U.S. patent application number 15/797865 was filed with the patent office on 2018-05-17 for coreless wound coil dispenser with optional cable storage for an optical terminal network.
The applicant listed for this patent is CommScope Technologies LLC. Invention is credited to Eric E. Alston, William Alan Carrico, Erik J. Gronvall, Julian S. Mullaney, Kathleen Terryll.
Application Number | 20180134512 15/797865 |
Document ID | / |
Family ID | 56127740 |
Filed Date | 2018-05-17 |
United States Patent
Application |
20180134512 |
Kind Code |
A1 |
Mullaney; Julian S. ; et
al. |
May 17, 2018 |
CORELESS WOUND COIL DISPENSER WITH OPTIONAL CABLE STORAGE FOR AN
OPTICAL TERMINAL NETWORK
Abstract
Packaged dispensers mountable to optical network terminals (ONT)
are disclosed. In some examples, the dispensers include coreless
wound coils and excess storage areas. Additionally, fiber optic
cable distribution systems and methods thereof utilizing the
disclosed coreless wound coils are further disclosed. In one
example, a length of telecommunications cable is wound into a
coreless coil that includes a plurality of winding separators at
least partially embedded within the coil, wherein the length of
telecommunications cable alternately passes on one of the first and
second sides of one winding separator and on the other of the first
and second sides of an adjacent winding separator. In one example,
an initially cylindrically shaped coreless wound coil, with or
without winding separators, can be placed into a non-round package
in which the wound coil is deformed and compressed by the sidewalls
of the package such that the coreless wound coil conforms to the
interior perimeter of the package to have a non-cylindrical
shape.
Inventors: |
Mullaney; Julian S.;
(Raleigh, NC) ; Alston; Eric E.; (Fuquay-Varina,
NC) ; Carrico; William Alan; (Raleigh, NC) ;
Gronvall; Erik J.; (Bloomington, MN) ; Terryll;
Kathleen; (Chaska, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CommScope Technologies LLC |
Hickory |
NC |
US |
|
|
Family ID: |
56127740 |
Appl. No.: |
15/797865 |
Filed: |
October 30, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14975021 |
Dec 18, 2015 |
9802786 |
|
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15797865 |
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62094656 |
Dec 19, 2014 |
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62233841 |
Sep 28, 2015 |
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62268473 |
Dec 16, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/4448 20130101;
B65H 55/046 20130101; B65H 55/02 20130101; G02B 6/4457 20130101;
B65H 2701/32 20130101; G02B 6/4466 20130101; H04B 10/25
20130101 |
International
Class: |
B65H 55/04 20060101
B65H055/04; G02B 6/44 20060101 G02B006/44; H04B 10/25 20060101
H04B010/25; B65H 55/02 20060101 B65H055/02 |
Claims
1.-10. (canceled)
11. A method for making a ageless wound coil of telecommunications
cable, the method comprising the steps of: a. providing a mandrel
assembly having a longitudinal axis about which the mandrel is
rotatable; b. providing an odd number of at least three winding
separators, each of the winding separators having a first side and
an opposite second side; c. securing the winding separators to the
mandrel assembly; d. securing an end of the telecommunications
cable to the mandrel; e. rotating the mandrel assembly to cause the
telecommunications cable to be wound about the mandrel to form a
wound coil of telecommunications cable; and f. weaving the
telecommunications cable between the winding, separators as the
telecommunications cable is being wound onto the mandrel such that
the telecommunications cable alternately passes on one of the first
and second sides of one winding separator and on the other of the
first and second sides of an adjacent winding separator.
12. The method for making a wound coil of telecommunications cable
of claim 11, further comprising the step of removing the wound coil
of telecommunications cable from the mandrel assembly with the
winding separators embedded at least partially within the wound
coil of telecommunications cable.
13. The method of making a wound coil of telecommunications cable
of claim 12, further comprising the step of placing the wound coil
of telecommunications cable into a package to form a packaged coil
dispenser.
14. The method for making a wound coil of telecommunications cable
of claim 11, wherein the step of providing an odd number of at
least three winding separators includes providing one of the
winding separators as a payout tube.
15. The method the making a wound coil of telecommunications cable
of claim 11, wherein the step of providing an odd number of at
least three winding separators includes providing five winding
separators.
16. The method for making a wound coil of telecommunications cable
of claim 11, further comprising installing a connector onto an end
of the telecommunications cable.
17.-18. (canceled)
19. A method for installing a telecommunications distribution
system within a building structure, the method including the steps
of: a. installing a conduit assembly extending through at least two
floors of the building structure; b. providing a wound coil
including: i. a length of telecommunications cable wound into a
coreless coil; and ii. a plurality of winding separators at least
partially embedded within the coil wherein the length of
telecommunications cable alternately passes on one of the first and
second sides of one winding separator and on the other of the first
and second sides of an adjacent winding separator; and c.
installing the length of telecommunications within the conduit
assembly.
20. A telecommunications distribution system for a building,
structure, the telecommunications distribution system comprising:
a. a conduit assembly extending through at least two floors of the
building structure; and b. a telecommunications cable extending
through the conduit assembly, the telecommunications cable being
pulled from a wound coil including: i. a length of
telecommunications cable wound into a coreless coil; and ii. a
plurality of winding separators at least partially embedded within
the coil wherein the length of telecommunications cable alternately
passes on one of the first and second sides of one winding
separator and on the other of the first and second sides of an
adjacent winding separator.
21.-29. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No.
14/975,021, filed Dec. 18, 2015, which application claims the
benefit of provisional application Ser. No. 62/094,656, filed Dec.
19, 2014, and titled "Fiber Distribution System and Coreless Wound
Coil" and provisional application Ser. No. 62/233,841, filed Sep.
28, 2015, and titled "Coreless Wound Coil Dispenser with Cable
Storage for an Optical Terminal Network" and provisional
application Ser. No. 62/268,473, filed Dec. 16, 2015, and titled
"Coreless Wound Coil Dispenser with Optional Cable Storage for an
Optical Terminal Network," which applications are incorporated
herein by reference in their entirety.
BACKGROUND
[0002] The demand for the installation of fiber optic
telecommunications cables within existing building structures, for
example multiple dwelling units (MDU' s), has recently increased.
However, providing for such installations can be challenging using
conventional optical fiber installation techniques and standard
optical fiber cable sizes. For example, pulling long riser cables
in buildings with congested cable pathways can be extremely
difficult and time consuming. At the concentration points of the
cables, for example, a basement, many times the fiber density is
too high to provide for adequate organization and can also present
a fire hazard. Due to this congestion, the number of cable splicing
locations increases, especially where congestion prevents the use
of pre-connectorized cables. This further increases costs and also
increases the skill level requirement for field installers.
Additionally, winding techniques used for conventionally sized
fiber optic cables can be problematic when applied to winding fiber
optic cables of a smaller dimension and of the type that may be
more suitable for installation in a pre-existing building structure
with limited available space.
SUMMARY
[0003] In one aspect of the disclosure, a packaged cable dispenser
including a coreless wound coil disposed in a package is disclosed.
The wound coil can be a length of telecommunications cable that has
been wound into a coreless coil. The wound coil can also include a
plurality of winding separators at least partially embedded within
the coil wherein the length of telecommunications cable alternately
passes on one of the first and second sides of one winding
separator and on the other of the first and second sides of an
adjacent winding separator. The wound coil can be disposed in a
package, wherein one of the winding separators is a payout tube
extending from an interior winding surface of the coreless coil to
the exterior of the package.
[0004] In another aspect of the disclosure, a packaged wound coil
is disclosed including a non-cylindrical package having a plurality
of interconnected sidewalls defining an interior perimeter. The
packaged wound coil can further include a length of
telecommunications cable wound into a coreless coil having an
interior winding surface and an exterior winding surface, the
interior winding surface defining a hollow interior, the exterior
winding surface defining an outside dimension. The coreless coil
can be deformed and compressed by the interconnected sidewalls of
the package such that the coreless coil conforms to the interior
perimeter of the package. A payout tube can also be provided that
extends the coreless coil between the hollow interior to the
exterior surface of the coreless coil and through one of the
interconnected sidewalls of the package, a portion of the
telecommunications cable extending through the payout tube.
[0005] In another aspect, a telecommunications distribution system
for a building structure is disclosed. The system can include a
conduit assembly extending through at least two floors of the
building structure, wherein a telecommunications cable extends
through the conduit assembly. The telecommunications cable can be
pulled from a wound coil including any of the aforementioned
features, for example, a coreless coil with winding separators
and/or a coreless coil that is compressed by the sidewalls of the
package.
[0006] A method for installing a telecommunications distribution
system within a building structure is also disclosed. One step can
be installing a conduit assembly extending through at least two
floors of the building structure. Another step can be providing a
wound coil including any of the aforementioned features, for
example, a coreless coil with winding separators and/or a coreless
coil that is compressed by the sidewalls of the package. Another
step can be installing the length of telecommunications cable
within the conduit assembly by pulling cable from the wound
coil.
[0007] In one example, a coreless wound coil can be manufactured by
providing a mandrel assembly having a longitudinal axis about which
the mandrel is rotatable and by providing an odd number of at least
three winding separators, wherein each of the winding separators
has a first side and an opposite second side. Other steps can be
securing the winding separators to the mandrel assembly, securing
an end of the telecommunications cable to the mandrel, and rotating
the mandrel assembly to cause the telecommunications cable to be
wound about the mandrel to form a wound coil of telecommunications
cable. The telecommunications cable can be woven between the
winding separators as the telecommunications cable is being wound
onto the mandrel such that the telecommunications cable alternately
passes on one of the first and second sides of one winding
separator and on the other of the first and second sides of an
adjacent winding separator. The wound coil with the winding
separators remaining embedded in the coil can then be removed from
the mandrel and placed in a package, if desired.
[0008] In one example, a coreless wound coil can be manufactured by
providing a mandrel assembly, securing an end of the
telecommunications cable to the mandrel, rotating the mandrel
assembly to cause the telecommunications cable to be wound about
the mandrel to form a generally cylindrical-shaped wound coil
having an initial outside dimension, and removing the wound coil
from the mandrel assembly. A package can be provided defining an
interior having a first interior dimension that is smaller than the
wound coil first outside dimension. The coreless wound coil can be
installed into the package by deforming the wound coil to have a
non-cylindrical shape conforming to the interior of the package
such that the wound coil has a deformed outside dimension smaller
than the initial outside dimension and such that the coil is
compressed by the sidewalls of the package.
[0009] The dispenser can be provided with a second section defined
within the package that is for storing cable that has been removed
from the dispenser but is not needed. In one aspect, the storage
section can include a spool portion extending from a common wall
between the first section (wound coil) and the storage section. The
spool portion can be configured to store excess lengths of the
telecommunications cable that has been removed from the coreless
coil. In a further aspect, the dispenser can be configured for
mounting to an optical terminal network (ONT).
[0010] A variety of additional aspects will be set forth in the
description that follows. These aspects can relate to individual
features and to combinations of features. It is to be understood
that both the foregoing general description and the following
detailed description are exemplary and explanatory only and are not
restrictive of the broad concepts upon which the embodiments
disclosed herein are based.
DRAWINGS
[0011] FIG. 1 is a schematic representation of a fiber optic
network disposed in a facility.
[0012] FIG. 2 is a schematic representation of an example residence
in which a subscriber cable is deployed to an optical network
terminal (ONT) having rapid cable deployment and storage
features.
[0013] FIG. 3A is a schematic representation of the ONT shown in
FIG. 2 in a first configuration having exemplary features of
aspects in accordance with the principles of the present
disclosure.
[0014] FIG. 3B is a schematic representation of the ONT shown in
FIG. 2 in a second configuration having exemplary features of
aspects in accordance with the principles of the present
disclosure.
[0015] FIG. 3C is a schematic representation of the ONT shown in
FIG. 2 in a third configuration having exemplary features of
aspects in accordance with the principles of the present
disclosure.
[0016] FIG. 4 is a view of an example configuration of the cable
storage features of the ONT shown in FIGS. 3A and 3B.
[0017] FIG. 5 is a view of an example configuration of the ONT
shown in FIG. 2.
[0018] FIG. 6 is a schematic top view of a first embodiment of a
packaged cable dispenser including a coreless wound coil disposed
in a package having exemplary features of aspects in accordance
with the principles of the present disclosure.
[0019] FIG. 6A is a perspective view of a packaged cable dispenser
similar to that shown in FIG. 6, but with a round package.
[0020] FIG. 6B is a perspective view of a packaged cable dispenser
similar to that shown in FIG. 6, but with fewer winding
separators.
[0021] FIG. 7 is a schematic top view of a flat layout of the
coreless wound coil shown in FIG. 6.
[0022] FIG. 8 is a perspective view of a physical example of the
packaged cable dispenser of FIG. 6.
[0023] FIG. 9 is a top view of the packaged cable dispenser of FIG.
8.
[0024] FIG. 10 is a bottom view of the packaged cable dispenser of
FIG. 9.
[0025] FIG. 11 is a perspective view of the packaged cable
dispenser of FIG. 9 with the top wall removed from the housing.
[0026] FIG. 12 is a top view of the packaged cable dispenser of
FIG. 9 with the top wall removed from the housing.
[0027] FIG. 13 is a side view of the packaged cable dispenser of
FIG. 9.
[0028] FIG. 14 is an exploded perspective view of the packaged
cable dispenser of FIG. 9.
[0029] FIG. 15 is a top perspective view of a winding separator of
the packaged cable dispenser of FIG. 9.
[0030] FIG. 16 is a bottom perspective view of the winding
separator shown in FIG. 15.
[0031] FIG. 17 is a top view of the winding separator shown in FIG.
15.
[0032] FIG. 18 is a first side view of the winding separator shown
in FIG. 15.
[0033] FIG. 19 is a second side view of the winding separator shown
in FIG. 15.
[0034] FIG. 20 is a top perspective view of a payout tube of the
packaged cable dispenser of FIG. 5.
[0035] FIG. 21 is a bottom perspective view of the payout tube
shown in FIG. 20.
[0036] FIG. 22 is a first side view of the winding separator shown
in FIG. 15.
[0037] FIG. 23 is a second side view of the winding separator shown
in FIG. 15.
[0038] FIG. 24 is a top view of the winding separator shown in FIG.
15.
[0039] FIG. 25 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a first state.
[0040] FIG. 26 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a second state.
[0041] FIG. 27 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a third state.
[0042] FIG. 28 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a fourth state.
[0043] FIG. 29 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a fifth state.
[0044] FIG. 30 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a sixth state.
[0045] FIG. 31 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a seventh state.
[0046] FIG. 32 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in an eighth state.
[0047] FIG. 33 is a perspective view of the packaged cable
dispenser of FIG. 9 while dispensing cable in a ninth state.
[0048] FIG. 34 is a top view of a second embodiment of a coreless
wound coil disposed in a package having exemplary features of
aspects in accordance with the principles of the present
disclosure.
[0049] FIG. 35 is a perspective view of the coreless wound coil
shown in FIG. 8.
[0050] FIG. 36 is a perspective view a third embodiment of a
coreless wound coil disposed in a package having exemplary features
of aspects in accordance with the principles of the present
disclosure.
[0051] FIG. 37 is a schematic side view of a building structure
within which a micro-conduit system is installed.
[0052] FIG. 38 is a perspective view of a coil of micro-conduit
usable with the micro-conduit system shown in FIG. 11.
[0053] FIG. 39 is a perspective end view of two sizes of
micro-conduit usable with the micro-conduit system shown in FIG.
11.
[0054] FIG. 40 is a schematic side view of a building structure
within which a telecommunications cable system is installed within
the micro-conduit system shown in FIG. 11 is installed, wherein the
telecommunications cable system includes cables pulled from a
coreless wound coil.
[0055] FIG. 41 is a perspective view showing a telecommunications
cable being inserted into a micro-conduit.
[0056] FIG. 42 is a schematic flow chart showing a first method for
forming a coreless wound coil having exemplary features of aspects
in accordance with the principles of the present disclosure.
[0057] FIG. 43 is a schematic flow chart showing a second method
for forming a coreless wound coil having exemplary features of
aspects in accordance with the principles of the present
disclosure.
[0058] FIG. 44 is a schematic flow chart showing a method for
installing a telecommunications distribution system within a
building structure utilizing any of the coreless wound coils formed
by the methods shown in FIGS. 16 and 17.
[0059] FIG. 45 is a schematic perspective view of a fourth
embodiment of a packaged cable dispenser for holding a coreless
wound coil having exemplary features of aspects in accordance with
the principles of the present disclosure.
[0060] FIG. 46 is a second perspective view of the dispenser shown
in FIG. 45.
[0061] FIG. 47 is an exploded perspective view of the dispenser
shown in FIG. 45.
[0062] FIG. 48 is a perspective view of a disassembled winding
separator of the dispenser shown in FIG. 45.
[0063] FIG. 49 is a top view of a winding separator half piece
shown in FIG. 48.
[0064] FIG. 50 is a bottom view of the winding separator half piece
shown in FIG. 49.
[0065] FIG. 51 is a perspective view of the winding separators of
the dispenser shown in FIG. 45 mounted into a winding hub
assembly.
[0066] FIG. 52 is a perspective view of the winding separators and
hub assembly shown in FIG. 51, with a second hub assembly part
removed from a first hub assembly part.
[0067] FIG. 53 is a perspective view of the assembly shown in FIG.
52, with a winding ring first part mounted to the winding
separators.
DETAILED DESCRIPTION
[0068] Reference will now be made in detail to exemplary aspects of
the present disclosure that are illustrated in the accompanying
drawings. Wherever possible, the same reference numbers will be
used throughout the drawings to refer to the same or like parts.
Some of the features in this disclosure are similar to those shown
and described in U.S. Patent Application Ser. No. 62/151,239, filed
on Apr. 22, 2015, the entirety of which is incorporated by
reference.
[0069] FIG. 1 is a schematic representation of a fiber optic
network 900 disposed in a facility F. In examples, the facility F
includes multiple individual residences R (e.g., apartments,
condominiums, businesses, etc.). In the example shown, the facility
F includes five floors, including a basement, that each have one or
more residences R located thereat. In other examples, the facility
F can have a greater or lesser number of floors.
[0070] The fiber optic network 900 includes a feeder cable 902 from
a central office (not shown). The feeder cable 902 enters a feeder
cable input location 904 (e.g., a fiber distribution hub, a network
interface device, etc.) disposed at the facility F (e.g., in the
basement of the facility). The fiber distribution hub 104 has one
or more optical splitters (e.g., 1-to-8 splitters, 1-to-16
splitters, or 1-to-32 splitters) that generate a number of
individual fibers.
[0071] At least one fiber optic enclosure 906 is mounted at each
floor of the facility F. In the example shown, a fiber optic
enclosure 906 is mounted at each floor above the basement. The
individual fibers generated by the optical splitters are routed to
the fiber optic enclosures 906 via one or more riser cables 908.
Examples of fiber optic enclosures 906 suitable for use in the
fiber optic network 900 can be found in U.S. Publication No.
2013/0094828, the disclosure of which is hereby incorporated herein
by reference.
[0072] Subscriber cables 910 are routed from the fiber optic
enclosures 906 to respective residences R. The subscriber cable 910
includes an optical fiber disposed in a jacket or protective
tubing. In some implementations, a subscriber cable 110 is routed
to a transition box at the respective residence R. In other
examples, a subscriber cable 910 is routed through the walls of the
residence R (e.g., within ducts) towards a wall outlet 912.
[0073] FIG. 2 is a schematic representation of an example residence
R including walls and a floor defining a room. A wall box 912 is
disposed at a desirable location within the residence R for optical
and/or optoelectronic equipment. In some implementations, the
subscriber cable 910 extends through ducts in the wall and enters
the residence R behind the wall outlet 912. In other
implementations, the subscriber cable 910 enters the residence and
extends over the wall to the wall outlet 912. In certain
implementations, the subscriber cable 910 can be routed through the
room by adhesively affixing the subscriber cable 910 to the walls,
floor, ceiling, and/or moldings within the room.
[0074] The wall box 912 serves as a demarcation point within the
residence R for the optical service provider. The subscriber cable
910 is optically coupled to an optical connector at the wall outlet
912. Accordingly, optical signals carried by the subscriber cable
910 are available at the optical connector.
[0075] In some implementations, the optical connector terminates
the subscriber cable 910. In some examples, the end of the
subscriber cable 910 can be fully connectorized with optical
connector so that the end can be plugged into a corresponding port
at the wall outlet 912. The terminated end can be factory installed
and factory inspected prior to installation in the field. In other
examples, the subscriber cable 910 can have a partially terminated
end that is fully connectorized as optical connector in the field
and plugged into a port at the wall outlet 912. Partially
terminated ends can be advantageously routed through small ducts to
facilitate passage through walls of the residence R. The partially
terminated end can be quickly installed in the field without tools,
such as an optical fusion splicer.
[0076] In other implementations, the optical connector terminates a
pigtail that is optically coupled to the subscriber cable 910. In
an example, the pigtail is spliced (e.g., fusion spliced or
mechanically spliced) to an unterminated end of the subscriber
cable 910. Unterminated ends can be advantageously routed through
small ducts to facilitate passage through walls of the residence R.
In another example, another connectorized end of the pigtail is
connected to a connectorized end of the subscriber cable 910 at an
adapter disposed at the wall outlet 912.
Optical Network Terminal (ONT) with Cable Storage
[0077] A user can choose to connect an optical network terminal
(ONT) 914 or other equipment to the connector of the wall outlet
912 to connect the ONT 914 or other equipment to the fiber optic
network 900. In some examples, the ONT 914 is provided with a
packaged cable dispenser 900 having a patch cord or jumper cable
102 that can extend between the ONT 914 and the wall outlet 912.
The ONT 914 also can have a power cord 918 that plugs into an
electrical outlet 911 to provide power to the ONT 914.
[0078] Referring to FIGS. 3A, 3B, and 3C, various embodiments are
shown of an ONT 914 to which a packaged cable dispenser 100 is
mounted. The dispenser 100 can be mounted by various means, such as
by a snap-fit connection, a plug and socket type connection, and/or
by mechanical fasteners. By providing a packaged cable dispenser
100 on the ONT 914, an installer can readily connect the ONT 914 to
the wall outlet 912 with the cable 102 without having to separately
provide the cable or other hardware.
[0079] As described in detail in the following section, the
packaged cable dispenser 100 is configured as a coreless wound
coil. In such a configuration, the cable 102 can be withdrawn
through an outlet opening 103 without requiring any moving parts
within the dispenser and without requiring that the cable 102 be
radially unwound about a core. Accordingly, the dispenser 100 can
be mounted to the ONT 914 and the cable 102 can be withdrawn from
the dispenser 100 without relative motion between the ONT 914 and
the dispenser 100.
[0080] As shown, the cable 102 is connected to a connector/adapter
915 of the ONT 914. In one example, the cable 102 is
pre-connectorized such that the cable 102 can be easily connected
to the connector 914 before or after the dispenser 100 has been
mounted to the ONT 914. Similarly, the end of the cable 102 that is
attached to the wall outlet 912 can also be pre-connectorized such
that the cable 102 can be easily connected to the wall outlet
912.
[0081] In one aspect, the packaged cable dispenser 100 has a wound
section 101, in which the coreless wound coil is stored, and an
excess cable storage section 103, in which cable 102 that has been
removed from the wound section can be wound to take up any excess
slack. As shown, sections 101 and 103 are provided within the same
package such that the dispenser 100 appear to be a unitary
structure, although they are separated by a common wall 101a. Once
cable 102 is withdrawn from the coreless wound coil through outlet
100a, the cable 102 cannot be re-fed back into outlet 100a such
that the cable 102 will be appropriately re-wound. As such, the
excess cable storage section 103 provides a storage location for
cable 102 that has been withdrawn from outlet 100a but may not have
actually been needed to reach the wall outlet 912 or another
component.
[0082] As shown, the excess cable storage section 103 can be
provided with a spool 103a and a flange 103b. The cable 102 can be
wound about the spool 103a and the flange 103b acts to retain the
cable 102 so as to not slide off of the spool 103a. The cable
storage section 103 can also be provided with package sidewalls
103c so as to partially conceal the storage area. Together, the
sidewalls 103c and the flange 103b define an opening 103d through
which the cable 102 can be inserted and wound about the spool 103a.
The flange 103c can be provided in many forms, such as a solid
disk. With reference to FIG. 4, the flange 103b is provided as
multiple extensions 103e extending radially from the end of the
spool 103a.
[0083] With respect to FIG. 3A, an example is shown in which the
dispenser 100 is configured in a bottom mount configuration in
which the excess storage section 103 is located below the ONT 914.
With respect to FIG. 3B, an example is shown in which the dispenser
100 is configured in a side mount configuration in which the excess
storage section 103 is located to the side of the ONT 914. The
excess cable storage section 103 can also be located above the ONT
914. FIG. 3C shows an example in which the excess cable storage
section 103 is defined by the outer portion of the dispenser 100
instead of being in a side-by-side relationship.
Packaged Cable Dispenser Examples
[0084] Referring to FIGS. 6-44, exemplary cable storage
arrangements 200, 300, 400, 500 are shown. Any of the disclosed
cable storage arrangements 200, 300, 400, 500 can be utilized with
the systems shown and described above. Examples of suitable cable
storage arrangements are also shown and described in U.S. Patent
Application Ser. No. 62/094,656, filed on Dec. 19, 2014, the
entirety of which is incorporated by reference.
[0085] Referring to FIG. 6, a first embodiment of a packaged cable
dispenser 10 is disclosed. FIG. 1A also shows a generally similar
packaged cable dispenser 10, but with a different packaging. As
shown, the dispenser 10 can have a coreless wound coil 100 disposed
in a package 200. In one aspect, the coreless wound coil 100
includes a length of telecommunications cable 102 wound to define
an exterior winding surface 104 and an interior winding surface 106
which further defines a hollow interior 108. In one example, the
wound coil 100 has an outside diameter equal to or less than about
5 inches, and preferably about 3 inches to about 31/2inches. In one
example, the telecommunications cable 102 is a fiber optic cable.
Because the disclosed teachings provide for the formation of a
wound coil of fiber optic material that is coreless, the total
length of cable 102 that can be wound into a single coil can be
greater than what is obtainable for fiber optic cables wound about
a core structure. This is due to the circumstances that cumulative
hoop stresses exerted by the cable itself on more interior wound
loops near the core structure limit the total length of the cable.
As such forces are essentially entirely absent in a coreless wound
coil, once removed from the mandrel about which it is formed, the
disclosed teachings represent a significant improvement.
[0086] In one example, the cable 102 has a factory ferrulized end,
such as is described in Patent Cooperation Treaty (PCT) patent
application publication WO 2014/085459, the entirety of which is
hereby incorporated by reference. In such a case, optical
connectors can be later mounted to the ferrulized end of the cable
102, as explained in the WO '459 publication and as explained in
United States patent application publication US 2014/0153878 A1,
the entirety of which is hereby incorporated by reference. One or
both ends of the cable 102 can also be connectorized as explained
in U.S. Pat. No. 8,439,577, the entirety of which is hereby
incorporated by reference. It is also noted that since the
non-pulled end of the cable 102 can be pre-connectorized within the
package 200, as the wound coil 100 does not rotate within the
package 200 during dispensation.
[0087] In one example, the telecommunications cable 102 has a
nominal diameter of less than 3 milimeters (mm), a diameter of less
than 2 mm, and/or a diameter of less than 1 mm. In one example, the
cable 102 has a nominal diameter from about 800 to about 900
microns and includes a plurality of individual optical fibers of
about 250 microns. In one example, the telecommunications cable 102
has a pull rating sufficient to allow the cable 102 to be pulled
through a conduit without damaging the fibers, for example a pull
rating of about 300 Newtons. In one example, the telecommunications
cable 102 is provided with sufficient stiffness to allow the cable
102 to be pushed through a conduit, for example the cable 102 can
be provided with stiffening aramid fibers or steel wire.
[0088] In another aspect, the package 200 can include
interconnected sidewalls 202, 204, 206, 208 extending between a top
side 210 and a bottom side 212. The sidewalls 202, 204, 206, 208
can define an interior perimeter 220. As shown, the exterior
winding surface 104 of the wound coil 100 is within the interior
perimeter 220 of the package 200. The package 200 may be formed
from a variety of materials, such as plastic or a paper product.
The package 200 may be provided with a closable opening for
inserting the wound coil 100 within the package 200. Referring to
FIG. 6A, the dispenser 10 is provided with a circular sidewall 202,
in contrast to the square packaging shown in FIG. 6.
[0089] In the exemplary embodiment shown, the wound coil 100
further includes a plurality of winding separators 110, 112
embedded within the wound coil 100. The winding separators 110, 112
function to create and maintain the winding pattern of the wound
coil 100 by preventing migration of the cable 102 across the width
of the wound coil 100. In one example, the winding separators 110,
112 are provided with a curved or rounded profile to reduce
friction between the cable 102 and the separators 110, 112 as the
cable 102 is being unwound from the interior winding surface 106.
As shown, each of the winding separators 110, 112 extends
completely through the wound coil 100. To achieve this function,
the winding separators 110, 112 can be provided with a respective
first end 110a, 112a extending at least to the interior winding
surface 106 and a second end 110b, 112b extending at least to the
exterior winding surface 104. Each of the winding separators 110,
112 may also be provided with a respective first side 110c, 112c
and a respective opposite second side 110d, 112d.
[0090] With reference to FIG. 7, a flat layout schematic is
presented of the wound coil 100 shown in FIG. 6 to illustrate the
winding pattern of the coil 100 with respect to the winding
separators 110, 112. As shown in FIG. 7, a plurality of wraps of
the cable 102 are illustrated with a single wrap 102 being shown in
bold for the purpose of discussion herein. During each wrap or pass
of the winding process, the cable 102 is woven between the
separators 110, 112 such that the cable 102 alternately passes on
one of the first and second sides 110c, 112c, 110d, 112d of one
winding separator 110, 112 and on the other of the first and second
sides 110c, 112c, 110d, 112d of an adjacent winding separator 110,
112. Accordingly, for the embodiment shown in which five winding
separators 110, 112 are provided, the cable 102 passes on the first
side 110c of the first separator 110, then on the second side 110d
of the next separator 110, then on the first side 110c of the next
separator 110 (or 112d of separator 112), then on the second side
110d of the next separator 110, then on the first side 110c of the
last separator 110. As the winding process is continuous, the cable
102 will then pass on the second side 110d of the first separator
110 and the cable 102 will continue to be woven on the opposite
sides of the separators 110, 112 than the previous winding pass of
the cable 102. As long as the total number of winding separators
110, 112 is an odd number, the cable 102 will wind on opposite
sides of the separators with each alternating winding wrap. Such an
approach which will ensure that half of the cable 102 in the fully
wound coil 100 is wound onto each side of the separators 110, 112
in a balanced manner with the cable 102 crossing over the
previously wound segment between each winding separator 110, 112 to
prevent cable twist during removal of the cable 102. Although five
winding separators 110, 112 are shown, it should be understood that
more or fewer winding separators 110, 112 may be utilized, for
example, three, seven, nine, and/or eleven winding separators 110,
112. In one example, and as presented in FIG. 6B, a packaged cable
dispenser 10 having three winding separators, including a payout
tube 112 and two separators 110, is shown. It is noted that the use
of fewer separators 110, 112 will result in fewer cable cross-overs
for each wound loop and a lower density winding, which can be
beneficial for accommodating cables of larger diameters.
[0091] In the embodiment shown, winding separator 112 is shown as
being formed as a hollow payout tube 112 having a hollow interior
112e and extending through the sidewall 202 of the package. As
configured, the starting end 102a of the cable 102 is pulled from
the interior winding surface 106 of the wound coil and through the
interior 112e of the payout tube 112. Accordingly, the cable 102
can be pulled from the package through the payout tube 112 such
that the wound coil is paid out from the interior winding surface
106 towards the exterior winding surface 104. As the cable 102 has
been wound in the above manner, the cable 102 can be pulled from
the wound coil 100 without a twist being imparted onto the cable
102. In one aspect, the hollow interior 112e has an interior
dimension that is large enough to not unduly restrict the cable 102
as it is being pulled, but not so large that a potentially kinked
or knotted cable 102 could enter into the interior 112e. In one
example, the hollow interior 112e is no greater than twice the
diameter of the cable 102.
[0092] Referring to FIGS. 9-24, a physical example of the packaged
cable dispenser 10 schematically shown at FIGS. 6-8 is presented.
As shown, package 200 is configured as a generally
cylindrical-shaped housing 200. However, it should be appreciated
that numerous housing shapes are useful with the disclosed
teachings, for example, housings that have any of a number of
geometric shapes (e.g. ovular, triangular, square, rectangular,
pentagonal, hexagonal, octagonal, etc.). As shown, housing 200 has
a continuous sidewall 202 defining the interior perimeter 220. The
housing 200 is also provided with a bottom wall 212 adjoining the
sidewall 202. As shown, the bottom wall 212 and the sidewall 202
are integrally formed as a single component. However, the bottom
wall 212 could be formed as a separate component which is either
permanently or removably joined to the sidewall 202. The housing
200 can also be provided with a top wall 210. As shown, the top
wall 210 is removably attached to the sidewall 202, but could also
be permanently attached, if desired. The top wall 210 can be
secured to the sidewall 202 by tabs 214 provided on the sidewall
202 and by the first ends or top edges 216b of mounting or channel
members 216 (discussed later) provided on the sidewall 202. In one
aspect, the top wall 210 is connected to the sidewall 202 with a
snap-fit type of connection. Together, the sidewall 202, the top
wall 210, and the bottom wall 212 form an interior volume 214
within which the coreless wound coil 100 can be stored.
[0093] In one aspect, the winding separators 110 can be provided
with a first end 110a, a second end 110b, a first side 110c, and a
second side 110d. In the example shown at FIGS. 9-24, each of the
winding separators 110 can be provided with a stem portion 114
extending from a base portion 116. The stem portion 114 is shown as
extending between the first and second ends 110a and having the
base portion 116 attached at the second end. As shown, the stem
portion 114 and the base portion 116 are integrally formed as a
single component, but may be formed as separate components that are
later joined together.
[0094] The stem portion 114 of the winding separator 110 is flared
at the first end 110a such that the first end 110a has a thickness
t1 that is greater than a thickness t2 of the stem portion 114 at
the second end 110. The flared first end 110a operates to retain
the cable 102 onto the winding separators 110 such that the cable
102 does not prematurely unravel with only one loop coming off the
separator 110 at a time. In one aspect, the flared first end 110a
can be provided with sloped portions 110e transitioning between the
first and second thicknesses t1, t2. The sloped portions 110e, 110f
can be configured to gently guide the cable 102 past the first end
110a while also preventing the cable 102 from becoming hung up or
caught on the first end 110a. Each winding separator 110 may also
be provided with rounded portions 110f that provide rounded
transitions between the first and second sides 110c, 110d. As the
cable 102 is passing from one side 110c, 110b of one separator 110
to the other side 100c, 110d of the adjacent separator 110, the
rounded portions 110f help to ensure that the cable is gently
guided along the pathway and is not exposed to any sharp edges. In
one aspect, the separators 110 are hollow or partially hollow at
the first end 110a in order to form the sloped portions 110e and
the rounded portions 110f. However, the winding separator 110 can
be provided as an entirely solid structure without departing from
the concepts presented herein.
[0095] As shown, the base portion 116 of each winding separator 110
can be defined as having a top side 116a and a bottom side 116b
extending between opposite sides 116c,d and between opposite sides
116e,f. In the example shown, the base portion 116 is provided with
a generally rectangular shape, although other shapes are possible.
During the winding process, the base portion 116 enables a greater
amount of cable 102 to be wound into a coil 100 in comparison to a
winding separator 110 not having a base portion 116. The top side
116a of the base portion 116 provides a positive surface against
which the cable 102 can be wound and retained thereby allowing
cable 102 to be wound all the way to the second end 110b of the
winding separator. Where no base portion 116 is provided, the
winding process must be stopped at a point such that at least a
portion of the second end 110b of the winding separators 110
remains exposed such that the cable 102 cannot unintentionally
unwind beyond the separator 110.
[0096] The base portion 116 also provides a mounting location for
the wound coil 100 to be mounted within the housing 200. As stated
previously, the housing 200 is provided with a plurality of channel
members 216 at the sidewall 202. In one configuration, the each of
the channel members 216 extends between a first end 216a adjacent
the bottom wall 212 towards a second end 216b adjacent the top wall
210. In one aspect, the second end 216b is recessed from the top
edge 202a of the sidewall 202 to accommodate the thickness of the
top wall 210. The channel members 216 may be each provided with a
first side member 216c and a second side member 216d that extend
between the first and second ends 216a, 216b. Together, the side
members 216c,d and the sidewall 202 define a channel that receives
and retains the base portion 116 of a winding separator 110. As
configured, the wound coil 100 can be formed on a winding apparatus
and then mounted within the housing 200 by aligning and then
sliding the base members 116 of each winding separator 110 into the
corresponding channel member 216. Although the use of base members
116 and channel members 216 are a useful configuration for
providing a connection between the wound coil 100 and the housing
200, it should be appreciated that other cooperating structures may
be used without departing from the concepts described herein.
[0097] A payout tube 112, which also functions as a winding
separator, is also provided in the packaged cable dispenser 10
shown in FIGS. 11-29. In one aspect, the payout tube 112 has a
first end 112a, a second end 112b, a first side 112c, and a second
side 112d. The payout tube 112 can also be configured with a stem
portion 118, a head portion 120, side flanges 122 and buttresses
124. In the example shown, the payout tube is a single molded
component. In combination, the head portion 120 and the stem
portion 118 define the hollow interior 112e through which the cable
102 can extend from the interior of the wound coil 100 to the
exterior of the housing 200. As shown, the side flanges 122 are
provided to define the first and second sides 112c, 112d and enable
the payout tube 112 to function as a winding separator in the same
manner as the winding separators 110. The side flanges 122 are also
provided with sloped regions 122a that gently slope to the head
portion 120 and allow a segment of unwinding cable 102 to be guided
up to the head portion 120 without excessive bending or catching of
the cable 102 on the head portion 120. As shown, the buttresses 124
extend from the side flanges and the stem portion 118 on the first
and second sides 112c, 112d towards the head portion 120. In one
aspect, the buttresses 124 provide a transition from the sides
112c, 112d and stem portion 118 to gently guide the cable 102 up to
the head portion 120 while also preventing the cable 102 from
becoming hung up or caught on the head portion 120.
[0098] The head portion 120 is also shaped to prevent the cable 102
from becoming bent too sharply or kinked as the cable 102 is being
pulled through the payout tube 112 and passing by one side 112c,
112d of the payout tube 112. The head portion 120 can be described
as having a rounded outer surface 120c for guiding the cable 102
about the payout tube 112 as the cable 102 passes by the payout
tube 112. The head portion 120 can also be described as having a
funneling surface 120d that smoothly guides the cable into the
hollow interior 112e. In one example, the head portion 120 is
provided as a toroidal shape having two axes of symmetry. For
example, and as most easily viewed at FIG. 24, the head portion 120
is symmetrical about an axis X and symmetrical about an axis Y. In
one aspect, the head portion 120 is elongated along the X axis
relative to the Y axis to create a rounded diamond-shape with a
leading edge 120a and a trailing edge 120b. The rounded leading
edge 120a aids in guiding the cable 102 to the appropriate side
112c, 112d of the payout tube 112 as the cable 102 is unwinding off
of the winding adjacent winding separators 110 which prevents
kinking or tangling of the cable 102. The outer surface 120c and
the funneling surface 120d also function as a bend radius limiter
for the cable 102. In one aspect, the outer surface 120c and
funneling surface 120d can be configured to define a radius of
about 1/4inch to about 1/2inch.
[0099] In one aspect, the payout tube 112 can be secured to the
housing with a clip member 130 that inserts into a corresponding
receptacle 230 provided at a notch 232 in the sidewall 202. As
shown, the clip member 130 is formed as a plate having an aperture
132 having a profile that matches at least a portion of the payout
tube 112. In the example shown, the aperture 132 is shaped to allow
the stem portion 118 and the side flanges 122 to be inserted
through the clip member 130. As shown, the clip member 130 is
formed as a separate component that can be mounted and secured onto
the payout tube 112 either before or after the cable 102 has been
wound to form the wound coil 100. Alternatively, the clip member
130 can be formed integrally with the rest of the payout tube 112.
As the payout tube 112 is slidable relative to the clip member 130,
the position of the payout tube 112 can be adjustable relative to
the housing 200 to optimize the location of the head portion 120
with respect to the interior of the wound coil 100. Such
adjustability would allow for the same constituent parts to be used
in multiple applications where differing cable dimensions and
properties and/or wound coil diameters may be associated with
different optimal locations for the head portion 120 within the
housing 200. In one embodiment, index positions can be provided on
the clip member 130 and/or the payout tube 112 such that the
desired position of the payout tube with respect to the housing 200
can be readily achieved during assembly. This general construction
is also advantageous in that different payout tubes 112 having
different lengths and head styles may be used with the same housing
200.
[0100] Referring to FIGS. 25-33, depictions of a cable 102 being
dispensed from a dispenser 10 having a clear package 200 at
different stages are shown in which the above described features of
the winding separators 110 and payout tube 112 are illustrated. In
FIG. 20, the cable 102 has just been unwound past the payout tube
112 second side 112d and is maintained on the first side 110c of
the adjacent winding separator 110-1 by the flared first end 110a
of the winding separator 110-1. FIG. 26 shows the cable 102 having
been pulled further through the payout tube 112 such that the cable
102 has lifted off of the winding separator 110-1 but is still
retained on the second side 110d of the next winding separator
110-2 by the flared first end 110a. Similarly, FIG. 27 shows the
cable 102 now having been lifted off of the winding separator 110-2
while still being maintained on the first side 110c of the adjacent
winding separator 110-3 by the flared first end 110a of the winding
separator 110-3. FIG. 28 shows the cable 102 having been pulled
further through the payout tube 112 such that the cable 102 has
lifted off of the winding separator 110-3 but is still retained on
the second side 110d of the next winding separator 110-4 by the
flared first end 110a.
[0101] Unlike the winding separators 110, the cable 102 is
simultaneously drawn through and past the payout tube 112 which
necessitates that the cable 102 flips over from one plane one side
of the payout tube 112 to another plane on the other side of the
payout tube 112. FIG. 29 shows the cable 102 at the beginning of
this process wherein the cable has lifted from the winding
separator 110-3 with the flared end 110e of the separator 110-3
having kicked the cable 102 out of plane such that the cable 102
can be transferred over from the second side 110d of separator
110-4 to the first side 112c of the payout tube 112. At the same
time, the rounded leading edge 120a of the payout tube head portion
120 is ensuring that the cable 102 continues to flip over to the
first side 112c as the cable draws nearer the payout tube 112.
FIGS. 30-32 show the cable 102 as it traces around the outer
portion 120c of the head portion and along the first side 120c of
the payout tube 112 until the cable 102 finally flips over and is
again engaged by the winding separator 110-1, but this time on the
second side 110d. The unwinding process continues in the same
manner for the next loop of cable 102 pulled through the payout
tube 112, but on opposite sides of the winding separators 110 and
the payout tube 112.
[0102] Referring to FIG. 42, a method 1000 for forming the above
described coreless wound coil 100 and packaged cable dispenser 10
is shown. In a step 1002, a mandrel assembly is provided having a
longitudinal axis about which the mandrel is rotatable. In a step
1004, an odd number of at least three winding separators 110, 112
is provided, wherein each of the winding separators 110, 112 has a
first side 110c, 112c and an opposite second side 110d, 112d. As
described previously, one of the winding separators 110, 112 may be
configured as a payout tube 112. In another step 1006, the winding
separators 110, 112 are secured to the mandrel assembly. The flared
ends 110a of the winding separators 110 and the head portion 120 of
the payout tube 112 may beneficially serve as gripping locations
for the mandrel assembly, which may be provided as two halves that
clamp on each side of the separators 110, 112. In a step 1008, an
end 102a of the telecommunications cable 102 is secured to the
mandrel. The mandrel is then rotated in a step 1010 to cause the
telecommunications cable 102 to be wound about the mandrel to form
a wound coil 100 of telecommunications cable 102. In a step 1012,
the telecommunications cable 102 is woven between the winding
separators 110, 112 as the telecommunications cable 102 is being
wound onto the mandrel. Accordingly, the telecommunications cable
102 alternately passes on one of the first and second sides 110c,
112c, 110d, 112d of one winding separator 110, 112 and on the other
of the first and second sides 110c, 112c, 110d, 112d of an adjacent
winding separator 110, 112. In a step 1014, the wound cable 102 can
be removed from the mandrel and installed within a package 200 to
form a packaged cable dispenser 10.
[0103] Referring back to FIGS. 34-35, a second embodiment a
packaged cable dispenser 10' including a coreless wound coil 100'
disposed in a package 200' is disclosed. A third embodiment 10'' is
shown at FIG. 36, which includes the same features of the second
embodiment, but with slightly different dimensions. The second and
third embodiments 10' and 10'' share many features in common with
the first embodiment 10. Accordingly, the description for the first
embodiment 10 is applicable for the second and third embodiments
10' and 10'', to the extent that similar features exist.
Accordingly, like references numbers will be used for like
features.
[0104] In one aspect, the coreless wound coil 100' includes a
length of a length of telecommunications cable 102 wound to define
an exterior winding surface 104 and an interior winding surface 106
further defining a hollow interior 108. In another aspect, the
package 200' includes interconnected sidewalls 202, 204, 206, 208
extending between a top side 210 and a bottom side 212. The
sidewalls 202, 204, 206, 208 can define an interior perimeter 220.
As shown, the exterior winding surface 104 of the wound coil 100 is
within the interior perimeter 220 of the package 200. The wound
coil 100' can be formed in the same general manner as that
described for coil 100, wherein the cable 102 is moved back and
forth across the width of the coil 100 such that the segment of
cable 102 being wound crosses over the previously wound segment of
cable 102 one or more times for each wrap of the coil 100.
[0105] As with the first embodiment 10, a payout tube 112 can be
provided. As shown, the payout tube 112 extends through the wound
coreless coil 100' between the hollow interior 108 and the exterior
surface 104 of the wound coreless coil 100'. The payout tube 112
further extends through one of the interconnected sidewalls 202,
204, 206, 208 of the package 200'. The end 102a of the
telecommunications cable 102 extends through the payout tube 112
from the interior winding surface 106 to allow the coil 100' to be
unwound from the interior winding surface 106 to the exterior
winding surface 104.
[0106] In contrast to the first embodiment of the packaged cable
dispenser 10, which uses winding separators 110, 112 to maintain
the winding pattern of the wound coil 100, the second embodiment
10' utilizes the package 200' to maintain the winding pattern
without the use of embedded separators 110. The coil 100' can be
initially provided as an initially generally cylindrically shaped
coil 100 having an exterior winding surface 104 with a dimension D1
while the sidewalls 202, 204, 206, 208 of the package 200' form a
non-cylindrically shaped package having a dimension D2 that is
smaller than the dimension D1. As such, when the wound coreless
coil 100' is inserted into the package 200', the wound coreless
coil 100' is compressed by the interconnected sidewalls 202, 204,
206, 208 of the package 200' thereby causing the shape of the wound
coreless coil 100' to be deformed to conform to the interior
perimeter 220 of the package 200'. Consequently, the wound coreless
coil 100' has an obround or non-cylindrical shape once disposed in
the package 200'. The compression caused by the package 200' aids
in maintaining the coil 100' in a wound state even after a
significant portion of the cable 102 has been removed from the
package 200' such that the winding pattern of the coil 100' remains
until all or nearly all of the cable has been removed from the
package.
[0107] Referring to FIG. 43, a method 1100 for forming the above
described coreless wound coil 100' and packaged cable dispenser 10'
is shown. In a step 1102, a mandrel assembly is provided having a
longitudinal axis about which the mandrel is rotatable. In a step
1104, an end 102a of the telecommunications cable 102 is secured to
the mandrel. The mandrel is then rotated in a step 1106 to cause
the telecommunications cable 102 to be wound about the mandrel to
form a generally cylindrically shaped wound coil 100 of
telecommunications cable 102. In one embodiment, the cable 102 is
moved back and forth across the width of the wound coil 100 as it
is being wound to cause the segment of cable 102 currently being
wound to cross and overlap the previously wound segment of cable
102 at least once. Once wound, the generally cylindrical-shaped
wound coil has an initial first outside dimension and can be
removed from the mandrel assembly in a step 1108. In a step 1110, a
package is provided that defines an interior having a first
interior dimension that is smaller than the wound coil initial
first outside dimension. In a step 1112, the wound coil is
installed into the package by deforming the wound coil to have a
non-cylindrical shape conforming to the interior of the package
such that the wound coil has a deformed outside dimension that is
smaller than the initial outside dimension and/or that is equal to
the package interior dimension.
[0108] Referring to FIGS. 45-53, another variation of the packaged
cable dispenser 10''' is shown. The description for the first
embodiment 10 is applicable for the fourth embodiment 10''', to the
extent that similar features exist. Accordingly, like references
numbers will be used for like features.
[0109] The dispenser 10''' includes winding separators 111 having
features in common with the winding separators 110, 112 shown in
the example presented at FIGS. 8-33. As such, the description for
winding separators 110, 112 is applicable to the winding separator
111 in certain aspects. In the example shown, three winding
separators 111 are shown, but other odd number of separators may be
used, for example 5, 7, and 9 separators.
[0110] In one aspect, the winding separators 111 are formed by a
pair of identical first and second half pieces 113. The individual
half pieces 113 can be most easily seen at FIGS. 47-50 in a
disassembled state. Each half piece 113 is provided with a pair of
posts 113a that insert into recesses 113b at each end of the half
piece 113. Each half pieces is also provided with a plurality of
second posts 113c received by corresponding recesses 113d between
the posts and recesses 113a, 113b. Each half piece 113 includes a
channel 113e extending between the ends of the half piece 113. In
the example shown, the recesses 113b, 113d extend all of the way
through the half piece 113 and are thus apertures through the half
piece 113. Alternatively, the recesses 113b, 113d can extend only
partially into the half piece material.
[0111] When mated together, the channels 113e of each half piece
113 form the payout tube 112 through which a cable 100 can be fed.
The second posts and recesses 113c, 113d aid in securing the half
pieces 113 along the channel 113e. The posts and recesses of the
half piece 113 are structured such that the half pieces can be
press-fit together and such that they are held together by
frictional forces. This configuration allows the half pieces 113 to
be pulled apart by a user after dispensing the cable 100. This
functionality is particularly desirable for the winding separator
111 that is actually used as the payout tube 112 for dispensing
cable as having separable half pieces 113 allows the winding
separator to be removed from the cable 100 without requiring
cutting. Other attachment means may be used. In an alternative
embodiment, the winding separator 111 that is used for the payout
tube 112 is formed with the half pieces 113 and the remaining
separators 111 are formed as a single unitary component.
[0112] Each half piece also defines a pair of channels 113f at one
end of the half piece and a pair of channels 113g at the other end
of the half piece. The channels 113f extends between a funnel
shaped inlet surface 113h and a funnel shaped outlet surface 113j
As discussed later, these channels enable the winding separators
111 to be secured to either a winding hub assembly 600 and/or to a
winding ring assembly 200'. Surfaces 113h,j provide a smooth,
rounded, and gradually expanding surface for guiding the cable
100.
[0113] Once mated together, the winding separators 111 define a
first end 111a at which a head portion 111c is defined and a second
end 110b at which a base portion 111d is defined. A stem portion
111e is defined between the head and base portions 111c, 111d. The
stem portion 111e is generally similar to the stem portion 116 of
separator 110 and the head portion 111c is generally similar to the
flared first end 110a of separator 110. Accordingly, these features
need not be further discussed here. However, and as stated
previously, the separators 111 define a central payout tube 112
which extends through the head portion 111c. Accordingly, during
dispensation of the cable 100, the cable 100 will continually loop
around the head portion 111c in the same general manner as
described for the head portion 120 of separator 112. In the example
shown, the separators 111 are held in place by a ring assembly 200'
that does not have end walls on either side of the separators 111.
It has been discovered of this application that a shape similar to
head portion 120 can be replaced with a head portion shaped
similarly to head portion 111c (or 110a) with satisfactory
operation when end walls (e.g. 210, 212) are not present.
[0114] Referring to FIG. 47, it can be seen that the dispenser
10''' is provided with a ring assembly 202 having a first ring part
202a and a second ring part 202b. Each of the ring parts 202a, 202a
has a notch 203 for receiving the flanges of the separators in a
secure position. Each ring part additionally has a plurality of
pins and recesses 205, 207 for forming a press-fit connection with
the other ring part. As with the separators 111, the ring assembly
202 can be disassembled after dispensation of the cable is complete
100. The ring parts also have a notch 209 for allowing the free end
of the cable 100 to pass through the ring assembly 202 that
functions as a sidewall to support the cable and that functions to
retain the winding separators 110. Each ring part 202a, 202b also
has a ridge or rim 290 that is raised from an outer surface 292 of
the ring such that a trough is formed about the ring part 202a,
202b. This features allows cable to be wound about the ring
assembly 202 outer surface 292 and retained from falling off by the
ridges 290.
[0115] Referring to FIGS. 51-53, a method by which the cable 100
can be wound onto the dispenser 10''' and packaged for dispensation
through the use of a winding hub assembly 600 is depicted. As shown
at FIG. 51, the winding separators 111 are installed onto the
winding hub assembly 600, which includes a first hub part 602 that
is mated to a second hub part 604 in a press-fit manner. The first
hub part 602 has a plurality of notches 606 while the second hub
part 604 has a plurality of projections 608. The notches 606 are
configured to engage with the channels 113f defined in the winding
separators 111 while the projections 608 close off the open end of
the notches 606 to secure the separators 111 onto the winding hub
assembly. In the position shown at FIG. 51, the cable 100 can be
wound about the hub and around the separators 111 in a manner
similar to described already for dispenser 10. In one example, the
first hub part 602 is mounted to a winding machine. Once winding is
complete, the second hub part 604 can be removed from the first hub
part 602, as shown in FIG. 52. Once the second hub part 604 is
removed, the first ring part 202a can be installed onto the winding
separators 110, as shown at FIG. 53. After this step, the first
ring part 202a and separators 111 can be removed from the first
winding hub part 602 and the second ring part 202b can be press fit
onto the first ring part 202a, as shown at FIG. 45.
[0116] Referring to FIGS. 37-41, components of a telecommunications
distribution system for a building structure 300 having floors 322,
324, 326, and 324 are shown. The building structure 300 is shown as
being a multiple dwelling unit, but may be any other type of
building structure. Referring to FIG. 11, the building structure
300 is shown as having a conduit assembly 302 extending through at
least two floors of the building structure 300. In one example, the
conduit assembly 302 is formed from multiple sections of conduit
304, as shown in FIGS. 12-13, joined by various elbows 304a, tees
304b, wyes, and other types of connectors. In one aspect, the
conduit sections 304 can be routed to telecommunications
distribution housings and/or panels 370. This type of construction
can be advantageous where pulling long continuous lengths of
conduit is difficult or impracticable due to congestion within the
building structure 300. The conduit 304 may be formed to be plenum
rated, riser rated, and/or LSHF rated cable. In one embodiment, the
conduit 304 is micro-conduit having a nominal internal diameter
between about 3 millimeters and 10 millimeters. As shown in FIG.
40, telecommunications cable 102 has been pulled through the
conduit assembly 302 and connected to telecommunications equipment
306 to form an installed telecommunications system 308. The system
308 may be further provided in accordance with the systems
described in the PCT WO '459 publication. The telecommunications
cable 102 can be pulled from either of the previously described and
disclosed packaged cable dispensers 10, 10', 10'', 10'''.
[0117] Referring to FIG. 44, a method 1200 for installing a
telecommunications distribution system within a building structure
is shown. One step 1202 may include installing a conduit assembly
extending through at least two floors of the building structure.
Another step 1204 may include providing a packaged cable dispenser
including a coreless wound coil of telecommunications cable. The
packaged cable dispenser can be any of the previously described and
disclosed packaged cable dispensers. In a step 1206, the
telecommunications cable can be installed within the conduit
assembly.
[0118] Various modifications and alterations of this disclosure
will become apparent to those skilled in the art without departing
from the scope and spirit of this disclosure, and it should be
understood that the scope of this disclosure is not to be unduly
limited to the illustrative embodiments set forth herein.
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