minimize finger usage for wiring operations such as untwisting, separating, and straightening wires, e.g., twisted-pair wires and network cables. This may include a system having a tool (e.g., wire tool) and a drive device (e.g., electrically powered and/or mechanically operated), e.g., modular or integral to each other. The drive device may include a motorized, non-motorized, lever-assisted, and/or battery-powered tool, e.g., a screwdriver device, impact driver, drill, similar tools, or a combination thereof.

The tool may be configured to perform multiple operations simultaneously or sequentially, e.g., using one or more applied force such as a rotational, longitudinal, radial, centrifugal, twist, contact, or combination force. As an example, the tool may simultaneously or sequentially provide a longitudinal force to feed the wire into the tool body, a rotational or centrifugal force to untwist and separate the wire along the channels, and a contact force to straighten the wire. The tool may apply a longitudinal force to advance the wire, a rotational and/or centrifugal force to separate the wire, a contact force between the wire and the rounded tip to straighten the wire, and a further rotational force to wrap the wire around the grooves of the outer shell to further straighten the wire.

The tool may be configured for one or more wire straightening operations. The rounded tip of the tool body may apply a contact force to the wire while a longitudinal force (e.g., pull or push) is applied along a longitudinal axis of the wire. The rotational force may be applied while the tool and the wire are pulled in opposite directions, thereby sliding the wire against the outer edge of the tool body to straighten the wire. The tool body may include one or a plurality of grooves (e.g., of any quantity such as six) such that the wire may be positioned around the outer shell and into the grooves, e.g., for further straightening the wire.

Embodiments may include a system having a wire tool, a drive device, or a combination thereof. An exemplary drive device may include a mechanical, motorized, or combination device configured to apply a rotational and/or longitudinal force on the wire tool. The drive device may include any electric, wired, wireless, or battery-powered tool. An exemplary drive device may include a screwdriver, impact driver, drill, or a combination thereof. The drive device may include a control switch (e.g., a button, toggle, slider, or touch panel) for activating and controlling the rotational speed of the wire tool.

A system may include the tool and the drive device, e.g., modular or integral to each other. This may include a mechanical or non-mechanical tool or may be used in combination with adapters. The tool may be used with any socket size (e.g., 5/32, ¼, ⅜, or ½ inch or 4 mm hex) for mechanical or non-mechanical tools. The tool may also be combined with an inset and/or magnetic adaptor, e.g., an inset magnetic adaptor bit. The tool may include or be used in combination with any mechanical or electrical device.

Embodiments may include customizable structures and features. The tool may include grooves of any quantity, shape, length, width, or height. The tool may include 3D printed or injected molded structures. The tool may include any finishes, coatings, and colors. The tool may include any material such as plastic, thermoplastics, polymers, metal, multi jet fusion (MJF), 3D printable, or composite materials. Exemplary materials may include MJF nylon 12, acrylonitrile butadiene styrene (ABS), steel, aluminum, bronze, or a combination thereof.

FIGS.1-20illustrate embodiments of the present disclosure. The devices, systems, and methods may take many different forms and include multiple and/or alternate components, structures, arrangements, and steps. While exemplary embodiments are shown, they are not intended to be limiting, and additional or alternative components and/or implementations may be used. Embodiments may be configured for one or more wiring operations such as twisting, untwisting, cutting, decoupling, crimping, or connecting operations or a combination thereof.

FIGS.1-12illustrate embodiments of tool100. Tool100may include body102, outer shell104, grooves106, nozzle108, outer edge110(e.g., with a rounded tip), inner edge112(e.g., inner edges112a,b), nose113(e.g., with a pointed, angled and/or star-structured tip), radial walls114, channels116(e.g., angled channels), distribution hub118, shaft120, and socket122.

Referring toFIGS.1,2, and3, tool100may include body102and shaft120. As shown inFIGS.4,5, and6, the tool body102may include socket122along the rotational axis of the tool body102, e.g., configured to receive shaft120. Shaft120and socket122may be configured as corresponding male and female connections, e.g., a hex and/or microwire tool. An exemplary connection may include 5/32″ (4 mm) hex-sized.

Tool body102may include outer shell104, distribution hub118, and one or more radial walls114. Radial walls114may extend longitudinally along and/or radially outward from all or any part of the tool body102, form respective channels116therebetween, receive a wire between the outer shell104and distribution hub118, and/or split the wire into wire strands via respective channels116. Channels116may receive the wire at leading end103, separate the wire into wire strands via nose113, expand the wire strands wire radially outward along tool body102, and output the wire strands at trailing end105.

Referring again toFIGS.1-7, tool body102may include leading end103, trailing end105, axis L (e.g., a rotational or longitudinal axis), and axis R (e.g., a transverse or radial axis from axis L). Tool body102may include outer shell104with outer edge110(e.g., a rounded tip), distribution hub118with inner edges112a,band nose113(e.g., angled, pointed, and/or star-structured tip), or a combination thereof.

As shown inFIGS.3,4,5,6, and7, tool body102may be configured to receive and direct the wire at the leading end103, separate the wire into respective wire strands via inner edges112a,band nose113, radially expand the respective wire strands along channels116of the distribution hub118, and discharge the separated wire strands at the trailing end105, or vice versa. The tool body102may be configured to receive a wire at leading end103in a unitary configuration (e.g., twisted), separate and expand the wire into wire strands between the leading end103and the trailing end105, and output the wire strands at trailing end105in a separated configuration (e.g., untwisted).

Body102may include outer shell104concentrically positioned along axis R and relative to distribution hub118along axis L. Tool body102may be configured to align axis L with a central axis of a wire such that leading end103is advanced along the central axis of the wire, separates the wire as it passes along axis L, expands the wire along axis R by channels116, and provides the separated wire at the trailing end105. The tool body102may be configured to adapt the wire between the unitary and separated configurations.

Tool body102may include one or more radial walls114forming respective channels116to separate the wire into respective strands. Channels116may be formed between outer shell104, radial walls114, and distribution hub118. Radial walls114may extend longitudinally between leading end103and trailing end105and radially outward toward the outer shell104. Radial walls114may be angled and/or twisted relative to axis L and/or axis R, e.g., to separate and expand the wire.

Radial walls114may be arranged to form one or a plurality of channels116between leading end103and trailing end105. Radial walls114and/or channels116may extend all or any part of tool body102. Tool body102may be configured to receive a wire between outer shell104and distribution hub118. Nose113, inner edges112, and radial walls114may be configured to split the wire into respective channels116that expand radially outward to capture, direct and separate the wire into wire strands.

Tool body102may include nozzle108tapering radially outward between outer edge110and outer shell104. Channels116may direct the wire between leading end103and trailing end105, e.g., along axis L and outward relative to axis R. Tool body102may include one or a plurality of grooves106(e.g., any quantity such as six), which may be configured to further straighten the wire.

FIGS.8,9,10and11illustrate exemplary configurations of leading and trailing ends103,105. As shown inFIGS.8and10, leading end103may include outer edge110, inner edges112a,b, and radial walls114. As shown inFIGS.9and11, trailing end105may include outer wall122and inner wall124. Outer edge110, inner edges112a,b, and radial wall114may form respective channels116(e.g., angled compartments) between leading end103and trailing end105.

Channels116may be formed by outer wall122, inner wall124, and opposing radial walls114. Outer edge110, inner edges112a,b, and radial wall114may include one or a plurality of angled, twisted, and/or curved surfaces relative to axis L and/or axis R, e.g., to direct the wire between the unitary and separated conditions. For example, tool body102may include leading end103with leading edge112, nose113(e.g., an angled, pointed, and/or star-structured tip), radial walls114, and channels116that are configured to separate the wire (e.g., twisted-pair wire) using the contact force and centrifugal force.

FIG.12illustrates an exemplary system300including, for example, tool100performing a wiring operation. Tool100may receive wire200between outer shell104and distribution hub118. Tool100may split wire200into respective channels116that expand radially outward to capture and separate wire200into wire strands202a,bcorresponding to respective channels116. Outer shell104may include outer edge110(e.g., a rounded tip). Distribution hub118may include one or more inner edges112a,band nose113(e.g., a pointed, angled, and/or star-structured tip). Tool100may be configured to receive and direct wire200at the leading end103, separate wire200into respective wire strands202a,balong distribution hub118, and discharge wire strands202a,bat trailing end105.

FIGS.13-14illustrate an exemplary drive system400, e.g., configured for powered wiring operations. System400may include tool100and drive device402, e.g., modular or integral to each other. Drive device402may include control switch404, battery406, driver408(e.g., electric motor), power/charge receptacle410, and power indicator412. Receptacle410may receive power via an electrical charger or cord and transfer power to and store power in battery406, which is operationally and electrically connected to driver408. Driver408may be operatively connected to and apply a rotational and/or longitudinal force to tool100, thereby rotating tool100by drive device402and causing tool100to twist and/or untwist a wire.

FIGS.15-20illustrate multi-operation system500, e.g., configured for simultaneous and/or sequential wiring operations as disclosed herein. As shown inFIGS.15-16, system500may include tool100and drive device502, e.g., modular or integral to each other. As shown inFIGS.17-18, drive device502may include lever504, crimp mechanism506, actuator508, driver510(e.g., gear drive), blade512, cutting channel514, release516, and drive receptacle518. Lever504may be operationally and mechanically connected to driver510by way of drive device502. Driver510may be integral or modular with respect to the drive receptacle518.

An exemplary system500may be configured for wiring operations such as twisting, untwisting, cutting, and/or connector crimping operations. Driver510may include a gear drive such as a worm gear connecting lever504and tool100. A compressive force (e.g., grip force) on lever504relative to (e.g., toward) drive device502may move lever504inwards or toward drive device502to activate one or multiple wiring operations, and release of the compressive or grip force may move or reset handle504outwards or away from drive device502for one or more further wiring operations. Referring toFIGS.15-17, a compressive force (e.g., grip force) on lever504may translate a rotational force on tool100, thereby causing tool100to perform wiring operations (e.g., twisting and/or untwisting) on a wire.

System500may include variable cutting operations and depths depending on an applied force. With reference toFIGS.18-19, lever504and/or actuator508may be spring-biased (e.g., spring-loaded) to an expanded condition and move to a retracted configuration depending on the location and magnitude of the applied force. Referring toFIG.18, drive receptacle518may be configured to receive and apply a rotational force to one or a plurality of bit types.

In embodiments, system500may include first and second forces applied to lever504and/or actuator508. Actuator508and/or cutting channel514may include blade512. A wire having a jacket and/or sheath may be positioned in cutting channel514. A first compressive force on lever504(e.g., grip force) and/or actuator508(e.g., thumb force) may move blade512to a sheath depth relative to cutting channel514(e.g., also having blade512), thereby cutting a portion of a wire (e.g., jacket and/or sheath) positioned in cutting channel514. A second compressive or grip force on lever504(e.g., grip force) and/or actuator508(e.g., thumb force) may move blade512to a wire termination depth, thereby cutting all or part of the remaining width of the wire positioned in cutting channel514. Lever504may be configured to cut a portion of the wire (e.g., to a jacket and/or sheath depth), and actuator508may be configured to cut the remaining width of the wire (e.g., to a wire depth), or vice versa.

System500may be configured for wire operations such as connector coupling. A wire connector may be received in connector channel506. A compressive or grip force on lever504may cause a crimping force by crimp mechanism507, thereby crimping together a wire connector and a wire positioned in connector channel506.

Any part of the systems, apparatuses, methods, and processes herein may occur in any arrangement, order, or sequence. Certain components or steps may occur simultaneously, others may be added, and/or others may be omitted. This disclosure illustrates certain embodiments and should in no way be construed to limit the claims.

The above description is illustrative and not restrictive. Many embodiments and applications, other than the examples provided, are apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the claims, along with the full scope of equivalents to which such claims are entitled. Future developments will occur in the technologies discussed herein, and the disclosed systems and methods will be incorporated into such future embodiments. The embodiments of this disclosure are capable of modification, variation, and adaptation.

All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. Use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.

The Abstract of the Disclosure is provided to allow the reader to ascertain the nature of the technical disclosure, but it should not be used to interpret or limit the scope or meaning of the claims. Various features of this disclosure may be grouped in various embodiments to streamline the disclosure, but the claimed embodiments shall not be interpreted as requiring more features than are expressly recited in each claim. The inventive subject matter of the claims lies in less than all features of a single disclosed embodiment. The claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.