U.S. patent application number 10/817562 was filed with the patent office on 2005-10-13 for flexible cable container payout tube.
Invention is credited to Miller, Lisa K., Reif, Gary.
Application Number | 20050224615 10/817562 |
Document ID | / |
Family ID | 35059569 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050224615 |
Kind Code |
A1 |
Miller, Lisa K. ; et
al. |
October 13, 2005 |
Flexible cable container payout tube
Abstract
A payout tube for containers that is used to package and store
continuous lengths of materials is described. The payout tube is
configured with a high degree of flexibility. With this
flexibility, the continuous lengths of material (like communication
cables) do not kink or tangle when being removed from the storage
container through the payout tube. The payout tube can be provided
with this flexibility by eliminating the rigidity of the payout
tube without destroying the structure of the tube, such as by
forming slots or corrugations in the portion of the payout tube
that needs to be flexible.
Inventors: |
Miller, Lisa K.;
(Hoisington, KS) ; Reif, Gary; (Hoisington,
KS) |
Correspondence
Address: |
STEVEN L. NICHOLS
RADER, FISHMAN & GRAVER PLLC
10653 S. RIVER FRONT PARKWAY
SUITE 150
SOUTH JORDAN
UT
84095
US
|
Family ID: |
35059569 |
Appl. No.: |
10/817562 |
Filed: |
April 1, 2004 |
Current U.S.
Class: |
242/171 |
Current CPC
Class: |
B65H 57/12 20130101 |
Class at
Publication: |
242/171 |
International
Class: |
B65H 057/18 |
Claims
1. A payout tube for a storage container, the payout tube
comprising: an elongated conduit with a flexible portion wherein
the flexible portion of the payout tube is designed to be placed in
an interior of the container.
2. (canceled)
3. The payout tube of claim 1, wherein the payout tube also
contains a portion that is designed to be exterior to the
container.
4. The payout tube of claim 1, wherein the flexible portion can
bend or flex in an angle ranging from about 1 degree to about 120
degrees.
5. The payout tube of claim 4, wherein the flexible portion can
bend or flex in an angle ranging from about 5 to about 90
degrees.
6. The payout tube of claim 1, wherein the storage container
includes a continuous length of material comprising communication
wires and cables, building wires and cables, electrical wires,
steel strands, tire cords and cables, ropes, and tubing.
7. The payout tube of claim 1, wherein the flexible portion
comprises a plurality of slots.
8. The payout tube of claim 7, wherein the number and size of slots
are relative to the desired flexibility and required strength of
the payout tube.
9. The payout tube of claim 7, wherein the shape of the slots are
substantially circular, rectangular, square, triangular, polygonal,
or a combination thereof.
10. The payout tube of claim 7, wherein the slots are located along
the entire length of the flexible portion or only a part
thereof.
11. The payout tube of claim 1, wherein the flexible portion
comprises corrugations.
12. The payout tube of claim 11, wherein the corrugations are
located along the entire length of the flexible portion or only a
part thereof.
13. A device for removing a continuous length of material from a
storage container, the device comprising: an elongated conduit with
a flexible portion wherein said flexible portion is designed to be
placed in an interior of the container.
14. (canceled)
15. The device of claim 13, wherein the device also contains a
portion that is designed to be exterior to the container.
16. The device of claim 13, wherein the flexible portion can bend
or flex in an angle ranging from about 1 degree to about 120
degrees.
17. The device of claim 16, wherein the flexible portion can bend
or flex in an angle ranging from about 5 to about 90 degrees.
18. The device of claim 13, wherein the flexible portion comprises
a plurality of slots.
19. The device of claim 18, wherein the slots are located along the
entire length of the flexible portion or only a part thereof.
20. The device of claim 13, wherein the flexible portion comprises
corrugations.
21. The device of claim 20, wherein the corrugations are located
along the entire length of the flexible portion or only a part
thereof.
22. A storage container for a continuous length of material, the
container comprising: a payout tube having an elongated conduit
with a flexible portion wherein said flexible portion of said
payout tube is designed to be placed in an interior of the
container
23. A system for removing a continuous length of material from a
storage container, the system comprising a device comprising an
elongated conduit with a flexible portion through which the
continuous length material is removed wherein said flexible portion
is designed to be placed in an interior of the container.
24. A method for removing a continuous length of material from a
storage container, the method comprising: providing a payout tube
having an elongated conduit with a flexible portion wherein said
flexible portion is designed to be placed in an interior of the
container; and removing a portion of the continuous length or
material from the storage container through the payout tube.
25. The method of claim 24, including providing the payout tube in
a wall of the storage container.
26. The method of claim 25, wherein the flexible portion of the
payout tubes bends towards the direction at which the continuous
length material enters the payout tube.
27. The method of claim 24, wherein the flexible portion bends or
flexes in an angle ranging from about 1 degree to about 120
degrees.
28. The method of claim 27, wherein the flexible portion bends or
flexes in an angle ranging from about 5 to about 90 degrees.
29. The method of claim 24, wherein the continuous length of
material does not substantially kink or tangle while being removed
from the storage container.
30. A method for providing a continuous length of material, the
method comprising: packaging a continuous length of material in a
storage container, the container comprising a payout tube having an
elongated conduit with a flexible portion wherein said flexible
portion is designed to be placed in an interior of the container;
and removing the continuous length of material from the storage
container through the payout tube.
31. The method of claim 30, wherein the flexible portion of the
payout tubes bends towards the direction at which the continuous
length of material enters the payout tube.
32. The method of claim 31, wherein the flexible portion can bend
or flex in an angle ranging from about 1 to about 120 degrees.
33. The method of claim 32, wherein the flexible portion can bend
or flex in an angle ranging from about 5 to about 90 degrees.
Description
FIELD OF THE INVENTION
[0001] This invention generally relates to voice, video and data
communication cables. More particularly, the invention relates to
storage containers for communication cables and methods for
removing the cables from these storage containers. Even more
particularly, this invention relates to flexible payout tubes for
storage containers and methods for using the flexible tubes when
removing the cable from the storage containers.
BACKGROUND OF THE INVENTION
[0002] Communication cables are generally used to transmit a
variety of signals, including voice, video, and data signals. Each
cable typically contains a single or multiple strands of a
transmission media (e.g., conductor often made of copper) coated
with an insulating material. The communication cables are generally
packaged, stored, and shipped in storage containers, such as cable
boxes or cartons.
[0003] The current practice in packaging cables is to coil the
cables in a "figure eight" configuration in the storage container
to reduce twisting of the wire as it is coiled. This configuration
has the added benefit of reducing the tendency of the cable to kink
as it is pulled from the container (typically through an opening in
one of the walls of the container). The process of pulling the
cable from the container can be facilitated by using a payout tube
that extends into the container. The payout tube can be affixed or
attached to a wall of the container so a portion also extends
outside of the carton.
[0004] There are numerous types and configurations of payout tubes.
As well, there are numerous types and configurations of mechanisms
used to attach the payout tubes to the wall of the container. See,
for example, U.S. Pat. Nos. 4,009,845, 4,022,399, 4,057,204,
4,274,607, 4,373,687, 5,042,739, 5,150,852, 5,152,476, 5,368,245,
5,520,347, 5,810,272, and 6,328,238, the disclosures of which are
hereby incorporated by reference. Most payout tubes currently used
are hollow elongated cylinders that are fairly rigid. As
illustrated in FIG. 1, these rigid tubes 1 often cause the cable 2
to hang up or tangle, making it difficult to pull the cable 2 from
the container. In some cases, the cable 2 kinks 3 so severely that
the container has to be opened to free the cable.
[0005] There have been many attempts to configure the payout tubes
to eliminate such kinking and tangling. Some of these attempts have
caused the design of the tubes to be enlarged, increasing the size
of the storage container and the payout tube. The added size also
increases the cost, decreases the number of containers that can be
shipped on a given pallet, and yet does not completely eliminate
the kinking and tangling. Other problems have also existed with
these attempts, such as degradation of electrical results.
SUMMARY OF THE INVENTION
[0006] The invention provides a payout tube for containers that are
used to package and store communication cables. The payout tube is
configured with a high degree of flexibility. With this
flexibility, the communication cable does not kink or tangle when
being removed from the storage container through the payout tube.
The payout tube can be provided with this flexibility by
eliminating the rigidity of the payout tube without destroying the
structure of the tube, such as by forming slots in the portion of
the payout tube that needs to be flexible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIGS. 1-4 are views of several aspects of the payout tubes
and methods for making and using the same according to the
invention, in which:
[0008] FIG. 1 shows a prior art device and the accompanying
problems with its use;
[0009] FIG. 2 shows the use of a payout tube in one aspect of the
invention;
[0010] FIG. 3 depicts a close-up view of a payout tube in one
aspect of the invention; and
[0011] FIG. 4 shows a close-up view of the use of a payout tube in
another aspect of the invention.
[0012] FIGS. 1-4 illustrate specific aspects of the invention and
are a part of the specification. Together with the following
description, the Figures demonstrate and explain the principles of
the invention and are views of only particular--rather than
complete--portions of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The following description provides specific details in order
to provide a thorough understanding of the invention. The skilled
artisan, however, would understand that the invention can be
practiced without employing these specific details. Indeed, the
present invention can be practiced by modifying the illustrated
cables and methods and can be used in conjunction with apparatus
and techniques conventionally used in the industry. For example,
the invention is described below for communication cables, but
could be used with any type of cable or wire that is extracted from
a storage container using a payout tube.
[0014] As noted above, the invention contains a flexible payout
tube that is used when extracting cable from a storage container.
In one aspect, the invention is used with the payout tubes and
storage containers cable illustrated in the Figures. Of course, the
invention could be used with other payout tubes and storage
containers, so long as the desired degree of flexibility can be
provided.
[0015] FIG. 2 shows a payout tube 5 that has been placed in a wall
10 of a storage container 50. The payout tube 5 of the invention
can be used with any known storage container in the art. Examples
of such storage containers include cartons, cardboard boxes, boxes,
buckets, bags, and the like. In one aspect of the invention, the
payout tube is used in combination with a cardboard box as the
storage container. As well, although illustrated as a cylinder with
a substantially circular cross-section, other cross-sections and
shapes can be used for the payout tube.
[0016] The communication cable 55 is stored in the storage
container for packaging and shipping of the cable. Generally, the
cable 55 is wound in any configuration that maintains the integrity
of the cable while maximizing the amount of cable within the
storage container. Typically, the cable is wound in a "figure
eight" configuration in the storage container.
[0017] As shown in FIG. 2, the payout tube 5 is mounted to the wall
of the storage container by any suitable means known in the art.
Examples of such means include a locking snap ring, cardboard
inserts, tabs, as well as the means described in the patents
referenced above.
[0018] In one aspect of the invention, and as shown in FIG. 2, the
mounting means is a flange 20 and opposed tabs 25. The flange 20 is
located on the inner side of the wall 10 of the storage container
while the tabs 25 are located on the exterior of the wall 10. The
purpose of the flange 20 and the tabs 25 is to mount the payout
tube 5 on the wall 10 of the storage container 50, as well as to
lock the payout tube 5 in place. Any configuration for the flange
20 and tabs 25 that accomplishes that function can be used in the
invention. In one aspect of the invention, the tabs and flange are
configured as illustrated in FIG. 3.
[0019] The payout tube 5 is mounted into the storage container by
sliding the front end 30 of the payout tube through a pre-existing
hole in the wall 10. The payout tube slides through the hole until
flange 20 substantially abuts the inner side of the wall. The tabs
are configured so that they slide through the hole when the payout
tube is inserted into the wall and then extend and abut the
exterior of the wall. With the flange 20 and tabs 25 abutting the
interior and exterior of the wall 10, their combination serves to
substantially lock the payout tube in place in the wall. In one
aspect of the invention, a snap ring (not shown) can be placed
between the tabs 25 and the wall 10 of the storage container to aid
in locking the payout tube in place relative to the wall 10.
[0020] The back end 35 of the payout tube 5 remains in the interior
of the storage container 50. In such a position, the cable is
extracted from the storage container through the back end 35 of the
payout tube 5, through the wall 10, and then through the front end
30 of the payout tube. Provided the payout tube 5 operates as
described herein, the front end 30 and the back end 35 can be made
either longer or shorter than as described and illustrated
(typically about 2 and about 8 inches, respectively). In one aspect
of the invention, this distance can range from about 1 to about 20
inches. As well, the diameter of the payout tube can be either
wider or narrower than as described (typically from about 11/2
times the material outer diameter (O.D.) to about 20 times the
material O.D.) and illustrated (about 3/4 inch inner diameter). In
one aspect of the invention, this diameter can range from about 3
to about 5 times the material O.D.
[0021] The back end 35 of the payout tube 5 is configured to
increase the flexibility of the payout tube 5 when compared to
known payout tubes. As described above, conventional payout tubes
are rigid and are not very flexible. When the cable is pulled from
the storage container, the cable enters the payout tube from many
angles (i.e., because of the "Figure 8" configuration in which the
cable is stored in the container). Since the payout tube does not
bend or flex, the cable becomes tangled or kinked on the end of the
payout tube as shown in FIG. 1.
[0022] Using the invention, the flexibility of the back end of the
payout tube is increased. Thus, when the cable enters the payout
tube, the tube bends and flexes towards the direction at which the
cable enters the payout tube. The net result is that kinking and
tangling of the cable is reduced or eliminated in most instances
since the angle at which the cable enters the payout tube is fairly
small.
[0023] The amount of increased flexibility that can--needs to--be
provided depends on the configuration of the cable within the
storage container, and the material used to make the payout tube
(e.g., polyethylene, polypropylene, ABS, cardboard, steel, wood,
and any other material conventionally used in the art of reel &
spool making). In one aspect of the invention, the payout tube of
the invention can bend or flex in a radius ranging from 1 to about
120 degrees. In another aspect of the invention, the payout tube of
the invention cab bend or flex in a radius from about 5 degrees to
about 90 degrees.
[0024] The increased flexibility for the back end of the payout
tube can be provided using any known mechanism. Examples of such
mechanisms include using more flexible materials in constructing
the payout tube, increasing the flexibility in the wall of the
storage container or mounting fixture (i.e. ball and socket), as
well as the mechanism described below. In one aspect of the
invention, and as illustrated in FIG. 4, the flexibility can be
provided using corrugations 45 in the payout tube 5. The width,
length, number, and placement of the corrugations 45 depend on the
material used, the process of making the corrugations,
(interlocking or ribbed), the desired flexibility, the length of
the back end 35, the type of corrugations (ribbed, wavy, uneven, or
flexible joints), and the type of locking mechanism. In one aspect
of the invention, the corrugations 45 can be placed along the
entire length (or only a portion) of the back end 35 in any desired
density.
[0025] In another aspect of the invention and as illustrated in
FIG. 3, the flexibility can be provided using a plurality of slots,
holes, grooves, discontinuities, or a combination thereof
(hereinafter "slots" 40) in the payout tube 5. The size, shape,
number, configuration, pattern, and placement of the slots 40
depend on the material used, the process of making the slots, the
desired flexibility, the length of the back end 35, length of tube
5 and the strength needed for the package material. For example,
the number of slots 40 should be relative to the desired
flexibility and required strength of the payout tube 5. The shape
of the slots 40 can be substantially rectangular, circular, square,
polygonal, triangular, or a combination thereof. The slots 40 can
be placed along the entire length (or only a portion) of the back
end 35 of the payout tube 5 in any desired density.
[0026] In the aspect of the invention illustrated in FIG. 3, the
back end 35 of the payout tube 5 is made flexible. In another
aspect of the invention, the front end 30 can also--or instead
of--be made flexible in a similar manner. Making the front end 30
also flexible is usually desired where the front end 30 of the
payout tube 5 extends a distance from the wall that would cause the
cable to kink or tangle, i.e., greater than about 1.5 times the
cross sectional distance of the continuous length material.
[0027] The payout tubes of the invention can be made in any process
that results in the structure described and illustrated herein. In
one aspect of the invention, the payout tube is purchased "off the
shelf" (i.e., EZ Tubes from Windings, Inc.) and the slots are then
formed by any suitable method. Examples of methods for forming the
slots include mill cutting processes, punch-out processes, torch,
drill, graft, or flexible tube abrasive cutting.
[0028] In another aspect of the invention, the flexible payout
tubes of the invention are made using an extrusion or molding
process as known in the art. In the invention, however, the mold
for the extrusion or other molding contains corresponding
components for forming the slots rather than a smooth surface.
Thus, when the molding process is completed, the payout tube will
contain the slots.
[0029] Using the flexible payout tube of the invention provides
several advantages. First, by making the tube flexible, the storage
container size and the packaging costs can be reduced. This
reduction can also lead to an increased pallet quantity, i.e., more
storage containers can be fit on a pallet that is used in shipping.
Another advantage is that the flexible payout tube also does not
degrade performance (i.e., electrical or physical) of the cables by
reducing or eliminating damage of the cable as it is pulled from
the storage container. Finally, less force is required to pull the
continuous length of material from the storage retainer, thereby
maintaining the physical properties of the cable at a maximum.
[0030] The invention could be also be used for any continuous
length of material that is packaged in a storage container and then
removed through a hole in the wall. Example of such materials
include communication wires and cables, building wires and cables,
electrical wires, steel strands, tire cords and cables, ropes, and
tubing.
[0031] Having described these aspects of the invention, it is
understood that the invention defined by the appended claims is not
to be limited by particular details set forth in the above
description, as many apparent variations thereof are possible
without departing from the spirit or scope thereof.
* * * * *