U.S. patent application number 10/822463 was filed with the patent office on 2004-12-09 for cable closure and assembly.
This patent application is currently assigned to Preformed Line Products Company. Invention is credited to Cloud, Randy G., Grubish, Christopher S., Pisczak, Philip J..
Application Number | 20040245008 10/822463 |
Document ID | / |
Family ID | 22909687 |
Filed Date | 2004-12-09 |
United States Patent
Application |
20040245008 |
Kind Code |
A1 |
Grubish, Christopher S. ; et
al. |
December 9, 2004 |
Cable closure and assembly
Abstract
A cable closure is provided which adapted to accommodate
different size cables and different splices. The closure includes
end plates designed to receive various size cables without
requiring modification during field use. The end plates are
interchangeable with stainless steel and injection molded closure
shells. A sealant is provided which allows multiple re-entries into
closure shell. Bolts are assembled on the exterior of the closure
shell to eliminate potential misalignments between the bolts and
closure shell holes. Washers are used within the end plates to seal
holes not used for storing cables. A cutter is provided which cuts
the washers in one 360.degree. rotation thus eliminating weak
points in the washer due to multiple cuts. Alternately a plug is
provided for the end plate holes which are adaptable to several
size holes to reduce the number of plugs required.
Inventors: |
Grubish, Christopher S.;
(Solon, OH) ; Cloud, Randy G.; (Mentor, OH)
; Pisczak, Philip J.; (Chagrin Falls, OH) |
Correspondence
Address: |
Michael E. Hudzinski
FAY, SHARPE, FAGAN,
MINNICH & McKEE, LLP
1100 Superior Avenue, Seventh Floor
Cleveland
OH
44114-2518
US
|
Assignee: |
Preformed Line Products
Company
|
Family ID: |
22909687 |
Appl. No.: |
10/822463 |
Filed: |
April 12, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10822463 |
Apr 12, 2004 |
|
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|
09981187 |
Oct 16, 2001 |
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6721483 |
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60241203 |
Oct 17, 2000 |
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Current U.S.
Class: |
174/92 ;
174/93 |
Current CPC
Class: |
G02B 6/4447 20130101;
G02B 6/4444 20130101; H02G 15/117 20130101; H02G 15/013 20130101;
H02G 15/113 20130101 |
Class at
Publication: |
174/092 ;
174/093 |
International
Class: |
H02G 003/06 |
Claims
1. A re-entrable housing assembly for enclosing and storing cable
splices comprising: first and second end plates axially aligned and
spaced apart from one another; first and second housing members
releasably and sealingly clamped to each other, said housing
members enclose said end plates, said end plates being located at
opposite ends of said housing members; a sealing member extending
along a length of said housing members and bonded onto a
longitudinal edge of at least one of said housing members; and, end
plate seal members embedded into grooves at opposing ends of seal
housing members.
2. The housing assembly of claim 1, further comprising a rigid bar
member having opposite terminal ends joined to the first and second
end plates to hold them in their axially aligned and spaced
relationship.
3. The housing assembly of claim 1, wherein each of said first and
second housing members includes a plurality of rib elements
extending from an exterior surface of said housing member to form a
support for permitting said housing member to rest stably on a flat
work surface.
4. The housing assembly of claim 1, wherein each of said first and
second housing members comprises a main body portion with
peripheral clamping flanges extending outwardly therefrom and
cooperatively positioned in opposed relationship to another of said
housing members to be clamped together, said clamping flanges have
inner end portions adjacent said main body portions and having free
outer end portions.
5. The housing assembly of claim 4, wherein said sealing member is
positioned between said inner end portions of said clamping
flanges, and is bonded into said inner end portions along a
longitudinal axis of said first and second housing members.
6. The housing assembly of claim 1, wherein said first and second
housing members each comprise an injection molded shell.
7. (Cancelled)
8. The housing assembly of claim 1, wherein at least one of said
first and second housing members comprises an alignment rib
extending along said longitudinal axis of said housing member.
9. The housing assembly of claim 5, further comprising a gasket
extending along said longitudinal axis of one of said first and
second housing members, said gasket being connected to said end
plate seal members.
10. The housing member of claim 9, wherein said gasket is recessed
within a groove along said longitudinal axis of said first housing
member, said gasket being located on a first side of said first
housing member, said sealing member being located along a second
side of said first housing member.
11. The housing member of claim 10, wherein said second housing
member carries said seal member located on a first side of said
second housing member and a gasket recessed within a groove along a
second, opposite side of said second housing member, wherein said
gasket of said first housing member and said seal member on said
second housing member are compressed together to form a seal, and
wherein said seal member of first housing member and said gasket of
said second housing member are compressed together to form a
seal.
12. The housing assembly of claim 11, wherein said gasket comprises
neoprene rubber.
13. The housing assembly of claim 11, further comprising a
plurality of tabs protruding from said first and second sides of
each housing member along said longitudinal axis.
14. The housing assembly of claim 13, further comprising first and
second retention members including a plurality of slotted openings
adapted to align with said tabs when the first and second housing
members are brought together to an intermated connected position,
said retention members clamping said first and second housing
members together.
15. The housing assembly of claim 14, wherein each of said
retention members includes a pair of members each having a
plurality of slotted openings and a plurality of fastening means to
secure said pair of slotted members to each other.
16. The housing assembly of claim 15, wherein said slotted members
are generally parallel to each other.
17. The housing assembly of claim 16, further comprising a spacer
which is compressed between said pair of slotted members to
transfer a uniform load along said longitudinal axes of said
housing members.
18. The housing assembly of claim 16, wherein said retaining
members are outboard of said clamping flanges of said housing
members.
19. The housing assembly of claim 1, further comprising a filling
flange attached to an outside surface of one of said housing
members.
20. The housing assembly of claim 19, wherein said filling flange
is spin welded to said housing member.
21. The housing assembly of claim 19, wherein said filling flange
includes a cap and an air valve sealed by said cap.
22. The housing assembly of claim 19, wherein said filling flange
includes a cap and a check valve for injecting encapsulant to said
housing, said valve being sealed by said cap.
23. The housing assembly of claim 19, wherein said filling flange
includes a cap and a grounding plug secured within said cap for
accommodating a grounding wire.
24. The housing assembly of claim 1, wherein said end plates each
include fastening means located within said end plates.
25. The housing assembly of claim 24, wherein said end plates
define at least one hole for cable insertion.
26. The housing assembly of claim 24, wherein said end plate
fastening means comprises a nut strip which distributes loads
required to draw end plate sections together to fasten said end
plate sections to each other.
27. The housing assembly of claim 1, further comprising an air and
grounding insert molded into an opening within each of said end
plates for connecting an associated air valve and grounding insert
to said housing.
28. The housing assembly of claim 1, wherein said end plates each
include at least one gripping member comprising teeth for gripping
cable and a slotted elongated member which extends to accommodate
cables of varying widths.
29. The housing assembly of claim 24, wherein said end plates
comprise varying outer diameters to accommodate housing members of
varying sizes.
30-75. (Cancelled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional
Application No. 60/241,203, dated Oct. 17, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to a cable splice
enclosure assembly. Assemblies of the type under consideration are
particularly suited for enclosing and housing copper splice cables,
and the invention will be described with particular reference
thereto; however, the apparatus could equally well be used with
other types of cables, such as fiber optic cables.
[0003] Many different types of cable enclosures are known in the
prior art. These prior enclosures are satisfactory to a greater or
lesser degree but often have certain defects which make them
inconvenient to use or prevent them from being readily adaptable to
changing environments and conditions. It is, accordingly, a primary
object of the present invention to provide a cable enclosure
assembly that is easy to assemble and use and which can be modified
or adapted for different size cables and can be formed in a variety
of different sizes that allow the size and number of splices to
vary. In addition, the present invention provides an enclosure that
allows ready access for changing or adding to the number of splices
in the enclosure. It is also an object of the to receive various
size cables without requiring drilling or modification during field
use.
[0004] It is desirable to provide end plates which are
interchangeable with stainless steel closure shells and injection
molded closure shells.
[0005] In existing closures, the sealing system utilizes mastic
sealants which need to be replaced upon each re-entry. Thus, it is
desirable to provide a seal which eliminates the use of mastic
sealant which has a tendency to "gum up" and have to be
replaced.
[0006] Existing closure systems typically have bolts captivated
within the actual closure shell. This approach makes assembly more
cumbersome, as each bolt needs to be accurately aligned to the
mating nut to avoid cross-threading. Thus, tolerance between the
bolt holes needs to be tightly kept. Thus, it is desirable to
provide a fastening system which eliminates the potential for
slight misalignment between fasteners and holes for fasteners.
[0007] While working on existing closures in an aerial location,
the craftsperson typically carries the closure shells down to
ground level to remove them from the work area. Once work is
completed on a splice point of cable, the craftsperson then returns
to ground level to retrieve the closure shells to reassemble the
unit. If the closure shells are carried down one at a time, the
craftsperson would need to scale up and down a ladder several times
thus creating inefficiencies during the work process. Accordingly,
it is desirable to provide a means for securing closure shells in
an aerial location while cable splices are worked on.
[0008] Existing end plate washers used with closures are thick
solid disks with concentric annular grooves which require a special
tool for cutting. One 360.degree. rotation of a cutting device
through a groove produces a properly sized hole through which the
cable can pass. The washer must be cut a second time from the outer
diameter to the inner diameter to create a split through which the
cable can be passed to the inner diameter. This cut (seam) creates
a weak point in the washer when it is assembled into their end
plate. Thus, it is desirable to develop a cutter for washers which
allows the washer to be cut with one rotation.
[0009] It is also desirable to provide a plug for end plate holes
which are adaptable to several size holes to reduce the number of
plugs required to fill the end plate holes.
[0010] Accordingly, it has been considered desirable to develop a
new and improved cable closure and assembly and washer cutter which
would overcome the foregoing difficulties and others while
providing better and more advantageous overall results.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a cable closure and
assembly. More particularly, it relates to a cable closure system
which is to provide a lower cost splice closure with performance
similar to a stainless steel splice case.
[0012] The closure can function with an existing foam-filled end
plate system. This approach allows substitution of lower cost
shells for the stainless steel shells. The existing customer base
is trained and equipped to drill the existing foam-filled end plate
system and are less likely to expend money for training personnel
to assemble the end plate. The design and assembly of the closure
shells is very similar to the stainless shells and does not require
extensive training.
[0013] The closure shell and gasket system of the present invention
is designed to function with the sealing washer end plate system of
the present invention, the current foam-filled end plate system or
a combination of both.
[0014] To reduce the closure cost even further, a sealing washer
end plate system is provided to allow assembly of an end plate
without any special drilling fixtures as required with the existing
foam filled end plate.
[0015] The sealing washer end plate system is designed as an
alternative to the existing foam-filled end plate system. However,
the end plate is compatible with existing stainless steel splice
case shells as well as the closure shells of the present
invention.
[0016] More particularly, the invention relates to the housing
assembly for enclosing and storing the cable splices. The housing
comprises first and second end plates axially aligned and spaced
apart from one another. First and second housing members are
releasably and sealingly clamped to each other and enclose the end
plates. The end plates are located at opposite ends of the housing
members. The housing members are symmetrical with respect to each
other.
[0017] A sealing member extends along a length of the housing
members and is located along the longitudinal edge of at least one
of the housing members. Third and fourth housing members are
interchangeable with the first and second housing members and are
also clamped to each other and enclose the end plates and are
symmetrical with respect to each other. First and second housing
members each comprise gas-assisted injection molded shells. Third
and fourth housing members each comprise stainless steel shells. A
rigid bar member is joined to the first and second end plates to
hold them in an axially aligned and spaced relationship.
[0018] The housing members each further include a plurality of rib
elements extending from exterior surfaces to form a support for
permitting the housing member to rest on a flat work surface. At
least one of the housing members comprises an alignment rib
extending along a longitudinal axis of the housing member. The
housing members each comprise a main body portion with clamping
flanges extending outwardly therefrom and in opposed relationship
to each other. The clamping flanges have inner end portions
adjacent to the main body portions and have free outer ends. The
seal member is positioned between the flange inner ends and is
positioned between the inner end portions along a longitudinal axis
of the housing members.
[0019] End plate seal members are embedded into channels at
opposing ends of the housing members. A gasket extends along the
longitudinal axis of the housing member and is connected to the end
plate seal members. The gasket is recessed within a groove along
the longitudinal axis of the first housing member. The gasket is
located on the first side of the housing member and the sealing
element member is located on the second side of the housing member.
The second housing member also comprises a seal member located on a
first side and a gasket recessed in a groove on a second side. The
gasket of the first housing member and the seal member on the
second housing member are compressed together to form a seal. The
seal member on the first housing and the gasket on the second
housing member are also compressed together to form a seal. The
gasket is preferably comprised of neoprene rubber.
[0020] First and second retention members are provided which
comprise a plurality of slotted openings which align with tabs on
the housings. The retention members clamp the first and second
housing members together. The retention members comprise a pair of
members each having a plurality of slotted openings and a plurality
of fastening means to secure the pair of slotted members to each
other. A spacer is compressed between the pair of slotted members
to transfer a uniform load along the longitudinal axis of the
housing members. Retaining members or outboard of the clamping
flanges of the housing members.
[0021] A filling flange is attached to an outer surface along the
housing members via spin welding. The filling flange comprises a
cap and an air valve sealed by the cap. Alternately, the filling
flange can comprise a cap and a check valve for injecting
encapsulant into the housing. Alternately, the filling flange can
comprise a cap and a grounding plug for accommodating a grounding
wire.
[0022] The end plates may comprise one, two, or three holes for
cable insertion. Each end plate further comprises a nut strip which
distributes the load and draws the end plate sections together and
fastens the end plate sections to each other. An air and grounding
insert is molded into an opening within each of the end plates for
connecting an associated air valve and grounding insert to the
housing.
[0023] A method for measuring the outer diameter of a cable prior
to insertion into a seal washer comprises inserting the cable
through a pair of seal washers, applying a layer of tape around the
outer diameter of the cable, applying a layer of sealant on the
cable and tape until an outer diameter of the sealant is at least
equivalent to an outer diameter of the seal washer, wrapping a
measuring tape around the sealant and using index lines to check
the quantity of tape needed prior to assembly.
[0024] An end seal washer for use with a cable closure comprises a
first washer disk having a first side and second side where the
first side has a plurality of ribs and the second side has a flat
surface. A second washer comprises a disk with a first side and
second side where the first side has a flat surface and the second
side has a plurality of ribs. The first and second washers are
symmetrical with respect to each other and are preferably formed of
thermoplastic. Each washer further comprises holes and tabs spaced
apart along a peripheral edge of where the holes in one washer
engages the tabs of the mating washer. The tabs engage the holes to
secure the first and second washer together.
[0025] A second side of the first washer and a first side of the
second washer each further comprise a plurality of sections with
grooves. Reference labels are provided adjacent each set of grooves
for determining which grooves will be cut on each washer. Grooves
of one of the washers may only engage a solid wall section of the
other washer. A third washer and a fourth washer which are similar
to the first and second washer are also assembled together and are
connected by a spool to the first and second washers.
[0026] A portable washer cutter for cutting an internal cut-out
from a flat washer comprises first and second enclosures which
adapted to cooperatively engage together to cut a circular internal
cut-out from the associated flat washer. The first enclosure has an
internal cavity with a cutting member and the second enclosure has
a supporting structure for the washer. The first and second
enclosures are connected by an axle extending through the
enclosures. The cutting member is radially adjustable between a
first position and a second position on opposite sides of the first
enclosure.
[0027] The first enclosure has a plurality of radial grooves
extending from the central axis of the enclosure. The second
enclosure has a plurality of ribs extending radially outward from
the center axis of the second enclosure. The ribs vary in height
from a first height greater than the second height. The ribs of the
first height space the washer from a surface of the second
enclosure and ribs of the second lower height engage spokes of the
washer preventing rotation of the washer. The ribs are spaced apart
in a radial direction to accommodate washers of varying
diameters.
[0028] The second enclosure further comprises a plurality of
extensions extending from a peripheral edge of the enclosure. Each
of the extensions comprise a detachably secure positioning member.
The extensions serve as hand grips during use of the cutter. A
positioning member is secured to first and second sides of the
second enclosure for securing the washer in place. The positioning
members are detached from the extensions and are placed into
openings in a second enclosure. Furthermore, one of the extensions
has a hole for storing a positioning member after being detached
from one of the extensions.
[0029] The second enclosure further comprises an alignment rib on a
first surface and a second surface. An alignment groove is provided
on the first enclosure which lines up with the alignment ribs of
the second enclosure for positioning the cutting member.
[0030] A handle is provided on the first enclosure which is
ergonomically shaped to approximate the shape of a user's hand. The
cutting member comprises an elongated member having a slot
therethrough and a blade positioned on one end of the member. The
cutting member also has a threaded member extending through a hole
in the first enclosure and through the slot of an elongated member.
The blade is moved to a location indexed by an index margin on the
first enclosure and secured into place by tightening the threaded
member. The first enclosure is aligned with the second enclosure
and is placed on as second enclosure is rotated 360.degree. to cut
the washer.
[0031] A plug is used for sealing the end plate opening which
comprises a first ring and a second ring spaced apart from the
first ring. A spool connects the first and second rings together.
The first and second rings have a groove extending around the
perimeter of the rings which allows the first ring to be separated
from the second ring to reduce the diameter of the ring.
[0032] A hanging clip for suspending the cable closure shells
during use comprises a body portion and a first and second member
extending from the body portion, a third member which extends from
the body providing a grip for the user's hand and a slot for
receiving a tie wrap. The first member is a snap finger for
engaging the exterior rib of an associated closure shell. The
second member is locator rib which contacts an interior surface of
the closure shell. The third member is a finger grip which is
adjacent to the first member. The slot comprises a first and second
slot generally perpendicular to each other. The clip is installed
on a closure shell by applying a force to the hanging clip via the
finger grip and separating the first and second members to engage
the rib on the shell. The tie wrap is inserted through the slot and
is tied onto a cable to suspend the closure shell from the
cable.
[0033] One advantage of the closure system lies in the flexibility
of cost and performance it provides. The closure can be configured
in a multitude of ways to address a specific customer's needs.
[0034] There are several advantages of the sealing washer end plate
system of the present invention versus the foam-filled end plate
system: a) no special drilling fixtures are required; b) no
electrical power source is required for the application; c) pliable
mastic sealing tapes used with seal washers promote a more
forgiving assembly than the foam-filled end plates; and d) higher
grade engineered plastic resins are required for the foam-filled
end plate system due to the heat generated during the foam filling
process. Utilization of part geometry to increase stiffness and
strength which allows for the use of lower grade resins in the end
plate system reduces costs.
[0035] Another advantage is the provision of the end plates being
interchangeable between the closure shells of the present invention
and stainless steel closure shells.
[0036] Yet another advantage of the present invention is the
provision of gaskets and seals which are embedded within the
closure and allow assembly and disassembly multiple times of the
closure.
[0037] Another advantage of the closure system is the provision of
bolt bars which allow for slight misalignment during
installation.
[0038] Still yet another advantage of the present invention is the
provision of hanger clips which allow closure shells to hang from a
cable during use.
[0039] Another advantage of the present invention is the provision
of a washer cutter which cuts washers in one rotation.
[0040] Still yet another advantage of the present invention is the
provision of an end plate hole plug which is adaptable to different
diameter holes.
[0041] Still other advantages and benefits of the invention will
become apparent to those skilled in the art upon a reading and
understanding of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The invention may take form in certain parts and
arrangements of parts, one embodiment of which will be described in
detail in this specification and illustrated in the accompanying
drawings which form a part hereof and wherein:
[0043] FIG. 1A is a perspective view of the cable closure in
accordance with one embodiment of the present invention.
[0044] FIG. 1B is a perspective view of half of the closure shell
of the closure of FIG. 1;
[0045] FIG. 2A is a perspective view of one of the closure
shells;
[0046] FIG. 2B is a perspective view of the mating closure shell
for the shell of FIG. 2A;
[0047] FIG. 3A is an enlarged view illustrating the seal in dashed
lines;
[0048] FIG. 3B is an enlarged view illustrating the bolt bar
assembly;
[0049] FIG. 4 is a perspective view of the closure shell half and
air/filling flange;
[0050] FIG. 5A is an exploded view of the air/filling flange;
[0051] FIG. 5B is a cross-sectional view of the air/filling
flange;
[0052] FIG. 5C is an exploded view of an air/filling flange with a
grounding cap;
[0053] FIG. 5D is a perspective view of an air/filling flange with
a grounding cap;
[0054] FIG. 5E is an exploded view of an air/filling flange with a
check valve;
[0055] FIG. 5F is a perspective view of an air/filling flange with
a check valve;
[0056] FIG. 6 is an exploded perspective view of the closure
illustrating bolt and torque bars;
[0057] FIG. 7 is a perspective view illustrating use of hanger
clips and tie wraps to hang closure shell halves during use;
[0058] FIG. 8A is a perspective view illustrating hanger clips
securing closure shell halves;
[0059] FIG. 8B is an enlarged perspective view of the hanger clip
and tie wrap of FIG. 8A;
[0060] FIG. 8C is an enlarged perspective view of the hanger clip
and tie wrap of FIG. 8A;
[0061] FIG. 9 is a perspective view of the hanger clip of FIG.
7;
[0062] FIG. 10 is an exploded perspective view of the closure
illustrating bolt and torque bars;
[0063] FIG. 11 is an exploded perspective view of a foam-filled end
plate and an end plate of the present invention in use with a
stainless steel closure;
[0064] FIG. 12A is an exploded perspective view of a two-hole 9.5"
end plate;
[0065] FIG. 12B is a perspective view of the two-hole 9.5" end
plate;
[0066] FIG. 13A is a perspective view of a gripper bracket extender
bracket;
[0067] FIG. 13B is a side elevational view of the gripper bracket
of FIG. 13A;
[0068] FIG. 13C is a front plan view of the gripper bracket of FIG.
13A;
[0069] FIG. 14A is a side elevational view of an air/ground insert
installed within an end plate;
[0070] FIG. 14B is a perspective cross-sectional view of the
air/ground insert of FIG. 14A along section A-A;
[0071] FIG. 15 is an exploded perspective view of an end plate with
a cable extending therethrough;
[0072] FIG. 16A is a sealing washer perspective view showing prep
tape wrapped around a cable extending therethrough;
[0073] FIG. 16B is a sealing washer assembly perspective view
displaying the cable extending therethrough and the mastic sealant
tape applied around the circumference;
[0074] FIG. 16C illustrates measure tape to measure compression of
the end plate and mastic;
[0075] FIG. 16D illustrates the use of the measure tape on the end
plate assembly;
[0076] FIG. 17A is a perspective exploded view of two washers and a
spool;
[0077] FIG. 17B is a perspective view of two washers attached to a
spool;
[0078] FIG. 18 is a perspective exploded view of two mating
washers;
[0079] FIG. 19 is a perspective view illustrating a plug wheel
installed in a three-hole end plate;
[0080] FIG. 20A is a top plan view of the plug wheel with sealing
tape wrapped thereon;
[0081] FIG. 20B is a front elevational view of the plug wheel;
[0082] FIG. 20C is a perspective view illustrating removable rings
of the plug wheel;
[0083] FIG. 20D is a perspective view of the plug wheel;
[0084] FIG. 21 is a perspective view of an assembled washer
cutter;
[0085] FIG. 22 is an exploded perspective view of washer cutter of
FIG. 21;
[0086] FIG. 23 is a perspective view of a top surface of the
base;
[0087] FIG. 24 is a perspective view of a 3.4-inch disk mounted on
the top surface of the base;
[0088] FIG. 25 is an exploded perspective view of the underside of
the cutter cap; and,
[0089] FIG. 26 is a perspective view of the underside of the cap
with the blade installed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0090] Referring to the drawings, wherein the showings are for
purposes of illustrating the preferred embodiments of the invention
only, and not for purposes of limiting same, FIGS. 1A and 1B show a
closure shell and gasket system A in accordance with a first
embodiment of the present invention.
[0091] The closure shells 10, 11 of the present invention are
preferably formed of injection molded components which utilize part
symmetry to reduce part inventory. A closure assembly requires two
of the same shells.
[0092] A rib structure 12, 14 is included on the exterior and
interior of the shells 10, 11 to provide the strength and stiffness
required for the closure to maintain an internal air pressure of 10
psi. The ribs are provided for structure and some form a support
for permitting the closure to rest stably on a flat work
surface.
[0093] Referring now to FIGS. 2A and 2B, the closure shell system
includes an end plate gasket channel 16 in which a gasket 18 (which
can be made of neoprene rubber)is located and bonded. The gasket is
located on one side of the closure shell. End plate area sealing
beads 20 are embedded into the gasket 18 on the flange of the
opposing shell to create a seal. A flange sealing bead 22 extends
the longitudinal length of the shell and embeds into the gasket on
the flange of the opposing shell to create a seal.
[0094] The closure gasket 18 is preferably of unitary construction
and formed of a compression molded neoprene rubber compound. The
gasket 18 has an area which is bonded into the end plate gasket
channel 16 at each end of the closure shell and has a T-shaped
portion which is bonded into the gasket retention groove along the
length of the shell.
[0095] When the two shells are brought together in their operative
assembled positions, a reinforcement member or wall 30 extends
beyond the flange of the opposing shell to add stiffness to the
closure assembly as it is pressurized. Furthermore, the member
serves to protect the cable bundles as the shells are mounted
together.
[0096] The gasket is pressed and bonded into a gasket retention
groove 32 to create a seal along the flange of the shell. In its
preferred form, the shell design is symmetrical, but is constructed
to be assembled in a single direction. This allows the flange
sealing bead and end plate area sealing bead of one closure shell
to be sequentially embedded into the gasket of the opposing shell
along a predetermined direction thus creating a seal. One advantage
of this seal is its re-enterability; that is, the shells can be
disassembled and re-assembled as desired without causing permanent
damage to the sealing system. Prior art mastic sealants must be
replaced upon each re-entry. The shells are symmetrical where one
side of the closure shell has the gasket and the opposite side has
the flange sealing bead and vice versa for the other closure shell.
An advantage of this seal is it eliminates the use of mastic
sealant which has a tendency to "gum up" and have to be
replaced.
[0097] Sealing beads or ribs 46 compress on the underside of the
gasket to prevent air from escaping out of this region. The gasket
has a seal area 48 on which an end plate rests and seals. An end
sealing face 50, 52 is compressed against an opposing flange to
create a seal. In FIG. 3A, the rectangular dashed line outlines the
region or area where the end sealing face 50 is compressed to
produce a seal. The sealing bead 22 is shown to create a seal
against the gasket 18. Sealing rings 200 (FIG. 3A)from the end
plate are forced outward to create a seal.
[0098] Referring to FIG. 3B, upwardly extending bolt bar retention
posts 34 are positioned in a spaced apart relationship along the
length of the closure shell over which bolt bars 40 and bolts 36
are assembled. The posts 34 locate and restrict the bolt bars 40
from sliding along the length of the closure and from migrating
outwardly upon pressurization of the closure.
[0099] Referring now to FIG. 6, the bolt bar fastening system
provides the clamping force required to draw the closure shells
together, which forces the sealing features of the end plate and
closure shells to seal against the gasket material. The bars 40 are
supplied as an assembly. To assemble, the bars are spread apart
enough to allow the bolt bar retention posts 34 to pass through the
slot in the bolt bar. Referring to FIG. 3B, as the bars are
tightened down, a spacer 38 is compressed between edge A and edge B
of the bars and transfers the load forward against the shell
flange. The primary purpose of the spacer 38 is to maintain
parallelism between plane A and plane B of the retention posts to
ensure a uniform compressive load is applied along the length of
the flange. The stiffness of the metallic bars 40 helps distribute
the load between the bolts 36. The bars 40 are symmetrical. Prior
art systems have bolts captivated within the actual closure shell.
This approach makes assembly more cumbersome, as each bolt needs to
be accurately aligned to the mating nut to avoid cross-threading.
Thus, tolerance between the bolt holes is essential. Since the
bolts and bolt holes in the bolt bars are external to the closure
shell, the bolt bars eliminate the potential for misalignment
between the bolts and holes in the closure shell.
[0100] Referring to FIG. 2A, fastening bosses 42 are provided into
which a self-tapping screw is installed to attach a customer
identification plaque. A flat boss area 44 is also provided onto
which the air/filling flange device is preferably spin welded.
[0101] Referring now to FIG. 4, a multi-purpose air/filling flange
60 provides a means for injecting air or pouring encapsulant into
the closure. The air/filling flange 60 is attached to the closure
shell preferably by using a spin welding process. Since the welding
process creates a hermetic seal, a washer, nut and o-ring which are
typically found in a similar assembly are eliminated.
[0102] A hole 62 is punched through the exterior of the closure
shell on the flat boss region 44 for the flange. The hole also acts
as a guide to help keep the flange concentric during the spin
welding process. After the air/filling flange 60 is welded to the
shell, different caps can be installed onto the flange for
different applications. As an example, an air valve cap 64 is
assembled onto the flange when closure pressurization is required.
The air valve cap 64 is then used for injecting air into the
closure.
[0103] Referring now to FIGS. 5A and 5B, the air/filling flange
assembly comprises a cap 80, a nut 82, a washer 84, a cap 86 with a
hole for an air valve, an air valve 88, the air filling flange 60
which has a top sealing surface 90 and drive slots 92. A washer 94
seals against the top of the air/filling flange 60 on surface
90.
[0104] When it is desired to fill the closure with encapsulant, the
encapsulant is poured through the air/filling flange 60 and then is
capped off with a blank cap 70 (see FIG. 4). A seal 72, such as a
rubber gasket, is pinched between the seal surface of the
flange.
[0105] When it is desired to provide a grounding wire out through
the closure shells, a separate cap assembly 77 is threaded into
place. Referring to FIGS. 5C and 5D, the air/filling flange cap 77
includes a hole and comprises a retaining cup/washer 73, a rubber
washer 74, a cap 75 and a grounding plug 76. A grounding strap 78
extends from the grounding plug 76.
[0106] Referring now to FIGS. 5E and 5F, a separate cap assembly 79
is provided for use with a check valve 81 for injecting encapsulant
into the closure. The cap assembly includes the check valve 81, a
cap 83, a rubber washer 85 and a retaining cup/washer 87.
[0107] A novel shell hanger clip system for improved closure
maintenance will be described with reference now to FIG. 7. In the
past, to work on a splice point within the closure, the
craftsperson needed to carry the closure shells down to ground
level to remove them from the work area. After work is completed on
a splice point of cable B, the craftsperson would then return to
ground level to retrieve the closure shells to reassemble the unit.
If the closure shelves are carried down one at a time, the
craftsperson would need to scale up and down a ladder several times
thus creating inefficiencies during the work process.
[0108] To avoid this, a pair of shell hanger clips 23 are provided
as a means for attaching a tie wrap 24 to each closure shell thus
allowing the shells to be hung near the splice point off of the
cable. This eliminates the need for a craftsperson to scale up and
down a ladder to deposit the closure shells thus saving time and
increasing efficiency. The hanger clips 23 also provide a secondary
benefit when a closure is being reassembled. The tie wrap 24 can be
threaded through a hanger clip at each end of the closure shells
and tightened around the cable entering the splice point. As the
tie wraps are tightened, the closure shell is drawn up against the
end plate system, as seen in FIG. 8A. FIGS. 8B and 8C illustrate
the detail of the tie wrap extending through the hanger clip. The
closure shells are then secure enough to free the hands of the
craftsperson to continue work on the assembly. Once installed, the
shell hanger clips do not obstruct the process of assembling or
disassembling closures. The shell hanger clip may remain attached
to the closure shell halves for use during a future re-entry.
[0109] FIG. 9 illustrates the detail of the preferred shell hanger
clip 23. The shell hanger clip comprises a pair of arms or clips
25, 26 which extend from a main body portion 27 and are used to
secure the clip onto an outer rim of the closure shells in a manner
shown generally in FIG. 7. Arm 25 is a snap finger which engages
over an exterior rib structure of the closure shell. Arm 26 is a
locating rib which is spaced apart from the snap finger and is
generally parallel thereto and contacts an interior surface of the
closure shell half. Handle 28 forms a thumb grip which provides a
point of leverage for removing the hanger clip from the closure
shell. The handle portion 28 of the main body is extruded to
provide a area to grasp the clip with fingers to detach the clip
from the closure shell. The hanger clip is preferably made of a
resilient plastic material which allows it to bend or deform
slightly as the user grasps the handle and bends the clip slightly
to release it from the end of the closure shell. Within the main
body portion is a pair of slots 29, 31 which extend through the
body and are generally normal to each other thus providing two
openings for the tie wrap to extend through. The tie wrap may
extend through either of the slots.
[0110] As shown in FIG. 7, torque bars 110 are used in the closures
to maintain rigid support of the end plates once the closure shells
have been removed. The exterior of the cable closure does not have
any holes or features which provide a means for hanging the closure
shells near the work area once they are removed from a splice point
of cable within the closure. During work on a cable closure in an
aerial application, access is required to the interior of the
closure in between the end plates 120.
[0111] An end plate system 120 is provided as an alternative to a
existing foam-filled end plate system 121 (see FIG. 10). The
preferred end plate system 120 is comprised of two major components
including end plate sections 122 and a sealing washer system 124
(see FIG. 1B). End plate 122 is compatible with existing stainless
steel splice case shells 123 (see FIG. 11) as well as the injection
molded closure shells. Thus, the foam filled end plate and end
plate system of the present invention are interchangeable with the
stainless steel closure shells and the gas-injected molded closure
shells of the present invention. The stainless steel closure
comprises two symmetrical shell sections 125, 127 which are secured
together by two sets of lockbars 129, 131. The lockbars have
slotted holes 133 which allow for alignment of one of the lockbars
with a mating lockbar. One of the mating lockbars has bolts 135
inserted through holes 137 which in turn are inserted through holes
139, 141 in flanges of the shells. The stainless steel enclosures
have a diameter which accommodates both of the end plate systems. A
problem with the stainless steel closures is that the bolt holes of
the lockbars must align with pre-existing holes in the shells;
thus, the lockbars do not allow for tolerances in positions of the
bolt holes in the lockbars and shells.
[0112] With reference to FIGS. 10-12B, the end plate system 120
provides sealed entry and exit points, at each end of the splice
enclosure, for cables passing through. With the existing
foam-filled end plate 121, each end plate is custom drilled in the
field, by the craftsperson, with the use of a portable drilling
fixture. This process is time consuming and requires an electrical
source to power the drilling fixture. The major benefit of the end
plate system 120 lies in the ability to drill custom hole sizes and
configurations in the end plate.
[0113] The end plate system 120 provides various standard hole
sizes and configurations. Each hole defines established maximum
allowable cable diameter and a sealing washer system which is used
to adapt each hole for the specific size of cable being used.
[0114] The closure system includes a wide range of end plate
constructions. The end plates provide several advantages including
utilization of common components to reduce costs and minimize
inventory. All fastening hardware is contained on the interior side
of the end plate for protection within the splice closure. This
allows for the elimination of the need for stainless steel
materials, thus further reducing part cost. Part symmetry is used
to reduce the total amount of tools required for producing all of
the end plates. Thus, common parts are re-usable in various end
plate configurations.
[0115] The end plates preferably include at least four sizes: 9.5
inches in diameter, 8 inches in diameter, 6.5 inches in diameter,
or 4 inches in diameter. The 9.5-inch end plates are available in
at least two configurations: two hole 130 (FIGS. 12A and 12B) and
three hole (not shown).
[0116] The two-hole assembly 130 is constructed from a two-hole
center section 134 and two one-hole end sections 136, 138. The
three-hole assembly is constructed from a three-hole center section
(not shown), a two-hole end section (not shown) and a one-hole end
section.
[0117] The 6.5-inch end plate assemblies are available in three
configurations: one hole, two hole, and three hole. Symmetry is
utilized on the one-hole 6.5-inch end plate to minimize the
inventory. This end plate includes two of the same end plate half
sections. The two-hole end plate is constructed from a one-hole end
section, a two-hole center section, and a one-hole end section. The
three-hole end plate is constructed from a two-hole end section, a
three-hole end section, and a one-hole end section.
[0118] The four-inch end plate has at least one configuration with
two holes. The two-hole 4-inch end plate is constructed from two
one-hole sections.
[0119] The eight-inch end plates are available in at least three
configurations: three-hole, two-hole, and one-hole.
[0120] With particular reference to FIG. 12A, a nut strip 150 is a
stamped, threaded strip of material acts as a large nut. The nut
strip provides a large amount of surface area to aid in
distributing the loads required to draw the end plate sections
together and is used on all of the end plate constructions. The end
plates are molded to support one end of the nut strip. The opposing
end of the strip is supported by a retainer clip 152. Due to the
manner in which the nut strip 150 is retained in the end plate, the
threaded hole in the nut strip is not centered over the strip's
length. To avoid manufacturing assembly errors, one end of the
strip has chamfered corners to indicate proper orientation. If the
strip is loaded backwards into the shell 134, the hole in the nut
strip will not align with the hole in the end plate section, thus
making it physically impossible to assemble the end plate.
[0121] The retainer clip 152 supports one end of the nut strip 150.
The clip 152 helps to retain the nut strip as the bolt is initially
threaded into place. Once the nut strip is pulled upward by the
bolt, the clip provides no support.
[0122] Referring to FIGS. 13A-13C, gripper brackets 156 are used in
conjunction with hose clamps to grip the cable passing through a
hole in the end plate. The slots 158 in the bracket allow for
adjustment to different cable diameters. The bracket is held in
place by a self-tapping screw 160 driven into the face of the end
plate. The teeth 162 around the perimeter of the bracket are driven
into the jacket of the cable by the force of the hose clamps. One
central tooth 164 is provided in the center of the bracket for
gripping smaller diameter cables.
[0123] If preferred, the gripping bracket 156 can be modified to
include an extender bracket 157 to extend the length of the slot
159 in the bracket (see FIGS. 13A, 13B, and 13C). The screws 160
(FIG. 12A) serve as pins on which the gripping bracket can be slid
to adjust for different cable diameters. Once the gripping bracket
is located to the proper diameter, the screw is tightened to
maintain the gripping bracket location. Once the cables are
installed into the end plate and the gripper brackets 156 are
located, a hose clamp (not shown) is placed around the diameter of
the cable on top of the gripper brackets. As the hose clamp is
tightened, it forces the teeth on the gripper bracket 156 to embed
into the cable sheath. This gripping condition provides strength to
retain the cable in the event an axial load would be imposed on the
cable.
[0124] A torque bar bolt 170 is used for attachment to the torque
bar 110. The bolt is passed through a cylindrical hole in the end
plate and the square head is contained in a square pocket. The bolt
is held in place by an e-clip 172 slipped over the threads. The
torque bar 110 is slipped over the bolt 170 and a jam nut is used
to fasten the torque bar in place. The square pocket containing the
bolt head eliminates rotation during tightening. This approach
eliminates the need for insert molding. If the threads of the bolt
are damaged, the bolt can be easily replaced without scraping out
the entire end plate section.
[0125] Mastic bead grooves 180 (FIG. 15) are molded into the end
plate to provide channels through which excess mastic sealant
compound 220 on the end plate seam can flow as the end plate is
being assembled.
[0126] Referring to FIGS. 14A and 14B, an air/grounding insert 182
is a member which is preferably molded into place in the end plate.
The insert 182 acts as an aperture onto which a standard air valve
is selectively connected for inducing air into the splice
enclosure. The insert 182 can also be used for attaching electrical
grounding devices. The insert 182 is adapted to receive a one-way
check valve. The insert 182 is fabricated from metal. O-rings 183,
allow for variation in temperature and for bonding surrounding
plastic material to the O-ring to the metal. Heat from the plastic
forms a membrane wall between the plastic and metal insert, which
in turn stops air and water from leaking in or out. The O-ring
flexes with temperature and allows the plastic and metal to expand
or shrink. A pipe thread 184 within the insert provides the ability
to connect a valve for air injection or a plug for grounding
purposes.
[0127] Alternately, a ground extender 186 (FIG. 12A) is threaded
into the air/grounding insert 182 to provide a member on which to
connect a grounding braid. Fastening bolts 190 are required for
drawing the end plate sections together. Washers 192 are installed
below the head of the fastening bolts to provide a more durable
surface on which the bolt is rotated. The washers also helps
distribute the surface area over which the bolt load is applied.
The fastening bolt 190 has a stud area 193 to retain the bolt after
it is assembled into the end plate.
[0128] As the end plate sections are drawn together, mastic
displacement ribs 194 embed into the mastic sealing tape. This
causes a displacement of mastic sealing tape 224 (see FIG. 16A)
which in turn produces a seal around the circumference of the
cable, the face of the washers and the surfaces of the end
plate.
[0129] Sealing rings 200 (FIG. 12A) are molded on each of the end
plate sections which embed into the end plate sealing area on the
closure shells, thus forming an air-tight seal between the closure
shell and the end plates.
[0130] After the cables are installed into the end plate and the
gripper brackets 156 are located, a hose clamp (not shown) is
placed around the diameter of the cable on top of the gripper
brackets. As the hose clamp is tightened, it forces the teeth on
the gripper bracket 156 to embed into the cable sheath. This
gripping condition provides strength to retain the cable in the
event an axial load would be imposed on the cable.
[0131] Referring to FIG. 15, sealing washers 210 serve as barriers
to contain mastic sealant compound 220 within the opening for the
cable 230 of an end plate assembly. The inner diameter of the
washer 210 can be cut to compensate for a range of cable diameters.
The cutting process can be accomplished with the use of scissors or
another cutting device.
[0132] Referring to FIGS. 16A-16D, the craftsperson measures the
diameter of the cable to be installed into the closure with
measuring tape 240. This diameter measuring tape displays letters
corresponding to different cable diameters. The sealing washers 210
also display letters corresponding to the measuring tape. The cable
is measured to identify the letter to be cut and the craftsperson
starts the cutting process.
[0133] The craftsperson scuffs the cable 230 to remove any
imperfections in the cable jacket which have the potential to
create a leak path. A single circumferential wrap of cable prep
tape 222 is applied around the outer diameter of the cable (see
FIG. 16B). This layer of tape provides a highly tacky surface and
promotes a strong bond against the outer diameter of the cable. A
second layer of R-sealant or mastic 224 is then wrapped
circumferentially, until the outer diameter of the mastic being
wrapped is at least equivalent to the outer diameter of the
specific washer assembly being used (see FIG. 16A). The R-sealant
is a mastic compound formulated to promote re-entry into the
closure. Therefore, it is desirable for the R-sealant to be less
tacky. This two-ply combination provides the benefits of a more
consistent seal against the outer diameter of the cable without
sacrificing the ability to easily re-enter the end plate if
necessary. Existing closures use either all R-sealant or all
B-sealant (same as the cable-prep tape), but not a combination of
both.
[0134] Prior to assembly of the cable/washer/mastic system into the
end plate, the craftsperson uses the check gauge on the measure
tape 240 (see FIG. 16C) to ensure the proper amount of compression
will occur between the end plate and mastic. The tape is wrapped
around the mastic, and if the index line falls within the shaded
area indicated on the tape, the amount of compression is
acceptable. The check range is previously established by test data
which displayed cables that were under-wrapped or over-wrapped had
a higher potential for failure (loss of pressure).
[0135] Referring to FIG. 16D, the measure tape 240 is wrapped
around the R-sealant or mastic tape 224 to measure the amount of
compression of the mastic sealant 224 and the end plate. The index
line 226 is used to determine if the sealant has been applied to an
acceptable size. A check zone for the 2.2-inch diameter washer is
illustrated by cross-hatched lines 228. A check zone for the
3.4-inch diameter washer is shown as lines 232. A check zone for
the 2.8-inch diameter washer is shown as lines 234. If index line
226 falls outside of zone 234, an adjustment must be made to the
amount of sealant to bring it within the zone.
[0136] Referring to FIGS. 17A and 17B, two washer assemblies 213,
215 can be snapped onto a universal washer spool 250 via snaps 251,
253 for applications where a hole will not be used when the end
plate is initially installed. A pair of washer halves 211 and 217
are snapped together to form a single washer assembly. The washers
preferably are sized to desired outer diameters, including at least
1.0 inch, 1.6 inch, 2.2 inch, 2.8 inch, and 3.4 inch sizes. The
spool 250 provides a surface around which the mastic tape can be
wrapped. If the user needs to add a cable at this location, they
can disassemble the end plate, remove the spool/washer assembly,
remove the spool and re-use the washers to install a new cable. The
small diameter of the spool allows it to be used at all hole
locations.
[0137] Referring to FIG. 18, the washers are designed symmetrically
and can only be assembled in one direction. Upon assembly, an open
window 270 of each washer is closed off by the opposing washer,
thus creating a solid washer assembly. The formation of a hole is
achieved by passing the cutting device to be described below
through the open window 270 and cutting along a groove 246 labeled
with the letter corresponding to the measuring tape. A second
washer 217 is also required to be cut to the same size and the two
washers 211, 217 are snapped together to form the desired hole
size.
[0138] The washers 210 further include the cutting groove 246 to
create a guide for scissors or the cutting device. The groove 246
allows for the creation of a thinner section of the washer to be
created to ease cutting without sacrificing the strength of the
washer.
[0139] Receiving holes 252 of washer half 211 receive the snaps 254
from a mating washer half 217. The snaps features cantilever posts
256 which engage and lock into the receiving holes of mating washer
211.
[0140] Letter labels 260 correspond to a letter on the measuring
tape. The labels 260 provide a reference for the center line of the
cutting groove to be cut to form the proper hole size.
[0141] The thinner groove section of washer can be cut with
scissors if necessary. Thus, no special tools are required. In
comparison, existing end plate washers are thick solid disks with
concentric annular grooves which require a special tool for
cutting. One 360.degree. rotation of a cutting device through a
groove produces a properly sized hole through which the cable can
pass. The washer must be cut a second time from the outer diameter
to the inner diameter to create a split through which the cable can
be passed to the inner diameter. This cut (seam) creates a weak
point in the washer when it is assembled into the prior art end
plate. In the present invention, a cut seam 280 for each washer is
protected by the opposing washer thus not allowing a seam which
passes directly through the entire washer assembly. This is
beneficial over the prior art in that it eliminates a potential
leak path and strengthens the washer assembly. Washers can only
snap together one way thus minimizing operator error. Symmetrical
washer design reduces washer inventory. Furthermore, the washers
are re-usable.
[0142] The sealing washer end plate system eliminates the need for
custom hole size drilling during use of the cable closure. The end
plates are provided with pre-determined hole size patterns. As
previously discussed, the end plate configurations range from
having a single hole configuration to a three or more hole
configuration. In some field applications not all holes in a
multi-hole input design are used. Therefore, washers are used to
plug unused hole(s). The washers and spools allow one spool to be
used with any size hole. However, additional mastic compound is
needed for the universal spool to plug the unused hole.
[0143] An alternate method for plugging an end plate hole is to use
a plug wheel 282 to reduce the amount of mastic or sealing type
required to produce a seal on an unused hole. Referring to FIG. 19,
the alternate plug wheel is shown installed in one of the unused
holes on an end plate. There are a range of at least five different
hole sizes used with the end plates. In order to minimize the
amount of plugs required to seal the range of hole sizes, the plugs
have rings 283 which have outer diameter rings 284 and inner
diameter rings 285 separated by a groove 286 therein which are
located on opposite sides of a wheel or spool 287. As seen in FIGS.
20C and 20D, the plug wheel is usable with at least two different
holes sizes by providing a breakaway outer ring 284 as shown in
FIG. 20C adapted to be broken away to decrease the outer diameter
of the plug wheel. Thus, the plug wheel can be used for different
hole sizes therefore permitting the end user to inventory half the
amount of plugs. For smaller hole sizes, the outer diameter ring
284 is broken away from the inner diameter ring 285. For the larger
hole sizes, the outer rings are left attached as seen in FIG. 20D.
FIG. 19 shows the plug wheel with the outer rings attached
installed within the end plate. Mastic seal 288 is wrapped around
the inner diameter of the plug wheel as seen in FIG. 20A. As seen
in FIG. 20B, the groove 286 is machined into the ring to promote
the easy breakaway of the ring when the outer ring is stressed.
Less sealing tape or mastic is then required for sealing the plug
wheel whenever the smaller diameter plug is used. The spool 250
previously illustrated in FIG. 17A is used on the smallest hole
size i.e., the one inch diameter hole. If the sealing washer end
plate is required to be re-entered to use a previously plugged
hole, the plug wheel can be removed and reused in another end
plate.
[0144] Referring now to FIGS. 21 and 22, a washer cutter apparatus
300 is used to cut a hole in the center of each washer for allowing
various size cables to pass through the washer. The washer cutter
assembly comprises an enclosure or base 302, an enclosure or blade
housing or cap 310, threaded spacer 320, thumbscrew 330, lock
washer 340, flat washer 342, and cutting blade 350. Key features of
the assembly include parts are contained within the volume located
between the base or second enclosure and cap or first enclosure and
protected from loss or damage. The two enclosures are preferably
held together, such as with an acorn hex nut 360, during shipment
and storage. The base 302 is preferably formed of injection-molded
plastic. The primary function of the base is to provide a fixture
for retaining any one of five plastic disks used in the closure end
plate. Proper retention and rotational restriction of the disk are
necessary for properly cutting one of fifteen possible hole
diameters and also for safety of the person doing the cutting. Many
of the key features relating to the base are for this purpose.
[0145] The disk is securely held in place in the base and the
user's hand is shielded from the path of the cutting blade. The
base has two sides. Referring to FIG. 23, the first or top side 304
retains the 3.4, 2.2, and 1.0-inch diameter disks. In contrast, the
second or bottom side retains the 2.8 and 1.6-inch diameter disks.
This feature allows for enough support for the disk when cutting
that would not be available if all five were positioned on the same
side.
[0146] The base ribs 308 position the disk off of the flat base
surface. This allows the cutting blade tip additional clearance
below the disk such that it will not scour the base surface.
[0147] High ribs 309 nest between the spokes of the disk to help
prevent rotation of the disk during cutting. The disks are shaped
such that all but one of the open areas between the spokes have
been filled in with a thin structural web. For purposes of
clearness, only one of the five disks are shown with this web
removed (see FIG. 24). Because of this web, the ribs preferably
take on two heights: the tallest 309 (which fits through the open
area of the disk) and shortest 311 (which fits between the spoke
but under the adjoining web). The disks are cut with flush surface
in the up position and the grooved cutting channels in the down
position.
[0148] Referring to FIG. 23, a permanent positioning member or pin
370 has two purposes. The first is to help orient the disk in the
proper annular position within the base. The second is to provide
additional anti-rotation resistance when cutting. This pin is a
permanent feature for the 3.4-inch diameter disk 218 (FIG. 24)
which is mounted on the first side 304 and for the 2.8-inch
diameter disk which is mounted on the second side of the base.
[0149] Permanent pins are not used with smaller disks, e.g. the
2.2-inch disk, 1.6-inch disk, and 1.0-inch, because they would
interfere with the blade cutting path of the 3.4 and 2.8-inch
diameter disks. The 2.2-inch disk and 1.0 inch disk are installed
on the first side of the base. The 1.6-inch disk is installed on
the second side of the base. Therefore, five movable pins 380 are
molded into the base for use with these three smallest disks. These
pins are located in five of six extensions 390 located about the
base. Preferably, the extensions are formed as semi-circular ears
evenly spaced around the perimeter of the base. The user breaks one
of the pins loose and inserts it into the proper square hole 382
depending on the disk to be cut. If one of the two largest disks
needs to be cut, then the pin may be removed from hole 382 and
placed in a storage hole 384 in the semicircular ear.
[0150] The ears 390 provide a grip for the user when the cap
holding the blade is turned to cut the disk. As previously
discussed, one of the ears is also used to house and protect the
movable positioning pin 380 and to provide storage for one pin
after use. A side opening 392 of each ear is designed to allow the
insertion of a tool or digit to help remove the largest disk. This
is not required for the other four disks.
[0151] The circular overall shape and construction of the base and
the inner ring sections provide a path 394 for the cap to travel
in.
[0152] A pair of alignment ribs 400, 402 are provided on each side
of the base of the alignment ribs to properly position the blade in
the cap relative to the base. Referring to FIG. 24, a groove 404 on
the cap is positioned in an aligned relationship with the rib(s)
400, 402 on either side for this alignment. The alignment ensures
that the cutting blade properly passes through the open window in
the washer prior to cutting and, thus, eliminates damaging the
cutting blade.
[0153] Surface 410 at the center of the base provides a reliable
bearing surface on which the threaded spacer 320 will ride.
[0154] The blade housing 310 is also preferably made of
injection-molded plastic and is used to position and retain the
cutting blade. Referring to FIG. 22, handle 420 is ergonomically
designed to approximate the curvature and fit of the average user's
hand. Crisscross ribs 430 provide strength as well as additional
surface are to alleviate the stress felt by the hand of the user.
Straight ribs 440 provide strength in the blade area and additional
support for the hand of the user. The swale in the middle of the
handle is designed to allow access to the thumb screw.
[0155] Referring to FIG. 25, the handle also houses the blade
member 350. The blade 350 can only be inserted in line with two
indexing ribs. The blade member 350 includes an elongated member
351 with slot 352 and a bent blade 353 at one end of the blade
member. Once inserted, the blade is slid to the other side of the
handle where it is held in place by two horizontal ribs. The blade
is slid with respect to the thumb screw 330 which extends through
slot 352. The blade is placed in an approximate position by
aligning the edge of the blade with one of the letters 460 in the
cap corresponding to the hole size needed to be cut. The blade is
then secured by tightening the thumb screw 330, which compresses
the threaded spacer 320 and external-toothed lock washer 340. The
blade can be installed in only one direction.
[0156] Grooves 470 in the top of the cap 310 stiffen the structure
and provide clearance for the snaps 254 of each washer disk. The
alignment groove 404 located on the outside of the cap is used to
properly line up the blade with the disk and base. The user lines
up this groove with the corresponding alignment rib on either side
of the base.
[0157] The blade 350 is shaped to work best in conjunction with the
corresponding disks. The two notches 450, 452 in the elongated
member 351 of the blade are for aligning the ribs in the handle
of-the cap. Referring to FIG. 26, the blade is positioned to the
proper cutting diameter by aligning the end of blade with a
corresponding letter 460 and is secured in position by tightening
the thumb screw and threaded spacer.
[0158] The washer cutter is used in the following manner. First,
the thumb screw is loosened. Second, the blade is positioned to
proper position using letter indices. The blade is slid along the
thumbscrew in the slot 352. The thumb screw is moderately
tightened. The desired diameter washer is placed on the threaded
spacer in the cap, with washer grooves pointing toward viewer. The
thumb screw is loosened and repositioned slightly so the blade is
in center of disk groove, if necessary. The thumb screw is then
tightened. The washer is then removed. The washer is then placed in
the proper base location and is held in place by a positioning pin.
The cap is joined with the base lining up the alignment rib(s) and
groove. The halves are positioned concentrically. The cap is turned
or rotated in a clockwise direction. After completing one turn, the
halves are separated and the cut washer is removed. The cut center
section of the washer is then discarded.
[0159] The invention has been described with reference to the
preferred embodiments. Obviously, alterations and modifications
will occur to others upon a reading and understanding of this
specification. It is intended to include all such modifications and
alternations insofar as they come within the scope of the appended
claim or the equivalents thereof.
* * * * *