U.S. patent application number 12/984181 was filed with the patent office on 2012-07-05 for system for storing a bulk supply of cable for controlled payout and method of using the system.
Invention is credited to Randy Blunt, Kevin Coldani.
Application Number | 20120168554 12/984181 |
Document ID | / |
Family ID | 46379893 |
Filed Date | 2012-07-05 |
United States Patent
Application |
20120168554 |
Kind Code |
A1 |
Blunt; Randy ; et
al. |
July 5, 2012 |
SYSTEM FOR STORING A BULK SUPPLY OF CABLE FOR CONTROLLED PAYOUT AND
METHOD OF USING THE SYSTEM
Abstract
A system and method for storing a wrapped supply of cable for
controlled payout. A container has a peripheral wall bounding a
storage space, a top and a bottom. A support assembly is provided
on the container for the supply of wrapped cable through which the
supply of wrapped cable, operatively placed within the storage
space, can be turned guidingly within the storage space around a
first axis. The peripheral wall has an opening through which cable
from the wrapped supply operatively placed in the storage space can
be directed and drawn to cause the operatively placed supply of
wrapped cable to turn around the first axis and thereby cause cable
to be controllably paid out.
Inventors: |
Blunt; Randy; (Mesa, AZ)
; Coldani; Kevin; (Murrieta, CA) |
Family ID: |
46379893 |
Appl. No.: |
12/984181 |
Filed: |
January 4, 2011 |
Current U.S.
Class: |
242/588.2 ;
242/588.3; 242/595 |
Current CPC
Class: |
B65H 57/18 20130101;
B65D 85/04 20130101; B65H 49/325 20130101; B65H 49/322
20130101 |
Class at
Publication: |
242/588.2 ;
242/595; 242/588.3 |
International
Class: |
B65D 85/676 20060101
B65D085/676; B65H 49/20 20060101 B65H049/20 |
Claims
1. A system for storing a wrapped supply of cable for controlled
payout, the system comprising: a container having a peripheral wall
bounding a storage space, a top and a bottom; and a support
assembly on the container for a supply of wrapped cable through
which a supply of wrapped cable operatively placed within the
storage space can be turned guidingly within the storage space
around a first axis, the peripheral wall having an opening through
which cable from a wrapped supply operatively placed in the storage
space can be directed and drawn to cause an operatively placed
supply of wrapped cable to turn around the first axis and thereby
cause cable to be controllably paid out.
2. The system for storing a supply of cable according to claim 1
wherein the peripheral wall has a cylindrical configuration with a
central axis that is substantially coincident with the first axis
and extends between the top and bottom of the container.
3. The system for storing a supply of cable according to claim 1 in
combination with a supply of wrapped cable operatively
placed/stored within the storage space.
4. The system for storing a supply of cable according to claim 3
wherein the peripheral wall has a top opening through which the
supply of wrapped cable can be directed to be operatively placed
within the storage space and the container has a bottom wall and
further comprises a lid that is removably attached to the
peripheral wall to selectively block the top opening.
5. The system for storing a supply of cable according to claim 4
wherein the support assembly comprises at least one guide component
on the bottom wall.
6. The system for storing a supply of cable according to claim 5
wherein the support assembly comprises at least another guide
component on the lid and the one and at least another guide
components cooperatively guide the operatively placed supply of
wrapped cable in movement around the first axis.
7. The system for storing a supply of cable according to claim 6
wherein the supply of wrapped cable comprises a reel with a core
around which the cable is wrapped.
8. The system for storing a supply of cable according to claim 7
wherein the reel comprises spaced flanges that bound a storage
region for cable around the core.
9. The system for storing a supply of cable according to claim 1
wherein the container further comprises a repositionable handle
that can be grasped by a user to lift and transport the
container.
10. The system for storing a supply of cable according to claim 1
wherein the peripheral wall opening is elongate in a direction
along the first axis, the storage space has an axial extent along
the first axis, and the opening extends over a majority of the
axial extent of the storage space.
11. The system for storing a supply of cable according to claim 1
in combination with at least one storage tray that is operatively
mounted within the storage space.
12. The system for storing a supply of cable according to claim 1
wherein the peripheral wall is made from molded plastic.
13. The system for storing a supply of cable according to claim 1
wherein the container is in the form of a standard paint container
with one of a 5 gallon or a 7 gallon capacity.
14. The system for storing a supply of cable according to claim 1
wherein there is at least one wheel on the container that can be
rolled against a subjacent surface to facilitate repositioning of
the system.
15. The system for storing a supply of cable according to claim 1
wherein there is a shoulder strap on the container that can be
engaged by a user to facilitate transportation of the system by a
user.
16. The system for storing a supply of cable according to claim 7
wherein the core has a surface that bears against part of the
support assembly to guide turning movement of the supply of wrapped
cable around the first axis.
17. The system for storing a supply of cable according to claim 16
wherein the core surface bears against part of the support assembly
on the lid to guide turning movement of the supply of wrapped cable
around the first axis.
18. The system for storing a supply of cable according to claim 3
wherein a frangible sheet layer is applied around the supply of
wrapped cable to confine the cable and the sheet layer is
progressively ruptured as the cable is controllably paid out from
the storage space.
19. The system for storing a supply of cable according to claim 1
in combination with at least one pouch for a plurality of discrete
objects that is releasably supported upon the container.
20. The system for storing a supply of cable according to claim 1
wherein the container has a bottom wall with a plurality of
discrete support feet projecting therefrom.
21. The system for storing a supply of cable according to claim 1
wherein the opening is bounded by an edge defined at least in part
by a material with high friction characteristics that resists
guided sliding movement of wire extending outwardly through the
opening inwardly back into the storage space.
22. The system for storing a supply of cable according to claim 4
wherein the lid is releasably snap fit to the peripheral wall.
23. The system for storing a supply of cable according to claim 8
wherein the system further comprises a brake assembly on the
container through which a variable friction force can be applied to
at least one of the spaced flanges to resist turning of the supply
of wrapped cable around the first axis.
24. The system for storing a supply of cable according to claim 3
wherein the cable is coaxial cable.
25. A method of storing and controllably paying out cable from a
wrapped supply of the cable, the method comprising the steps of:
providing a container with a storage space bounded by a cylindrical
peripheral wall and a bottom wall and having an open top that is
selectively blocked by a lid; directing a supply of wrapped cable
through the open top into the storage space so that the supply of
wrapped cable is operatively placed and cooperates with the
container to allow the supply of wrapped cable to be turned
guidingly within the storage space around a first axis; directing
the cable from within the storage space through the peripheral
wall; and pulling the cable extended through the peripheral wall to
thereby cause the supply of wrapped cable to turn around the first
axis and thereby cause cable to be controllably paid out through
the peripheral wall.
26. The method of storing and controllably paying out cable
according to claim 25 wherein the cable is coaxial cable.
27. The method of storing and controllably paying out cable
according to claim 25 wherein the first axis extends between the
bottom wall and open top.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to bulk cable storage and, more
particularly, to a system that allows controlled payout of cable
from a stored supply thereof. The invention is also directed to a
method of using such a system.
[0003] 2. Background Art
[0004] The continuing evolution of the cable industry, and increase
in the number of cable users, bring with them the need for
additional and efficient installation and after-sale maintenance
capability. The challenging economy has placed even greater demands
upon installers who are even further challenged by an increasing
number of entities vying for such business.
[0005] Installers working in the cable industry are routinely
required to visit multiple field sites in a given day for purposes
of performing installations and/or effecting repairs or
maintenance. These installers will typically equip themselves with
a supply of tools and components that will address all anticipated
demands for at least an entire day. Unforeseen field conditions may
necessitate use of special components, such as connectors, and
tools through which such connectors and other components are
installed.
[0006] To compete in this industry, it is important that installers
be able to complete work on any given site within as short as
possible a visit time. Return trips to a site, if great enough in
number, may significantly adversely affect profits and could
conceivably lead to the demise of an entity if not adequately
limited.
[0007] To meet the above objectives, installers may stock their
vehicles each day with a multitude of tools and components to
hopefully address every field condition that will be encountered.
While this approach addresses on-site versatility, it introduces
another problem that may also reduce efficiency. That is, by
keeping on hand so many different tools and components, an
installer is challenged to control their accessibility so that they
can be readily located and retrieved for use on a job site.
[0008] Cable installers will commonly use vans, or like vehicles,
to transport their materials from one site to the next. While such
vans have a substantial storage capability, access to different
regions of the van to retrieve particular components may not be
convenient. Further, as a practical matter, it is difficult, if not
impossible, to strategically place components in a van so that they
can be efficiently accessed as needed. Thus, time may be wasted in
searching for a needed component. Oft times, an installer may have
a needed component in such a vehicle but may not be able to locate
the same. This may necessitate a follow-up visit or an attempt to
jury rig available components that may result in a compromised
installation.
[0009] Field installations commonly demand substantial lengths of
coaxial cable. Conventionally, coaxial cable, and other types of
cable, are stored in bulk by forming the wire independently into a
coil or wrapping it directly against a core on a reel. With reels,
spaced end flanges confine the cable to the core with the volume
capacity dictated by: a) the radial space between the flanges and
core; and b) the axial space between end flanges. Wrapped cable
tends to pay off a reel in a relatively straight form and thus
reels are desirable for this reason.
[0010] Wrapped coaxial cable generally will have sufficient memory
that it tends to unwind from a wrapped state, whether pre-coiled or
wrapped around a core. To address this problem, typically two
different approaches are taken, which are described hereinbelow for
a supply of cable wrapped directly against a core on a reel, but
apply as well to a pre-coiled wire supply that is slid onto a
core.
[0011] With one approach, the free end of the cable is fixed in
place as by taping or stapling the end to the reel or underlying
turns. While this approach is effective for purposes of
transporting unused bulk supplies, once the free end of the cable
is released, an unraveling problem presents itself. This unraveling
condition may result in significant amounts of the cable paying off
on its own, as a result of which the cable may entangle with other
proximate objects. Alternatively, the turns of the unraveling cable
may entangle to develop "birds' nests" at the reel whereupon paying
off of the cable as needed may be difficult or impossible.
[0012] To address the above problem, it is known to place the reel
with the wrapped cable supply thereon in a surrounding container.
Typically, the container will be a square box with dimensions
selected to nominally match that of the reel with the cable supply
thereon. This system is convenient from the standpoint that it
creates conveniently stackable units in which the wrapped cable is
for the most part confined upon the reel.
[0013] Different mechanisms are incorporated into this system to
allow access to the cable. In one system design, lid flaps are
opened. The cable is drawn off of one reel end through a space
between the upper flange and the surrounding container wall.
[0014] This system has certain drawbacks. First of all, it may be
difficult for the user to conveniently grasp the end of the cable
that may drop downwardly into the container. This may necessitate
partial or full separation of the reel from the container to gain
access to the cable end so that it can be drawn away from the
reel.
[0015] Further, by drawing the cable axially off the end of the
reel, the cable turns may bind and ultimately entangle,
particularly with certain winding patterns for the cable. When this
situation presents itself, the user may then again have to separate
the reel from the container to remedy the problem.
[0016] This problem is particularly prevalent in the absence of a
reel. Coiled wire tends to have set twists and turns that inhibit
smooth paying off of cable from the supply.
[0017] Another problem with using containers as described above is
that they are commonly made from cardboard material that has a
number of inherent limitations in this particular application. To
avoid unnecessary expense, the cardboard is commonly made with a
gauge and construction that does not add appreciably to the weight
of the overall system and can be inexpensively purchased or made.
After repeated uses, the container may begin to fall apart to the
point that the user will separate the reel and contend with the
above noted problems.
[0018] Untreated cardboard is also prone to deterioration in the
presence of moisture. Since installations are frequently carried
out in outside environments wherein rain and snow are experienced,
these containers are prone to progressive deterioration such that
they might eventually have to be separated from the reel before an
initial supply of cable is exhausted.
[0019] Further, once the supply of cable is exhausted, the
installer must appropriately dispose of the reel and container.
With the ever-increasing concern about environmental impact,
disposal of these components becomes a problem.
[0020] It is also known to treat the cardboard or paper containers
with an agent that repels moisture. While this addresses the
problem of deterioration due to exposure to moisture, it introduces
the additional problem that the container may be less
biodegradable.
[0021] Regardless of the nature of the cardboard material, it is
normally of a nature that it will readily collapse under forces
imparted during storage and/or use. Again, this may compromise the
ability to use the combined reel and container system.
[0022] Wooden reels are often used within boxes. Wooden reels can
be re-used; however, if used in conjunction with boxes, the above
problems are contended with, including that of discarding the
boxes, and the reel if the same is not practically re-usable.
Typically, such a reel will have non-biodegradable components.
While it is known to make a re-usable box, the above-noted problems
associated with a "reel-in-box" persist.
[0023] It is also known to use reels, as made from wood, without a
surrounding container. The reel can be supported on a pipe or dowel
for guided turning, as in a van compartment. While facilitating
cable payout, the user is limited to drawing the cable off from
within the van compartment. Portable caddies with spool guides have
been developed for small gauge wire and limited lengths of a larger
cable and are generally not practical to transport significant
quantities of cable, such as coaxial cable, that may be required on
a job.
[0024] Typically, as an installer arrives at a site, he/she will
accumulate the anticipated components required for performance of
all tasks at the site. The installer may take, for example, a box
of cable, a diverse supply of connectors, installation tools, and
electronic and other testing equipment. If needed components/tools
are not brought to the work location from the vehicle, repeated
trips to the vehicle may be necessitated.
[0025] The ability to strategically accumulate and store components
that will be needed challenges even the most experienced
installers. Generally, an installer will deal with the competing
objectives of minimizing back-and-forth maneuvering to a vehicle
and carrying only the necessary supplies from the vehicle to the
work site.
[0026] Further, there is often not a practical way to arrange
components in close quarters of a van compartment that allows an
efficient accumulation of components that an installer anticipates
will be needed. As noted above, the placement of these various
tools and components in a van may be such that significant amounts
of time are required for putting them together to transport from
the van to the site.
[0027] Still further, these small and loose components are
inherently difficult to transport in a convenient manner.
Containers with a large supply of cable may be heavy and awkward to
carry. Typically, the containers are required to be cradled in a
user's arms during transportation. This may preclude simultaneous
transportation of tools and other components that are needed.
[0028] Another problem that is contended with is that the
containers with reels of cable are often placed on the floor of the
transporting vehicle. It may be awkward for an installer to
conveniently position him/herself to grasp the underside of the
container to effect lifting. This may lead to fatigue after
repeated lifting and, in a worse case, injury.
[0029] The above problems have been contended with for decades in
spite of the need over this time period for efficiency and
convenience in terms of handling bulk supplies of wire, other
system components and tools on job sites.
SUMMARY OF THE INVENTION
[0030] In one form, the invention is directed to a system for
storing a wrapped supply of cable for controlled payout. The system
includes: a) a container having a peripheral wall bounding a
storage space, a top and a bottom; and b) a support assembly on the
container for a supply of wrapped cable through which a supply of
wrapped cable operatively placed within the storage space can be
turned guidingly within the storage space around a first axis. The
peripheral wall has an opening through which cable from a wrapped
supply operatively placed in the storage space can be directed and
drawn to cause an operatively placed supply of wrapped cable to
turn around the first axis and thereby cause cable to be
controllably paid out through the peripheral wall opening.
[0031] In one form, the peripheral wall has a cylindrical
configuration with a central axis that is substantially coincident
with the first axis and extends between the top and bottom of the
container.
[0032] In one form, the container is provided in combination with a
supply of wrapped cable that is operatively placed within the
storage space.
[0033] In one form, the peripheral wall has a top opening through
which the supply of wrapped cable can be directed to be operatively
placed within the storage space. The container has a bottom wall
and further includes a lid that is removably attached to the
peripheral wall to selectively block the top opening.
[0034] In one form, the support assembly has at least one guide
component on the bottom wall.
[0035] In one form, the support assembly has at least another guide
component on the lid. The guide components cooperatively guide the
operatively placed supply of wrapped cable in movement around the
first axis.
[0036] In one form, the supply of wrapped cable includes a reel
with a core around which the cable is wrapped.
[0037] In one form, the reel has spaced flanges that bound a
storage region for cable upon the core.
[0038] In one form, the container further includes a repositionable
handle that can be grasped by a user to lift and transport the
container.
[0039] In one form, the peripheral wall opening is elongate in a
direction along the first axis. The storage space has an axial
extent along the first axis and the opening extends over a majority
of the axial extent of the storage space.
[0040] In one form, at least one storage tray is operatively
mounted within the storage space.
[0041] In one form, the peripheral wall is made from molded
plastic.
[0042] In one form, the container is in the form of a standard
paint container with one of a 5 gallon or a 7 gallon capacity.
[0043] In one form, there is at least one wheel on the container
that can be rolled against a subjacent surface to facilitate
repositioning of the system.
[0044] In one form, there is a shoulder strap on the container that
can be engaged by a user to facilitate transportation of the system
by a user.
[0045] In one form, the core has a surface that bears against part
of the support assembly to guide turning movement of the supply of
wrapped cable around the first axis.
[0046] In one form, the surface bears against a part of the support
assembly on the lid to guide turning movement of the supply of
wrapped cable around the first axis.
[0047] In one form, a frangible sheet layer is applied around the
supply of wrapped cable to confine the cable and the sheet layer is
progressively ruptured as the cable is controllably paid out from
the storage space.
[0048] In one form, at least one pouch for a plurality of discrete
objects is releasably supported upon the container.
[0049] In one form, the container has a bottom wall with a
plurality of discrete support feet projecting therefrom.
[0050] In one form, the opening is bounded by an edge defined at
least in part by a material with high friction characteristics that
resists guided sliding movement of wire, extending outwardly
through the opening, inwardly back into the storage space.
[0051] In one form, the lid is releasably snap fit to the
peripheral wall.
[0052] In one form, the system further includes a brake assembly on
the container through which a variable friction force can be
applied to at least one of the spaced flanges to resist turning of
the supply of wrapped cable around the first axis.
[0053] In one form, the cable is coaxial cable.
[0054] The invention is further directed to a method of storing and
controllably paying out cable from a wrapped supply of the cable.
The method includes the steps of: providing a container with a
storage space bounded by a cylindrical peripheral wall and a bottom
wall and having an open top that is selectively blocked by a lid;
directing a supply of wrapped cable through the open top into the
storage space so that the supply of wrapped cable is operatively
placed and cooperates with the container to allow the supply of
wrapped cable to be turned guidingly within the storage space
around a first axis; directing the cable from within the storage
space through the peripheral wall; and pulling the cable extended
through the peripheral wall to thereby cause the supply of wrapped
cable to turn around the first axis and cable to be controllably
paid out through the peripheral wall.
[0055] In one form, the cable is coaxial cable.
[0056] In one form, the first axis extends between the bottom wall
and open top.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 is a perspective view of one form of system,
according to the present invention, including a container that
defines a storage space within which a wrapped supply of cable is
operatively place/stored and from which a free end of the cable
projects;
[0058] FIG. 2 is a cross-sectional view of the system taken along
line 2-2 of FIG. 1 and with a handle repositioned from a stored
position in FIG. 1 towards a lifting position;
[0059] FIG. 3 is a side elevation view of a reel around which the
cable within the storage space is wrapped;
[0060] FIG. 4 is a plan view of the reel in FIG. 3;
[0061] FIG. 5 is an enlarged, fragmentary, partial cross-sectional
view showing the cooperation between a guide component on a lid on
the container and one end of the reel;
[0062] FIG. 6 is a view as in FIG. 5 showing the cooperation
between another guide component on the container and the opposite
end of the reel;
[0063] FIG. 7 is an enlarged, fragmentary, elevation view showing a
high friction material disposed over an edge of an opening through
which cable is directed outwardly from the container storage
space;
[0064] FIG. 8 is a view of a reel as in FIG. 3 with a supply of
cable wrapped therearound and a frangible sheet disposed thereover
to prevent unraveling of the cable;
[0065] FIG. 9 is a schematic representation of a releasable
connection between a peripheral wall on the container and the lid,
as shown FIGS. 1 and 2;
[0066] FIG. 10 is a schematic representation of reel guide
components on a lid and bottom wall of a container according to the
invention;
[0067] FIG. 11 is an exploded, perspective view of a modified form
of system, according to the invention;
[0068] FIG. 12 is a perspective view of a further modified form of
system, according to the invention, and including a parts container
that is accessible with the lid separated as in this Figure;
and
[0069] FIG. 13 is a view as in FIG. 12 of a further modified form
of system, according to the invention, and including an optional
tool/parts apron and optional shoulder strap for lifting and
transporting the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0070] Referring initially to FIGS. 1-6, one form of system for
storing a wrapped supply of cable, for controlled payout thereof,
is shown at 10. The system 10 consists of a container 12 having a
peripheral wall 14 bounding an internal storage space 16. The
container 12 has a bottom wall 18, with a plurality of feet 20
thereon to engage a subjacent support surface 22 upon which the
container 12 bears to be operatively oriented, as shown in FIGS. 1
and 2. The peripheral wall 14 has a top opening 24 through which a
supply 26 of wrapped cable 28 can be directed to be operatively
placed within the storage space 16, as seen in FIG. 2. The
container further has a lid 30 that can be removably attached to
the peripheral wall 14, as through a snap fit connection, to
selectively cover/block and expose the top opening 24. The
peripheral wall 14 has a cylindrical configuration with a central
axis 32 that extends between the top and bottom of the container 12
and either a constant or tapered diameter between its axial
ends.
[0071] The cable supply 26 consists of a reel 34 made up of a
cylindrical core 36 with a central axis 38, and optional spaced,
disc-shaped flanges 40, 42 that project radially outwardly at the
axially opposite ends of the core 36. Each flange 40, 42 has a
diameter D. The cable supply might alternatively be provided with
only a core.
[0072] The supply 26 is formed by situating the wrapped cable 28
around the core 36 to partially or entirely fill the annular region
44 radially between the core outer surface 46 and the peripheral
edges 48, 50 of the flanges 40, 42, respectively, and axially
between the flanges 40, 42. The cable 28 can be pre-coiled and slid
axially over the core 36 or wrapped directly against the core
36.
[0073] In this embodiment, the core 36 and flange 42 are formed
together as an inseparable unit. The flange 40 is provided with a
stub component 52 that can be nested in a complementary receptacle
54 on the core 36. The stub component 52 and core 36 may be
releasably maintained together through frictional engagement, or
otherwise as by the use of cooperating threads. With this
arrangement, the flange 40 can be selectively separated from the
core 36 to allow the core end 56 to be directed through a
pre-coiled supply of cable 28. Alternatively, the cable 28 might be
wound directly against the core 36 to progressively accumulate the
cable therearound. It is also contemplated that the stub component
52 may be fixed permanently to the core 36, as through an
adhesive.
[0074] A support assembly is provided on the container through
which the supply 26 of wrapped cable 28, operatively placed within
the storage space 16 as shown in FIG. 2, can be turned guidingly
within the storage space 16 around the axis 32. The support
assembly consists of separate guide components 58, 60, respectively
on the bottom wall 18 and the lid 30 of the container 12. The guide
components 58, 60 each is in the form of a truncated cone
respectively with axes 66, 68 that are substantially coincident
with the lid 30 attached to the peripheral wall 14, as shown in
FIG. 1.
[0075] The guide components 58, 60 cooperate with the reel 34 at
its opposite ends. To interact with the guide components 58, 60,
the core 36 is provided with a central throughbore 70 with a
diameter D1 that is slightly greater than the diameters of the free
end surfaces 72, 74 of the guide components 58, 60, respectively.
The relative diameters of the throughbore 70 and surfaces 72, 74
are chosen so that the exemplary guide component 58 can be directed
into the bore 70 an axial distance X, at which point an annular
edge/surface 76 on the flange 42 will abut to the outer surface 78
of the guide component 58. The guide component 60 cooperates with
the reel 34 in the same manner at the reel flange 40.
[0076] With the supply 26 of wrapped cable 28 operatively placed
within the storage space 16 and the lid 30 attached, the
interaction of the guide components 58, 60 and the core 36, as
described above, causes the axes 66, 68 to be coincident with the
core axis 38, that is in turn coincident with the axis 32. The
components are relatively dimensioned so that with the lid 30
attached, the truncated cones 62, 64 and the guide components 58,
60 penetrate the bore 70 from axially opposite directions but are
not pressed against the core flanges 40, 42 with any significant
binding force, whereby the guide components 58, 60 support the
supply 26 of wrapped cable 28 so that it can be freely turned
guidingly within the storage space 16 around the axis 32.
[0077] The diameter of the radially inwardly facing surface 80,
bounding the storage space 16, is selected to be preferably larger
than diameter D (FIG. 3) so that the supply 26 of cable 28 can turn
without any interference between the supply 26 of cable 28 and
surface 80. To minimize the overall size of the container 12, the
surface 80 can be made with a diameter that is only slightly
greater than the diameter D.
[0078] In this embodiment, the peripheral wall 14 has a non-uniform
diameter that creates a draft angle that facilitates formation, as
by molding, and stacking of multiple containers 12, as at a
manufacturing facility or by an end user. Of course, the surface 80
could have a uniform diameter.
[0079] In one form, the container 12 is made by modifying certain
components of a conventional plastic paint bucket with a 5 or 7
gallon capacity. While this is one design option that allows
utilization of some existing, standard components and/or tooling,
of course all of the components of the system 10 might be
individually designed to produce desired structural and operating
characteristics. Still further, as described hereinbelow, the
container may be made by simply modifying a completed paint
bucket.
[0080] Formation of the container 12 from a plastic material is
desirable from the standpoint that the same can be made by molding
using a lightweight moldable material. With this construction, the
container 12 can be easily and economically produced.
[0081] A repositionable, U-shaped handle 82 may be utilized, as on
conventional paint buckets, to facilitate transportation of the
container 12 with the supply 26 of cable 28 operatively placed
therewithin. The handle 82 shown has a U-shaped wire body 84 with a
graspable component 86 that can be comfortably engaged by a user's
one hand to lift and transport the container 12. The body 84 is
pivotable from a lifting position to a side storage position, as
shown in FIG. 1, wherein the lid 30 can be selectively attached to,
and separated from, the peripheral wall 14, without interference
from the handle 82. In FIG. 2, the handle is shown pivoted from the
stored position towards the lifting position wherein component 86
is at its highest point.
[0082] Aside from affording a convenient means for transporting the
supply 26 of cable 28, the system 10 also is designed to facilitate
controlled payout of cable 28 from the supply 26 thereof within the
storage space 16. More particularly, the peripheral wall 14 has an
opening 88 therethrough through which a free end portion P of the
cable 28 can be directed and drawn from externally of the storage
space 16. As the cable 28 is drawn in this manner, the reel 34
turns guidingly around the axis 32, whereby the cable 28 is
progressively and smoothly paid out.
[0083] In this embodiment, the opening 88 has a circumferential
width W that is greater than the diameter D2 of the cable 28 so
that the cable 28 can be drawn generally in a circumferential
direction, to maximize the turning force component, thereby to turn
the supply 26 without significant interference between the cable 28
and the edge 90 bounding the opening 88. In this embodiment, the
opening 88 extends preferably over substantially the entire axial
extent of the annular winding region 44 and over at least a
majority, and potentially substantially the entirety, of the axial
extent of the storage space 16.
[0084] In the event that the peripheral wall 14 is made from a
plastic material, the edge 90 may generate sufficient friction
against the cable outer surface 92 such that the projecting cable
portion P is inhibited from being drawn back into the storage space
16 by forces resulting from a set in the cable turns. In the event
that the projecting portion P is drawn back into the storage space
16, the lid 30 might have to be removed to re-thread the cable 28
through the opening 88.
[0085] As shown in FIG. 7, a high friction material 94 may be
disposed about the edge 90. This material 94 may be held in place
by an adhesive or applied through an overmolding process, or by
placement of a press-fit component that conforms to the overall
shape of the edge 90. Alternatively, the material 94 may be held in
place using fasteners such as rivets, screws, etc.
[0086] With the supply 26 of cable 28 separate from the container
12, it is desirable to control unravelling of the cable 28. As
shown in FIG. 4, at least one opening 96, and in this case four
openings 96, are provided in one of the flanges 40, 42. The free
end of the cable 28 can be directed through any one of the openings
96 to prevent unravelling.
[0087] Alternatively, as shown in FIG. 8, a frangible sheet 98 may
be wrapped around the cable 28 in a continuous fashion to avoid
unravelling. The sheet material is selected so that it will
progressively tear/rupture as the cable 28 is pulled by the user
with the system in the operative state of FIG. 1. Accordingly, the
wrapped supply 26 of cable 28 can be stored without the fear of
unravelling and operatively placed within the storage space 16
without removing the frangible sheet 98. Due to the above-described
operation, the frangible sheet 98 will progressively be broken away
and will not appreciably interfere with payout of the cable 28 in
use.
[0088] To control turning of the supply 26 of cable 28 within the
storage space 16, a braking mechanism may be provided, as shown at
100 in FIG. 2. The braking mechanism 100 consists of a component
102 that can be urged with a variable pressure against the reel
flange 40. An external actuator 104 is operable to reposition the
component 102 to select a resistance that results in the paying out
of the cable 28 in the desired manner.
[0089] In FIG. 9, a generic form of structure for releasably
connecting the lid 30 and peripheral wall 14 is shown. The
invention contemplates virtually an unlimited number of different
arrangements utilizing cooperating components 106, 108,
respectively on the lid 30 and peripheral wall 14. The components
106, 108 may be cooperating threads. Alternatively, the components
106, 108 may be snap-fit components as conventionally used on paint
buckets. While the details of this structure are not critical to
the invention, what is desirable is the ability to be able to
selectively separate the lid 30 from the peripheral wall 14 to
operatively place the supply 26 of cable 28 and subsequently remove
the reel 34 once the supply of cable 28 is exhausted to allow a new
supply 26 of cable 28 to be replaced, whether as a totally separate
structure or utilizing the reel 34 with a replenished supply of the
cable 28.
[0090] What is desirable also is that the lid 30 be connected to
the peripheral wall 14 in a manner so that the lid 30 is rigidly
joined to the peripheral wall 14. With this rigid connection in the
depicted configuration, the container 12 can be used as a seat for
the user or a step to facilitate access to an elevated location. To
that end, the aforementioned feet 20 can be made from a material,
and with a construction, so that the feet 20 do not tend to slip
against the subjacent surface 22 upon which the container 12 is
supported.
[0091] The guide components 58, 60 may be integrated into a
standard 5 gallon or 7 gallon paint bucket as opposed to modifying
certain basic components thereon, as described above. As one
example, as shown in FIG. 10, a conventional paint bucket may be
utilized with a lid 30' to which the guide component 58' is added,
as through a layer that includes the guide component 58' and can be
attached to the lid 30', as by adhesive bonding. A similar
arrangement can be made to incorporate the guide component 60' into
the bottom wall 18' of a conventional paint bucket.
[0092] In FIG. 11, a further modified form of system is shown at
10'' that uses a conventional container 12'' consisting of the
"bucket", with a peripheral wall 14'', a bottom wall 18'', and a
top opening 24'', with the top opening 24'' blocked selectively by
a lid 30''. These components can be purchased as standard paint
buckets, with the peripheral wall 14'' modified by forming the
opening 88''.
[0093] In this embodiment, the guide components 58'', 60'' have the
same or a similar construction, with the exemplary guide component
58'' having a base 110 with a fixed annular sleeve 112. A shaft 114
is mounted for guided movement within the sleeve 112 about an axis
116.
[0094] The guide component 60'' has a base 118, sleeve 120, and
shaft 122 corresponding to the base 110, sleeve 112, and shaft 114,
consecutively.
[0095] The base 110 is secured to the bottom wall 18'' through
threaded fasteners 124. The base 118 is attached to the lid 30''
using similar fasteners 124. The bases 110, 118 may have
pre-threaded bores 126, 128, respectively, to allow the fasteners
124 to be directed thereinto to captively hold the bottom wall 18''
and lid 30''. With the guide components 58'', 60'' secured in
place, the shafts 114, 122 are coaxial and project towards each
other.
[0096] A reel 34'' has a two-component construction, with a
combined flange 42'' and core 36'' making up one component and a
separate flange 40'', with an associated stub component 52'',
making up the other component.
[0097] The reel 34'' with wrapped cable 28 around the core 36'' can
be directed into the storage space 16'' with the shafts 114, 122
directed oppositely into the bore 70'' defined through the reel
34''. The reel 34'' is thus captively located between facing,
annular shoulders 130, 132 defined on the guide components 58'',
60'', respectively. With this configuration, while the shoulders
130, 132 may perform some guiding function by acting against the
reel 34'', guided movement is primarily the result of the movement
of the shafts 114, 122 within their respective sleeves 114, 120 as
the reel 34'' turns around the axis 116.
[0098] In FIG. 12 a further embodiment of the invention is shown
wherein a container 12''' has an upwardly projecting shaft 134 from
the center of a bottom wall 18'''. The shaft 134 projects into a
throughbore 70''' in a reel 34'''. The shaft 134 is a guide
component that makes up a support assembly for the reel 34'''. The
shaft 134 may be fixed, or guided in movement, relative to the
bottom wall 18'''.
[0099] As one example, a disc-shaped wall 135 may define a guide
component on a support assembly to bear the weight of the reel
34''' and guide the same in the same manner as a "lazy susan". This
can be used in any of the embodiments herein and potentially allows
the use of a less robust upper guide component or the elimination
of the same altogether.
[0100] In this embodiment, the reel 34''' has an axial dimension
that is less than that for the storage space 16'''. As a result,
with the supply 26''' of cable 28 operatively placed within the
storage space 16''', there is a cylindrical space 136 atop the reel
34''' within which a parts container 138 can be nested, as to rest
upon the top of the reel 34'''. The parts container 138 has a
divider 140 to define, in this embodiment, four different
receptacles R1, R2, R3, R4. With this arrangement, the user has the
convenience of carrying potentially parts, tools, meters, etc.,
together with the cable 28, in one convenient package with the
container 12'''.
[0101] Further, in this embodiment, at least one wheel 142 is shown
as an option that can be incorporated into the container 12''' and
any other containers as herein described. The wheel(s) 142 allows
the container 12''' to be conveniently rolled against a subjacent
surface.
[0102] In FIG. 13, a further modification of the container 12''' is
shown wherein a tool apron 144 is secured at the outside surface
146 of the peripheral wall 14'''. The tool apron 144 may have a
wall portion 148 that extends fully around the surface 146. The
wall portion 148 may have a continuous and fixed diameter or
alternatively may be of a variable diameter by incorporating a
securing strap 150 that is shown separated from the remainder of
the wall portion 148 in dotted lines in FIG. 13. The securing strap
150 may be permanently fixed to the remainder of the wall portion
148 or releasably connected, as through a buckle arrangement, hook
and loop fastener, or the like.
[0103] In this embodiment, the tool apron 144 has a plurality of
compartments C1, C2, C3, C4 designed to accommodate parts, tools,
meters, etc., as may be used on a job.
[0104] In FIG. 13, an optional shoulder strap 152 is shown
connected to the container 12'''. The shoulder strap 152 may be
temporarily or permanently connected to the container 12''' using
any conventional type shoulder strap construction and means for
connection. The shoulder strap 152 may be used to lift or otherwise
reposition the container 12'''.
[0105] It should be understood that the features shown in the
different embodiments are all contemplated for interchangeable use.
Many other variations are contemplated within the disclosure of the
invention that is made herein.
[0106] For example, the material making up the various components
may be changed depending upon objectives. As just one example, the
guide components 58, 60 could be made from plastic or metal, with
the latter less susceptible to wear and potentially affording a
more solid guide base.
[0107] The construction of each of the reels is not limited to any
particular material. The reels may be made partially or wholly from
metal, wood, plastic, composite or other non-metallic material. The
selection of materials for the reels may be dictated in part by
whether or not they will be reused and whether they are to be
disposed of in an environmentally friendly manner.
[0108] The inventive system is particularly useful for cable
installation, wherein the cable 28 is a coaxial cable.
[0109] The foregoing disclosure of specific embodiments is intended
to be illustrative of the broad concepts comprehended by the
invention.
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