U.S. patent application number 16/405607 was filed with the patent office on 2020-02-20 for flexible extruded cable molding system, methods, and tools.
The applicant listed for this patent is CommScope Technologies LLC. Invention is credited to Wayne M. Kachmar, Ronald J. Kleckowski, Thomas G. LeBlanc, Thomas Marcouiller, Derek Sayres.
Application Number | 20200057227 16/405607 |
Document ID | / |
Family ID | 41378303 |
Filed Date | 2020-02-20 |
View All Diagrams
United States Patent
Application |
20200057227 |
Kind Code |
A1 |
Sayres; Derek ; et
al. |
February 20, 2020 |
FLEXIBLE EXTRUDED CABLE MOLDING SYSTEM, METHODS, AND TOOLS
Abstract
A molding system includes a flexible cable carrier body that
defines a sealing opening that provides access to an interior
channel. A continuous length of the flexible cable carrier body is
wrapped about a spool for storage and for ease of dispensing at a
work site. The continuous length of the cable carrier body is cut
to desired custom lengths during installation at the work site. An
insertion tool having a plow and feeder channel can facilitate
payoff of the fiber/cable into the cable carrier body.
Inventors: |
Sayres; Derek; (Lonsdale,
MN) ; Marcouiller; Thomas; (Shakopee, MN) ;
LeBlanc; Thomas G.; (Westminster, MA) ; Kachmar;
Wayne M.; (North Bennington, VT) ; Kleckowski; Ronald
J.; (Manchester Center, VT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CommScope Technologies LLC |
Hickory |
NC |
US |
|
|
Family ID: |
41378303 |
Appl. No.: |
16/405607 |
Filed: |
May 7, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14950428 |
Nov 24, 2015 |
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16405607 |
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14057634 |
Oct 18, 2013 |
9618720 |
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14950428 |
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12472905 |
May 27, 2009 |
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14057634 |
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61128960 |
May 27, 2008 |
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61056478 |
May 28, 2008 |
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61142811 |
Jan 6, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/50 20130101; Y10T
156/1002 20150115; H02G 11/02 20130101; G02B 6/4446 20130101; B65H
75/38 20130101; B65H 75/22 20130101; G02B 6/4457 20130101; B29C
48/355 20190201; H02G 1/06 20130101; B65H 75/40 20130101; H02G
3/0481 20130101; B65H 75/14 20130101; B29C 2793/0018 20130101; G02B
6/4459 20130101; H02G 3/34 20130101; B29C 48/09 20190201; B29C
48/12 20190201; H02G 3/32 20130101; Y10T 156/1062 20150115; G02B
6/46 20130101 |
International
Class: |
G02B 6/50 20060101
G02B006/50; G02B 6/44 20060101 G02B006/44; G02B 6/46 20060101
G02B006/46; H02G 3/04 20060101 H02G003/04; B29C 48/12 20060101
B29C048/12; B29C 48/09 20060101 B29C048/09; B65H 75/38 20060101
B65H075/38; H02G 11/02 20060101 H02G011/02; H02G 1/06 20060101
H02G001/06; B65H 75/14 20060101 B65H075/14; B65H 75/40 20060101
B65H075/40 |
Claims
1. A fiber optic outlet assembly, comprising: an enclosure defining
a cavity therein; a spool received in the cavity, the spool having
first and second flanges spaced apart from one another with a core
between inside surfaces of the first and second flanges and an
extension extending from an outside surface of the first flange,
wherein the first and second flanges and the core are all situated
to rotate about a common rotation axis; a fiber optic adapter mount
on the spool; a fiber optic cable opening extending through the
enclosure for paying out fiber optic cable from the enclosure; and
a fiber optic adapter opening extending through the enclosure to
provide access to a fiber optic adapter received by the fiber optic
adapter mount.
2. The fiber optic outlet box assembly of claim 1, wherein the
fiber optic mount is connected to the outside surface of the first
flange, the fiber optic outlet assembly further comprising: a fiber
optic adaptor received by the fiber optic adapter mount; a first
fiber optic cable having a first end connected to the fiber optic
adapter; a first portion of the first fiber optic cable extending
from the first end and wrapped around the core; a second portion of
the first fiber optic cable extending through an opening in the
first flange and wrapped around the core; and a third portion of
the first fiber optic cable extending through the fiber optic cable
opening.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
14/950,428, filed on Nov. 24, 2015, which is a continuation of
application Ser. No. 14/057,634, filed on Oct. 18, 2013, now U.S.
Pat. No. 9,618,720, which is a continuation of application Ser. No.
12/472,905, filed on May 27, 2009, now abandoned, which application
claims the benefit of provisional application Ser. No. 61/128,960,
filed on May 27, 2008, provisional application Ser. No. 61/056,478,
filed on May 28, 2008, and provisional application Ser. No.
61/142,811, filed on Jan. 6, 2009, which applications are
incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to devices for use
in the telecommunications industry, and various methods associated
with such devices. More particularly, this disclosure relates to a
cable molding system, and various methods associated with cable
molding systems.
BACKGROUND
[0003] Molding systems are used to hold, protect, and in some cases
conceal cabling. Cabling is sometimes run or is installed in
corners of walls, ceilings, and/or floors of new or existing
structures. Conventional molding systems used to contain such
cabling are rigid and provided in short straight sections. The
short straight sections are typically made of metal or plastic and
joined or mated together in areas having long cabling runs.
Accessory components are required to join section ends of long
cabling runs. Joining section ends of such conventional molding
systems adds time and expense to installation procedures, and can
further cause long cabling runs to look clutter and unappealing. As
can be understood, the rigid short sections of such conventional
systems also do not conform well to anything other than straight
surfaces. Improvement of molding systems is desired.
SUMMARY
[0004] The present disclosure relates to a molding system that
contains cabling, such as fiber optic cabling. The molding system
includes a flexible cable carrier body. In one aspect, the flexible
cable carrier body has a sealing opening that provides access to
and encloses an interior cable-carrying channel. In another aspect,
the flexible cable carrier is manufacture in a continuous length
that is wrapped about a spool for storage. In another aspect, the
continuous length of flexible cable carrier body is dispensed from
the spool at a work site; the dispensed cable carrier body being
cut to a desired custom length.
[0005] A variety of examples of desirable product features or
methods are set forth in part in the description that follows, and
in part will be apparent from the description, or may be learned by
practicing various aspects of the disclosure. The aspects of the
disclosure may relate to individual features as well as
combinations of features, including combinations of features
disclosed in separate embodiments. It is to be understood that both
the foregoing general description and the following detailed
description are explanatory only, and are not restrictive of the
claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a cross-sectional view of one embodiment of a
molding system, in accordance with the principles disclosed;
[0007] FIG. 2 is a schematic representation of one mounting
configuration of the molding system of FIG. 1 in accordance with
the principles of the present disclosure;
[0008] FIG. 3 is a schematic representation of another mounting
configuration of the molding system of FIG. 1 in accordance with
the principles of the present disclosure;
[0009] FIG. 4 is a diagrammatic representation of a method of
manufacturing the molding system of FIG. 1 in accordance with the
principles of the present disclosure;
[0010] FIG. 5 is a diagrammatic representation of a method of
installing the molding system of FIG. 1 in accordance with the
principles of the present disclosure;
[0011] FIG. 6 is a cross-sectional view of another embodiment of a
molding system, in accordance with the principles disclosed in
accordance with the principles of the present disclosure;
[0012] FIGS. 7, 8A, 8B, 9 and 10 show alternative fiber optic
carrier bodies in accordance with the principles of the present
disclosure;
[0013] FIG. 11 shows a cutting configuration for carrier bodies in
accordance with the principles of the present disclosure;
[0014] FIG. 12 shows a cable installation system in accordance with
the principles of the present disclosure;
[0015] FIGS. 13-16 show a fiber optic cable insertion tool usable
with the system of FIG. 12 in accordance with the principles of the
present disclosure;
[0016] FIGS. 17 and 18 show an outlet box usable with the system of
FIG. 12;
[0017] FIGS. 19 and 20 are first side perspective views of an
example insertion tool for use in the cable installation systems
described herein in accordance with the principles of the present
disclosure;
[0018] FIGS. 21 and 22 are second side perspective views of the
example insertion tool of FIGS. 19 and 20 in accordance with the
principles of the present disclosure;
[0019] FIGS. 23 and 24 are first and second side views,
respectively, of the example insertion tool of FIGS. 19 and 20 in
accordance with the principles of the present disclosure;
[0020] FIGS. 25 and 26 are first and second end views of the
example insertion tool of FIGS. 19 and 20 in accordance with the
principles of the present disclosure;
[0021] FIGS. 27 and 28 are top and bottom plan views, respectively,
of the example insertion tool of FIGS. 19 and 20 in accordance with
the principles of the present disclosure;
[0022] FIGS. 29-31 show the example insertion tool of FIGS. 19 and
20 with a pivoting section arranged in an open position in
accordance with the principles of the present disclosure;
[0023] FIGS. 32 and 33 are first side perspective views of an
example base section of an insertion tool for use in the cable
installation systems described herein in accordance with the
principles of the present disclosure;
[0024] FIGS. 34 and 35 are second side perspective views of the
example base section of FIGS. 32 and 33 in accordance with the
principles of the present disclosure;
[0025] FIGS. 36 and 37 are first and second side views,
respectively, of the example base section of FIGS. 32 and 33 in
accordance with the principles of the present disclosure;
[0026] FIGS. 38 and 39 are first and second end views of the
example base section of FIGS. 32 and 33 in accordance with the
principles of the present disclosure;
[0027] FIGS. 40 and 41 are top and bottom plan views, respectively,
of the example base section of FIGS. 32 and 33 in accordance with
the principles of the present disclosure;
[0028] FIGS. 42 and 43 are first side perspective views of an
example pivoting section of an insertion tool for use in the cable
installation systems described herein in accordance with the
principles of the present disclosure;
[0029] FIGS. 44 and 45 are second side perspective views of the
example pivoting section of FIGS. 42 and 43 in accordance with the
principles of the present disclosure;
[0030] FIGS. 46 and 47 are first and second side views,
respectively, of the example pivoting section of FIGS. 42 and 43 in
accordance with the principles of the present disclosure;
[0031] FIGS. 48 and 49 are first and second end views of the
example pivoting section of FIGS. 42 and 43 in accordance with the
principles of the present disclosure;
[0032] FIGS. 50 and 51 are top and bottom plan views, respectively,
of the example pivoting section of FIGS. 42 and 43 in accordance
with the principles of the present disclosure;
[0033] FIGS. 52 and 53 are first side perspective views of an
example covering section of an insertion tool for use in the cable
installation systems described herein in accordance with the
principles of the present disclosure;
[0034] FIGS. 54 and 55 are second side perspective views of the
example covering section of FIGS. 52 and 53 in accordance with the
principles of the present disclosure;
[0035] FIGS. 56 and 57 are first and second side views,
respectively, of the example covering section of FIGS. 52 and 53 in
accordance with the principles of the present disclosure;
[0036] FIGS. 58 and 59 are first and second end views of the
example covering section of FIGS. 52 and 53 in accordance with the
principles of the present disclosure; and
[0037] FIGS. 60 and 61 are top and bottom plan views, respectively,
of the example covering section of FIGS. 52 and 53 in accordance
with the principles of the present disclosure.
DETAILED DESCRIPTION
[0038] Reference will now be made in detail to example 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.
[0039] FIG. 1 illustrates one embodiment of a cable molding system
10 in accordance with the principles disclosed. The molding system
10 includes a flexible, extruded molding or cable carrier body 12
that can mount in the corner of two walls or surfaces, and that can
mount to a flat surface of a wall, floor, or ceiling. The molding
system 10 is designed for use in routing optical fibers and/or
fiber optic cables within the interior of a building. The molding
system is also designed for use in routing fibers and/or cables at
the exterior of a building.
[0040] The extruded cable carrier body 12 of the depicted cable
molding system 10 defines a fully enclosed cavity or interior
channel 14 for containing cabling, such as fiber cabling, for
example. What is meant by "fully enclosed" is that the cavity or
interior channel is entirely enclosed such that no gap exists
around a perimeter or circumference of a cross-section of the
interior channel 14. The enclosed interior channel 14 protects
cabling placed within the channel from environmental damage. In
other embodiments, the interior channel may be partially
enclosed.
[0041] The cable carrier body 12 of the cable molding system of
FIG. 1 has a quarter-round cross-sectional shape. The quarter-round
cross-sectional shape includes a first exterior mounting surface 16
and a second exterior mounting surface 18. The exterior mounting
surfaces 16, 18 are generally planar exterior mounting surfaces. A
non-mounting surface 22 defined by an exterior, convexly curved
surface extends between the first and second exterior mounting
surfaces 16, 18 to close the cable carrier body 12.
[0042] The cable carrier body 12 of the cable molding system 10
defines an opening 24 that provides access to the enclosed interior
channel 14. In the illustrated embodiment, the opening 24 is
located in the non-mounting surface 22 of the cable carrier body
12. Preferably, the opening 24 is a sealing opening that not only
provides access to the interior channel, but also seals and
encloses the interior channel 14 after placement of one or more
cables 44 (one cable shown in dashed line in FIG. 1) within the
interior channel. In the illustrated embodiment, the sealing
opening 24 includes a labyrinth structure 26. The labyrinth
structure 26 is defined by a non-linear cut 28 in the cable carrier
body 12. The non-linear cut 28 extends from the exterior (e.g.,
exterior surface 22) of cable carrier body to the interior channel
14.
[0043] The sealing opening 24 of the present molding system defines
first and second closing portions 30, 32 of the cable carrier body
12. The first and second closing portions 30, 32 can be flexed open
to allow placement of cabling within the interior channel 14 of the
cable carrier body 12.
[0044] A first protrusion 34 defined by the non-linear cut 28 is
formed by the first closing portion 30 of the cable carrier body
12, and a second protrusion 36 defined by the non-linear cut is
formed by the second closing portion 32 of the cable carrier body.
The first protrusion 34 and the second protrusion 36 are aligned
between the interior channel 14 and the exterior of the cable
carrier body to create the labyrinth structure 26 that seals and
encloses the interior channel 14.
[0045] The extruded cable carrier body 12 is made of a flexible
material. As will be described in greater detail hereinafter, the
flexible construction of the cable molding system permits a
continuous length of the cable carrier body 12 to be wrapped around
a spool for storage prior to installation, and for payoff or
dispersal at installation.
[0046] The flexible construction of the present cable molding
system 10 further permits an installer to mount the cable carrier
body 12 in a number of bending or curving configurations, includes
at least first and second curving configurations. In the first
curving configuration, shown in FIG. 2, one of the exterior
mounting surfaces 16, 18 of the cable carrier body 12 is mounted to
a curved surface 38. In this first configuration, the extruded
cable carrier body 12 bends with the curved surface 38 in a first
direction along a non-linear pathway. In the second curving
configuration, shown in FIG. 3, one of the exterior mounting
surfaces of the cable carrier body is mounted to a planar surface
40 such that only the cable carrier body 12 bends or curves along
the planar surface. In this second configuration, the extruded
cable carrier body 12 bends in a second direction of a non-linear
pathway along the planar surface, the second direction being
transverse to the first direction. In yet another configuration,
the cable carrier body 12 can be mounting in a snaking or radius
manner (e.g., see FIG. 3) to a curved surface (e.g., see FIG. 2)
such that the cable carrier body 12 bends in both the first and
second directions.
[0047] As described, the flexible construction of the present
molding system 10 permits the cable carrier body 12 to bend in both
the first direction and the second transverse direction. To bend in
both directions, not only are the closing portions 30, 32 flexible
(to allow placement of cabling within the interior channel), but
also the entire body 12 of the cable molding system 10 is
flexible.
[0048] FIG. 4 is a flowchart illustrating one example manufacturing
process 1001. In the manufacturing process 1001, a continuous
length of the cable carrier body 12 is extruded at an extruding
operation 1010. As noted above, the extruded length of cable
carrier body 12 defines an interior channel 14. In one embodiment,
the extruding operation 1010 forms a carrier body with a
semi-circular transverse cross-section. In another embodiment, the
extruding operation 1010 forms a carrier body with a quarter-round
transverse cross-section. In another embodiment, the extruding
operation 1010 forms a carrier body with a square transverse
cross-section.
[0049] A cutting operation 1020 provides an opening 24 in the cable
carrier body 12 extending between an exterior of the cable carrier
body and an interior channel 14. Typically, the cutting operation
1020 provides a non-linear cut 28 in the cable carrier body 12. The
cutting operation 1020 creates the first and second closing
portions 30, 32 of the cable carrier body 12, as well as the first
and second protrusions 34, 36 of the labyrinth structure 26. In an
optional applying operation 1030, an adhesive material or backing
42 (shown in dashed lines in FIG. 1) can be applied to one or more
of the exterior mounting surfaces (e.g., surfaces 16, 18) of the
cable carrier body 12.
[0050] After cutting the opening 24 at the cutting operation 1020
and optionally applying the adhesive backing 42 at applying
operation 1030, a spooling operation 1040 wraps the continuous
length of the extruded cable carrier body 12 around a spool for
storage. In one embodiment, the spooling operation 1040 wraps and
stores a continuous length of about 500 feet on the spool. As can
be understood greater or lesser continuous lengths can be provided
on the spool for particular storage or work-project
applications.
[0051] In some embodiments, an installer can pre-measure the
required custom lengths of molding to be installed at a remote work
site for a particular application. The installer can pre-cut the
cable carrier body 12 to the required custom lengths for
installation at the remote work site. Alternatively, and referring
to FIG. 5, the cable carrier body 12 can be cut onsite in one
example installation process 1100.
[0052] In installation process 1100, the installer can transport
the spool with the uncut carrier body 12 to the work site at a
transport operation 1110. In some embodiments, the installer can
transport multiple spools of the extruded carrier body 12 to the
work site. At the work site, an installer may dispense a portion of
the continuous length of the extruded cable carrier from the spool
in a payout operation 1120. In one example embodiment, the
installer payouts a portion of the carrier body 12 along and/or
adjacent to a surface to which the carrier is to be secured.
[0053] The installer decides (at determination module 1130) whether
to cut the extruded molding first or whether to secure the extruded
molding first. In the case of the former, the installer cuts the
cable carrier body 12 to an appropriate length at a cut operation
1140 prior to securing the cut body to an existing surface at an
affix operation 1150. In the case of the latter, the installer
first secures the cable carrier body 12 to an existing surface at
an affix operation 1140' prior to cutting the cable carrier body 12
to an appropriate length at a cut operation 1150'.
[0054] At the end of the installation process 1100, the installer
then feeds cabling (e.g., one or more optical fibers) into the
interior channel 14 of the carrier body 12.
[0055] In one method of use, the adhesive backing 42 secures the
molding system 10 to the existing surface. As previously described,
the adhesive backing 42 can be applied to the cable carrier body 12
prior to storage on the spool. The adhesive backing 42 also can be
applied instead to the existing surface, and the cable carrier body
secured to the surface-applied adhesive backing. As can be
understood, the adhesive backing 42 can include material suitable
for adhesion to an exterior surface of a building or an interior
surface of a building.
[0056] Further, in some applications, only a selected single
exterior mounting surface (e.g., surface 16) is adhered to the
existing surface. In such an application, the adhesive backing 42
is applied to the pre-determined mounting surface 16 of the cable
carrier body 12 prior to spooling, or is applied at the work site,
either to the building surface or to the mounting surface 16 of the
cable carrier body 12. In other applications, more than one
selected exterior mounting surface (e.g., both surfaces 16 and 18)
of the carrier body is adhered to existing building surfaces.
[0057] In addition and as previously described, the cable carrier
body 12 can be installed or secured to the existing building
surface or surfaces along a non-linear pathway, such as described
above with regards to the first and second curving
configurations.
[0058] When the cable carrier body 12 is secured, the installer
inserts cabling into the interior channel 14 of the cable carrier
body. Insertion can be assisted by use of a plow tool that opens
the opening 24 of the cable carrier body. In some embodiments,
after insertion, the opening 24 of the cable carrier body 12
recovers to enclose the cabling within the interior channel 14.
What is meant by "recovers" is that the closing portions 30, 32 of
the cable carrier body return to a closed, sealed position without
assistance from the installer. That is, the installer does not need
to close a flap or cover, and does not need to snap-fit or
press-closed any structure of the carrier body. The carrier body
instead recovers without assistance to close automatically and to
enclose the interior channel. In other embodiments, cable carrier
bodies can be provided with catches or latches that allow the
opened portion to be manually closed and then retained in the
closed position.
[0059] In some applications, two or more ends of lengths of cable
carrier bodies can be joined along straight pathways, non-linear
pathways, and angled pathways by way of a joining device. Because
of the ability to dispense custom lengths of the cable carrier body
from the spooled continuous length, less joining is required. This
provides a molding system having a cleaner look that can be
installed in less time than conventional systems with short
sections that require more joined unions.
[0060] Referring now to FIG. 6, another embodiment of a cable
molding system 210 is illustrated. Similar to the previous system
embodiment, the molding system 210 includes a flexible, extruded
molding or cable carrier body 212 that can mount in the corner of
two walls or surfaces, and that can mount to a flat surface of a
wall, floor, or ceiling. The molding system 210 is also similarly
designed for use in routing cables within the interior of a
building or at the exterior of a building.
[0061] Like the previous embodiment, the extruded cable carrier
body 212 of the cable molding system 210 defines an enclosed cavity
or interior channel 214 for containing cabling, such as fiber
cabling, for example. In this embodiment, the enclosed interior
channel 214 is centrally located in the cable carrier body 212. The
enclosed interior channel 214 protects cabling placed within the
channel from environmental damage.
[0062] The cable carrier body 212 of this cable molding system has
a square cross-sectional shape. The square cross-sectional shape
includes a first exterior mounting surface 216, a second exterior
mounting surface 218, and a third exterior mounting surface 220.
The exterior mounting surfaces 216, 218, 220 are generally planar
exterior mounting surfaces.
[0063] The cable carrier body 212 of the cable molding system 210
defines an opening 224 that provides access to the enclosed
interior channel 214. In the illustrated embodiment, the opening
224 is located in a non-mounting surface 222 of the cable carrier
body 212. Preferably, the opening 224 is a sealing opening that not
only provides access to the interior channel, but also seals and
encloses the interior channel 214 after placement of a cable within
the interior channel. In the illustrated embodiment, the sealing
opening 224 includes a labyrinth structure 226 that encloses the
interior channel 214. The labyrinth structure 226 is defined by a
non-linear cut 228 in the cable carrier body 212. The non-linear
cut 228 extends from the exterior (e.g., exterior surface 222) of
cable carrier body to the interior channel 214. As previously
described, the non-linear cut 228 defines first and second closing
portions 230, 232, of the cable carrier body, as well as first and
second protrusions 234, 236 that create the labyrinth structure 226
to seal and enclose the interior channel 214.
[0064] Also as previously described, the extruded cable carrier
body 212 is made of a flexible material for the advantages
aforementioned. The methods of manufacture and the methods of
installation herein described with respect to the first molding
system embodiment apply to the molding system 210 of FIG. 6 as
well.
[0065] Referring now to FIGS. 7 and 8A, another embodiment of a
cable molding system 310 is illustrated. The molding system 310
includes a flexible, extruded molding or cable carrier body 312
that can mount to a flat surface of a wall, floor, or ceiling. The
molding system 310 is also similarly designed for use in routing
cables within the interior of a building or at the exterior of a
building.
[0066] The extruded cable carrier body 312 of the cable molding
system 310 defines a cavity or interior channel 314 for containing
cabling, such as fiber cabling, for example. In one embodiment, the
channel 314 is adapted to contain a plurality of fiber optic cables
each including at least one bend insensitive fiber. In certain
embodiments, the fiber optic cables can have outer diameters less
than 2 millimeters, or less than 1.5 millimeters, or about 1.2
millimeters. The interior channel 314 protects cabling placed
within the channel from environmental damage.
[0067] The cable carrier body 312 of the cable molding system 310
has a semi-circular transverse cross-sectional shape. The cable
carrier body 312 includes a base portion 307 and a cover portion
309 that projects outwardly from the base portion 307. The base
portion 307 and the cover portion 309 cooperate to define the
interior channel 314. The base portion 307 includes a planar
exterior mounting surface 316 that extends between edges 313, 315.
The cover portion 309 includes a convex exterior surface 317 having
a convex curvature that extends generally from edge 313 to edge
315.
[0068] The cable carrier body 312 of the cable molding system 310
defines an access location 324 that provides access to the interior
channel 314. In the illustrated embodiment, the access location 324
is defined through the cover portion 309 of the cable carrier body
312. Preferably, the access location 324 opens to provide access to
the interior channel 314, and also closes (e.g., seals) to enclose
the interior channel 314 after placement of a fiber optic cable
within the interior channel 314.
[0069] In the illustrated embodiment, the access location 324 is a
weaker region of the cover portion 309 which provides a predefined
opening location that extends along the length of the carrier body
310. The predefined opening location preferably can be opened by
tearing, cutting, or otherwise pulling apart the portions of the
cover portion 309 located on opposite sides of the weaker region.
The access location 324 can be provided by perforating, notching or
otherwise weakening a predefined location of the cable carrier body
312. In certain embodiments, the cable carrier body 312 can be slit
at the access location as the carrier body 312 is extruded. After
extrusion, the slit region may partially reseal, but will be weaker
than the remainder of the carrier body 312.
[0070] A rip cord 321 can be embedded in the cover portion 309 at
the access location 324 to facilitate tearing open the access
location 324. The rip cord 321 can be pulled at the factory or can
be pulled in the field at the time the carrier body 310 is being
used. Once the rip cord 321 has been pulled, the access location
324 can be readily opened by applying a spreading/separating force
to the access location 324 to spread apart portions of the cover
portion 309 (e.g., the flaps) located on opposite sides of the
access location thereby forming an open slot or gap at the access
location 324. It is preferred for the carrier body 312 to have a
resilient construction such that the cover portion 309 is biased to
resiliently return from the open position to a closed position once
a fiber optic cable has been installed in the carrier body 310 and
the spreading/separating force is no longer being applied at the
access location 324.
[0071] In FIG. 8A, the access location 324 is defined through the
cover portion 309 in close proximity to the base 307. In this
embodiment, the interior of the carrier body 312 is access by
flexing open a main flap 323 that defines a majority of the cover
portion 309. FIG. 8B shows a carrier body 412 having a base 407 and
a cover portion 409. An access location 424 is provided at a
mid-point of a cover portion 409. In this embodiment, the interior
of the carrier body 412 is access by flexing apart flaps 421
located at opposite sides of the access location 424. In still
other embodiments, weakened portions forming the access locations
may not be provided during the extrusion process. Instead, access
locations may be formed by slitting or otherwise cutting the
carrier body after the extrusion process. This cutting or slitting
of the main body may take place in the factory, or can be done in
the field during installation of the carrier body.
[0072] Referring to FIG. 8A, the carrier body 312 includes one or
more strength members 325 embedded in the base portion 307. In the
depicted embodiment, the carrier body 312 includes a pair of
spaced-apart strength members 325 that extend along the length of
the carrier body 312. In certain embodiments, the strength members
325 can include strands of aramid yarn, metal wires, rods formed of
glass fiber reinforced epoxy or other structures adapted to
reinforce the base portion 307 to resist tearing of the base
portion 307 upon installation. As shown at FIGS. 9 and 10, the
carrier body 312 can be secured to a structure, such as a wall, by
one or more fasteners 330 (e.g., a screw or bolt), 332 (e.g., a
staple) that extend through the base portion 307 at a location
adjacent the strength members 325. Fastener 330 is shown extending
between the strength members 325 with a head of the fastener
overlapping the strength members 325. Fastener 332 is shown
straddling the strength members 325.
[0073] Also as previously described, the extruded cable carrier
bodies 312 and 412 are made of a flexible material for the
advantages aforementioned. The methods of manufacture and the
methods of installation herein described with respect to the first
molding system embodiment also apply to the carrier bodies 312 and
412.
[0074] In each of the embodiments of FIGS. 1, 6, 8A and 8B, the
molding system can be spooled for easy storage and payoff. The
molding or cable carrier body can be unspooled or dispensed and cut
to length at a job site during installation, or can be cut to
pre-measured custom lengths off site. The flexibility of the
present molding system not only allows continuous lengths to be
efficiently stored, but also allows for routing such molding along
large radii and other curved and odd shaped surfaces. The
accommodation of custom lengths by the present molding system
provides cabling pathways having a cleaner, less jointed
appearance.
[0075] It will be appreciated that the carrier bodies can be cut at
various angles (e.g., straight cuts and 45 degree angled miter
cuts). For example, FIG. 11 shows two pieces of carrier body 312
cut at 45 degree miter angles so as to form a 90 degree corner
section. FIG. 12 shows a plurality of carrier bodies 312 cut at 45
degree miter angles so as to define a plurality of 90 degree T
branches locations.
[0076] Other aspects of the present disclosure relate to systems
for installing drop cable or optical fibers in a building, such as
a multi-dwelling unit (e.g., a mid-rise or high-rise building).
When installed, the cable carrier is used to route optical fiber
701 or fiber cable from a wall box 900 (e.g., a fiber distribution
hub, drop terminal, optical network terminal, or other enclosure)
to one or more optical outlet boxes 800, which provide optical
connections to subscriber locations 850. Example outlet boxes 800
are shown in FIGS. 17 and 18.
[0077] One example installation system 500 in which example cable
carrier 312 is deployed is shown schematically in FIG. 12. As will
be understood, however, other types of cable carrier, including any
of the cable carrier configurations disclosed herein, could be used
in installation system 500. Generally, the installation system 500
includes a spool 501 on which the flexible cable carrier 312 is
mounted and one or more spools 700 of fiber optic cable 701 (e.g.,
fiber optic cable having bend insensitive fibers as described
above) to be paid out in the cable carrier 312. In certain
embodiments, the installation system 500 includes a fiber insertion
tool 600 (e.g., see FIGS. 13-16) to facilitate cable payout as will
be discussed in greater detail herein.
[0078] To install the flexible cable carrier, an installer unwinds
the carrier 312 from its spool 501 and cuts it into pieces of
appropriate length. The pieces of the cable carrier 312 are then
secured along a desired cable routing path. A wall box 900 is
installed at one end of the cable routing path and one or more
optical outlet boxes 800 are mounted at spaced apart locations
along the cable routing path. For example, the outlet
boxes/terminals 800 can be mounted at different subscriber
locations 850 (e.g., apartments, residences, businesses, etc.)
positioned along the cable routing path. In the example routing
path shown in FIG. 12, a main trunk 312M of the cable carrier 312
extends away from the wall box 900. Multiple branches 312b of the
cable carrier 312 each extends between the main trunk 312M and one
of the outlet boxes 800.
[0079] The fiber optic cables/optical fibers 701 wrapped around the
fiber spools 700 preferably have connectorized ends 701a, 701b. The
connectorized ends 701a of the fiber optic cables/optical fibers
701 can be plugged into fiber optic adapters provided at an adapter
bank 902 mounted at the wall box 900. The installer then feeds the
cables/fibers 701 into the cable carrier 312. When the
cables/fibers 701 are paid out, the spool 700 can be positioned
within the outlet terminal 800 so that any excess fiber optic cable
remaining on the spool can be stored within the outlet terminal
800. The second connectorized end 701b of the fiber optic cable 701
can be plugged into a first port of a fiber optic adapter 1000
either carried by the spool 700 or provided separately at the
outlet terminal 800. A connectorized end 1002 of a fiber optic line
1004 routed into the subscriber location can be plugged into a
second port of the fiber optic adapter 1000 to provide an optical
connection between the line 1004 and the fiber optic cable 701.
[0080] In some embodiments, an appropriate length of the fiber
optic cables/optical fibers 701 being paid out are unwound from the
spools 700 and laid out next to the installed cable carrier 312. An
installer then can feed the cable/fibers 701 into the carrier body
312 using a fiber insertion tool (see 600 of FIGS. 13-16). In other
embodiments, the cables/fibers 701 can be installed into the
carrier body 312 directly from the fiber optic spools 700 without
first being laid out. For example, in one embodiment, the fiber
optic spools 700 can be mounted on spindles 602 provided on the
fiber insertion tool 600 (see FIGS. 13-16). In another embodiment,
the fiber optic spools 700 can be coupled to a belt or other
accessory worn by the installer.
[0081] In certain embodiments, the spools 700 on which the fiber
optic cables/optical fibers 701 are wrapped are relatively small in
diameter. In one embodiment, each of the spools upon which the
fiber optic cables is wrapped has an inner diameter less than 2
inches, an outer diameter less than 6 inches and a spacing between
flanges less than 2 inches. In a more preferred embodiment, each of
the spools has an inner diameter less than 1.5 inches. In a still
more preferred embodiment, each of the spools has an inner diameter
less than 1 inch. In other embodiments, however, the spools 700 can
have an outer diameter of twelve or more inches.
[0082] It is also preferred for the fiber optic cables/optical
fibers 701 installed within the flexible cable carrier to be
relatively small in diameter. By way of example, the fiber optic
cables/optical fibers 701 can have a diameter less than 2000
microns, or less than 1500 microns, or less than 1000 microns. In
certain embodiments, the fiber optic cables can include an optical
fiber, a buffer layer surrounding the optical fiber, a reinforcing
layer made of a material such as aramid yarn surrounding the buffer
layer, and an outer jacket. In other embodiments, bare or
upjacketed optical fibers are utilized instead. In certain
embodiments, the fiber insertion tool can be adapted for installing
12 or more fibers or cables at one time, and the cable carriers can
be sized for holding at least 12 optical fibers or cables, each
having a diameter of 1.2 millimeters.
[0083] In general, the fiber insertion tool is configured to spread
apart one or more portions of the carrier body 312 to provide
access to the internal channel 314 as the fiber insertion tool is
slid along the access opening 324 of the carrier body 312. The
fiber insertion tool also is configured to route the cables/fibers
701 into the internal channel 314 from an exterior of the carrier
body 312 after spreading apart the carrier body 312. More
particularly, the fiber insertion tool includes a body having a
plow/spreader that is configured to open the carrier body and a
feeder channel that is configured to route the fibers/cables into
the carrier body.
[0084] In use, the plow/spreader of the fiber insertion tool can be
inserted into the main trunk 312m of the flexible cable carrier 312
of the installation system 500. The insertion tool is then moved
along the length of the main trunk causing the plow to spread open
a portion of the flexible cable carrier 312. As the flexible cable
carrier 312 opens, the fiber insertion tool lays the fiber optic
cables/optical fibers 701 into the interior channel of the flexible
cable carrier 312 through the feeder channel. In one embodiment,
the fiber insertion tool feeds the cables/fibers 701 into the
carrier 312 from the spools 700. In another embodiment, the fiber
insertion tool feeds the cables/fibers 701 into the carrier 312
from a laid out position adjacent the carrier.
[0085] When the fiber insertion tool reaches a first breakout
location 505 (e.g., a location where one of the outlet
boxes/terminals 800 is located), a second fiber insertion tool can
be used to lay the optical cable/fibers 701 in one of the branch
sections 312B of flexible cable carrier 312 that extend from a main
trunk 312M of cable carrier 312 to one of the outlet terminals 800.
Thereafter, the spool 700 can be positioned within the outlet
terminal 800 so that any excess fiber optic cable remaining on the
spool can be stored within the outlet terminal 800. The second
connectorized end 701b of the fiber optic cable/fiber 701 can be
plugged into a first port of a fiber optic adapter 1000 that is
either carried by the spool 700 or provided separately at the
outlet terminal 800. A connectorized end 1002 of a fiber optic line
1004 routed into the subscriber location can be plugged into a
second port of the fiber optic adapter 1000 to provide an optical
connection between the line 1004 and the fiber optic cable 701.
[0086] Thereafter, the fiber insertion tool is again moved along
the length of the main trunk 312M of flexible cable carrier 312 and
the process is repeated at various breakout locations until the
desired number of fiber optic cables/optical fibers 701 routed
through the main trunk 312M of flexible cable carriers 312 have
each been routed to a corresponding one of the outlet
boxes/terminals 800.
[0087] FIGS. 13-16 schematically depict one example embodiment of
the fiber optic cable insertion tool 600 described as being usable
with the installation system 500 of FIG. 12. The fiber optic cable
insertion tool 600 includes a handle assembly 606 attached to the
plow 604. The handle assembly 606 includes an extension arm 608
having a base end 610 attached to the plow 604 and an outer end 612
attached to a gripping member 614. As shown at FIG. 14, the handle
assembly 606 can be mounted at a central position 616 of the plow
604, a leftward offset position 618 of the plow 604, or a rightward
offset position 620 of the plow 604. In certain embodiments,
depending on the style of carrier body being used or the location
at which the carrier body is mounted, an operator can mount the
handle assembly 606 at any one of the mounting positions to promote
ergonomic ease of use.
[0088] The gripping member 614 is preferably removably attached to
the outer end 612 of the extension arm 608. One or more dies or
blades 615 for use in cutting the carrier bodies 312 can be stored
within the gripping member 614. When it is desired to cut a carrier
body, the gripping member 614 can be removed from the extension arm
608, the appropriate blade or die can be selected and attached to
one end of the gripping member 614, and then the gripping member
614 can be used to provide the desired cut to the carrier body
312.
[0089] The plow 604 has tapered configuration suitable for opening
the access location 424 as the fiber optic cable insertion tool 600
is slid along the length of the carrier body 312. The front of the
plow includes a narrow front tip 624 adapted to be inserted within
the interior channel of the carrier body 312. From the front tip
624, the plow widens both laterally and vertically as the plow
extends in a rearward direction. The maximum width and height of
the plow are selected to ensure that the cover portion 307 of the
cable carrier body 312 is spread open as the plow is slid
longitudinally within the interior channel of the carrier body 312.
In use, the front tip 624 of the plow 604 is inserted into the
interior channel of the carrier body 312 and the insertion tool is
manually pushed or pulled in direction 650 (FIG. 13) by pressure
applied through the handle assembly 606.
[0090] In certain embodiments, the fiber optic insertion tool 600
can include a cutting element for slitting the carrier body 312 as
the fiber optic cable insertion tool is moved along the length of
the carrier body 312. In other embodiments, the fiber optic
insertion tool 600 can include a rip cord pulling tool for pulling
the rip cord 321 from the carrier body 312 as the fiber optic cable
insertion tool is moved along the length of the carrier body
312.
[0091] A fiber optic cable feed opening 630 is provided adjacent a
rear end of the plow 604. An access slot 631 allows fiber optic
cables 701 from the spools 700 to be loaded into the feed opening
630. As shown at FIG. 15, an open region 632 is defined at the
underside of the plow 604. In certain embodiments, the feed opening
can be rounded or can include rollers to facilitate passing the
fiber optic cables 701 through the feed opening 630 with minimal
friction.
[0092] In certain embodiments, spindles 602 can be provided on a
bar 640 of the fiber optic cable insertion tool 600. The bar 640
can be attached to the extension arm 608 of the handle assembly
606. In one embodiment, at each breakout 505 on the main trunk 312M
of the carrier 312, one of the spools 700 is removed from its
corresponding spindle 602 on the fiber insertion tool 604 and
placed on a spindle of the second fiber insertion tool. The spool
700 can be removed from the second fiber insertion tool and loaded
into the outlet terminal 800 when the corresponding fibers have
been paid out.
[0093] In use of the fiber optic cable insertion tool 600, the
cable/fiber spools 700 can be mounted to the spindles 602. The
fiber optic cables 701 of the spools 700 are then routed laterally
into the feed opening 630 of the plow 604 through slot 631. As the
plow 604 is moved along the length of the flexible cable carrier
312, the plow pushes the access location 324 of the carrier body
open to form an open slot through which the extension arm 608 of
the handle assembly 606 can pass. As the plow 604 moves
longitudinally through the interior region of the carrier body 312,
the fiber optic cables 700 are pulled from the spools 700 causing
the spools to rotate to allow the fiber optic cables 701 to be paid
off the spools 700. As the fiber optic cables 701 are paid off from
the spools 700, the fiber optic cables 701 pass through the feed
opening and are laid in the interior region of the carrier body
312.
[0094] FIGS. 17 and 18 show an example of one of the outlet boxes
800 that can be used in the system of FIG. 12. The outlet box 800
includes an enclosure 802 for housing one of the spools 700. The
enclosure 802 includes a base piece 804 and a cover 806. The base
piece 804 is adapted for connection to a structure such as a wall.
The enclosure 802 is depicted as being generally rectangular. In
one embodiments, the enclosure has a height less than about 7
inches, a width less than about 7 inches and a depth less than
about 3 inches. The base piece 804 includes a spindle 806 on which
the spool 700 rotatably mounts. The base piece 804 also defines a
cable opening 808 through which cable 701 from the spool 700 can be
dispensed. The base piece 804 can also include an access slot 810
for allowing the cable 701 to be laterally inserted into the cable
opening 808.
[0095] Referring still to FIGS. 17 and 18, the spool 700 includes a
first piece 710 and a second piece 712 that can be connected
together (e.g., by a snap-fit connection) to form the spool 700.
The first piece 710 include includes a spool flange 714 on which a
plurality of adapter mounts 716 are provided. The adapter mounts
716 allow one or more of the fiber optic adapters 1000 to be
mounted to the spool 700. As shown at FIG. 18, the fiber optic
connector 701b of the fiber optic cable/optical fiber 701 is
mounted in a first port of the fiber optic adapter 1000, and a dust
plug 1006 is mounted in a second port of the fiber optic adapter
1000. When the spool 700 is mounted within the enclosure 802, the
second port of the fiber optic adapter is configured to align with
a selected opening 820 defined though the enclosure 802. Openings
820 are provided at each side of the enclosure to allow the
installer to access the adapter 1000 from a variety of positions.
By removing the dust plug, the connector 1002 of the subscriber
line 1004 can be inserted through the opening 820 and into the
second port of the fiber optic adapter 1000. In other embodiments,
the subscriber line can be routed through an opening at another
location (e.g., the back) of the enclosure.
[0096] The second piece 712 of the spool 700 includes a spool
flange 720 and a core 722 positioned at a center of the spool
flange 720. The core 722 is adapted to snap within an opening
defined by the flange 714 of the first piece 710 of the spool 700.
The core 722 defines an inner diameter of the spool 700 about which
the fiber optic cable/optical fiber 701 is wrapped. The fiber optic
cable/optical fiber 701 is wrapped about the core 720 at a location
between the flanges 714, 720. A portion of the fiber optic cable
701 also passes through the flange 714 from the region between the
flanges 714, 720 to a front side of the flange 714. The front side
of the flange 714 includes a core extension 730 about which a
portion of the fiber optic cable/optical fiber 701 nearest to the
connector 701b is wrapped. Outermost portions of the flanges 714,
720 define an outer diameter of the spool 700.
[0097] Fiber optic cable from the spool 700 can be dispensed from
the spool while the spool is located within the enclosure 802. For
example, the enclosure 802 can be mounted to a structure (e.g., a
wall) and the connectorized end 701a of the fiber optic cable 701
can be pulled causing the spool 700 to rotate within the enclosure
about the spindle thereby allowing fiber optic cable to be paid out
through the opening 808. For example, the fiber optic cable/optical
fiber 701 can be pulled from the enclosure 802 and the end 701a can
be plugged into a wall box such as wall box 900 of FIG. 12.
Alternatively, the end 701a can be plugged into wall box 900, and
the installer can then move the enclosure 802 to the desired
mounting location while the spool 700 spins within the enclosure
802 to allow the fiber optic cable/optical fiber 701 to be paid out
from the enclosure as the enclosure 802 is moved away from the wall
box 900. Further, the fiber optic cable/optical fiber 701 can be
paid off the spool 700 which the spool 700 is outside the enclosure
(as described with respect to the system of FIG. 12), and the spool
700 can be loaded into the enclosure 802 after the fiber optic
cable 701 has been paid out.
[0098] FIGS. 19-60 illustrate various views of another example
fiber insertion tool 1200 having features that are examples of
inventive aspects in accordance with the principles of the present
disclosure. The example fiber insertion tool 1200 includes a body
1205 defining a plow/spreader tool 1206 and a feeder channel 1208.
The plow/spreader tool 1206 is configured to spread apart one or
more portions of a carrier body to provide access to the internal
channel as the fiber insertion tool 1200 is slid along the access
opening of the carrier body. The feeder channel 1208 defines a
pathway along which cables/fibers 701 are routed into the internal
channel from an exterior of the carrier body.
[0099] In use, a user mounts carrier molding to a surface (e.g.,
using an adhesive backing on the carrier molding). The user pays
off cable/fiber from a spool along the length of the carrier
molding. For example, the user can mount the carrier molding to a
wall adjacent the ceiling and pay off the cable/fiber on the floor
along the wall. The user loads the cable/fiber into the feeder
channel 1208 of the insertion tool 1200, inserts the plow 1206 into
an opening of the carrier molding, and slides the insertion tool
1200 along the carrier molding to pay out the cable/fiber into the
carrier molding.
[0100] The body 1205 can include a support section 1202 and a
handle section 1204 that facilitates manipulation of the support
section 1202 during cable/fiber payout. In some embodiments, the
handle section 1204 is thicker than the support section 1202. For
example, the support section 1202 can have a thickness T.sub.1 that
is less than a thickness T.sub.2 of the handle section 1204 (see
FIG. 25). In one example, the thickness T.sub.1 of the support
section 1202 is sufficiently thin to enable the support section
1202 to fit through the opening defined in a carrier body that
leads to the inner channel. In other embodiments, only the plow
1206 and the feeder 1208 are sufficiently thin to fit within the
opening of the carrier body.
[0101] Some example handles 1204 widen out as the handle 1204
extends away from the support section 1202 (e.g., see FIG. 23).
Other example handles 1204 can taper inwardly or remain a constant
width along their length. In the example shown in FIG. 23, the
handle 1204 defines opposite planar surfaces connected by a rounded
edge. Other example handles can define other shapes, such as
cylindrical shapes, frustro-conical shapes, or organic shapes. Some
example handles also can define finger grooves or other gripping
features to accommodate the user's hands or to otherwise facilitate
gripping of the handle 1204.
[0102] When the insertion tool 1200 is used during cable/fiber
payout, the plow 1206 is inserted into the opening of the carrier
body and pulled in a travel direction (e.g., using the handle
1204). In some embodiments, the plow 1206 extends outwardly from
the body 1205 in the travel direction. In certain examples, the
plow 1206 tapers inwardly as the plow 1206 extends away from the
body 1205. In the example shown in FIG. 23, the plow 1206 defines a
wedge shape having a rounded tip 1211. In other examples, the plow
1206 can define a pointed tip or a flat edged tip. In still other
embodiments, the plow 1206 can define other shapes, such as more
rounded or organic shapes.
[0103] In some embodiments, the plow 1206 has a blade 1212 along at
least one edge of the plow. In the example shown in FIG. 23, the
blade 1212 extends along upper and lower edges of the plow 1206.
One example blade 1212 can be molded from a softer material than
the remainder of the plow 1206, for example, using overmolding
techniques. In other embodiments, the plow 1206 can have a
monolithic construction. In some such example, the blade 1212 can
have a different thickness than the remainder of the plow 1206. For
example, the blade 1212 can be thinner than the remainder of the
plow 1206 (e.g., see FIGS. 22 and 54).
[0104] The feeder channel 1208 extends from a first end 1207 to a
second end 1209. In general, the fibers/cables enter the feeder
channel 1208 at the first end 1207 and exit the feeder channel 1208
from the second end 1209. In the example shown in FIGS. 19-23, the
first end 1207 faces the travel direction and the second end 1209
faces in a generally opposite direction. In other embodiments, the
first and second ends 1207, 1209 can face in other directions. For
example, the second end 1209 can face in a downward direction
extending away from the handle.
[0105] In some embodiments, the feeder channel 1208 defines a
sufficient curve to maintain a minimum bend radius of the
fibers/cables as the fibers/cables are being paid out. In the
example shown, the feeder channel 1208 defines a curve so that the
first end 1207 extends generally upwardly and the second end 1209
extends generally in line with the plow 1206 (see FIG. 23).
Accordingly, the fibers/cables are fed into the internal channel of
a molded carrier as the plow 1206 opens the carrier body.
[0106] Some example feeder channels 1208 are substantially enclosed
as shown in FIGS. 19, 21, 25, and 26. Such feeder channels 1208
contain and protect the fibers/cables routed through the feeders
1208. One such feeder channel 1208 can define a substantially
cylindrical transverse cross-section. Another such feeder channel
1208 can define a substantially oval transverse cross-section
(e.g., see FIG. 25). Other example feeder channels include grooves
or open slots defined within a surface. Such channels can include
retaining flanges to retain the fibers/cables within the
channels.
[0107] The body 1205 of the insertion tool 1200 can be formed from
one or more pieces. In some embodiments, the support section 1202
includes a first section 1221 pivotally coupled to a second section
1222 at a hinge 1225. In the example shown, the hinge 1225 includes
a pivot rod 1231 having stops 1234 arranged on either end (see
FIGS. 42-46). The pivot rod 1231 extends along a pivot axis P (see
FIGS. 23 and 30). The second section 1222 of the support section
1202 is configured to mount pivotally or rotatably to the pivot rod
1231 using couplers 1232. In another embodiment, the second section
1222 can define the pivot rod 1231. The hinge 1225 is coupled to
the body 1205 of the insertion tool as will be discussed in greater
detail herein.
[0108] In certain embodiments, each section 1221, 1222 defines a
portion of the feeder channel 1208. In the example shown in FIGS.
29-31, the first section 1221 defines a first portion 1223 of the
feeder channel 1208 and the second section 1222 defines a second
portion 1224 of the feeder channel (see FIGS. 32-41). In the
example shown, each portion 1223, 1224 defines about half of the
feeder channel 1208. In other embodiments, however, one of the
sections may define a greater portion of the feeder channel 1208
than the other section.
[0109] One of the sections 1221, 1222 can be pivoted open (i.e.,
away from the other section) to arranged the feeder channel 1208 in
an open configuration. Arranging the feeder channel 1208 in the
open configuration provides access to the interior of the feeder
channel 1208. Accordingly, opening the feeder channel 1208 can
facilitate initial loading of fibers/cables into the feeder channel
1208. In the example shown in FIGS. 29-31, only the second section
1222 pivots relative to the handle 1204. In other embodiments,
however, both sections 1221, 1222 can be pivotally mounted to the
handle 1204.
[0110] In some embodiments, the plow 1206 is fully defined by one
of the sections. In the example shown, the plow 1206 is fully
defined by the second (i.e., pivotally mounted) section 1222. In
another embodiment, the plow 1206 can be fully defined by the first
(i.e., non-pivotally mounted) section 1221. In other embodiments,
each section 1221, 1222 can define a portion of the plow 1206. For
example, each section 1221, 1222 may define a half-section of the
plow 1206.
[0111] In some embodiments, the first and second sections 1221,
1222 are held together using first retention features. In one
example, the first retention features are detent features. For
example, as shown in FIGS. 29-31, each of the sections 1221, 1222
can include flanges 1226 and can define cutout portions 1227, 1228
into which the flanges can snap to secure the sections together. As
shown in FIG. 29, the sections 1221, 1222 can define open cutout
portions 1227 and/or closed cutout portions 1228 to receive the
flanges 1226. In one embodiment, the flanges 1226 extend and curve
inwardly from the respective sections to facilitate retention of
the fibers/cables in the feeder channels 1208 when the feeder
channel is arranged in an open configuration.
[0112] In some embodiments, the handle 1204 of the insertion tool
1200 also can include two or more sections. For example, as shown
in FIG. 31, one example handle 1204 includes a first member 1241
and a second member 1251 that cooperate to house the hinge 1225. In
certain embodiments, the members 1241, 1251 fasten together using
second retention features. For example, the second retention
features can include snap or latch features. In the example shown,
the second retention features include protrusions 1255 that snap or
latch into receptacles 1245.
[0113] In certain embodiments, the insertion tool 1200 can be
formed in three parts. For example, a pivoting piece 1231 and a
cover piece 1251 can be mounted to a base piece 1201. One example
base piece 1201 is shown in FIGS. 32-41; one example pivoting piece
1231 is shown in FIGS. 42-51; and one example cover piece 1261 is
shown in FIGS. 52-61. In other embodiments, however, the insertion
tool 1200 can be formed from one, two, four, or more pieces. For
example, the insertion too 1200 can be formed from two clam-shell
pieces. In another embodiment, the insertion too 1200 can be
integrally formed.
[0114] Referring to FIGS. 32-41, one example base piece 1201 of the
insertion tool 1200 includes the first section 1221 of the support
section 1204 and the first member 1241 of the handle 1204. The
first section 1221 includes the first portion 1223 of the feeder
channel 1208. The first member 1241 of the handle 1204 can be
reinforced with ribs 1248. In one example embodiment, the base
piece 1201 can be formed (e.g., injection molded) as a unitary
piece.
[0115] In the example shown, the base piece 1201 also includes a
mounting structure 1248 at which the hinge 1225 can be mounted. In
some embodiments, the mounting structure 1248 includes a cradle
1246 and retaining arms 1247 configured to hold the hinge 1225. In
the example shown, the mounting structure 1248 includes a retaining
arm 1247 arranged on opposite sides of the cradle 1246. When
assembled, a pivot rod 1232 of the hinge 1225 fits in the cradle
1226 and snaps into the retaining arms 1247. In certain
embodiments, the base piece 1201 also defines cutouts 1242 sized
and configured to accommodate ends 1234 of the pivot rod 1232. In
other embodiments, the mounting structure 1248 or another type of
mounting structure 1248 can be arranged on the cover piece 1261 or
another pieces of the insertion tool 1200.
[0116] Referring to FIGS. 42-51, one example pivoting piece 1231 of
the insertion tool 1200 includes the second section 1222 of the
support section 1204 and the hinge 1225. In the example shown, the
second section 1222 includes the second portion 1224 of the feeder
channel 1208 and the plow 1206. In other embodiments, the plow 1206
can be arranged on the base piece 1201 or can be split between the
base piece 1201 and the pivoting piece 1231. In the example shown,
the second section 1222 defines cutouts 1235 to accommodate the
cover piece 1261 disclosed in greater detail herein.
[0117] In some embodiments, the second section 1222 is pivotally
coupled to a pivot rod 1232 of the hinge 1225 by couplers 1233.
Enlarged tips 1234 are arranged on each end of the pivot rod 1232.
In one embodiment, the enlarged tips 1234 retain the couplers 1233
on the pivot rod 1232. As discussed above, the pivot rod 1232 can
be snap fit into retaining structure 1248 of the base piece 1201 to
pivotally mount the pivoting piece 1231 to the base piece 1201.
When the hinge 1225 is secured in the retaining structure 1248, the
second portion 1224 of the feeder channel 1208 aligns with the
first portion 1223 of the feeder channel 1208 to allow the second
portion 1224 to be pivoted between open and closed positions
relative to the first portion 1223.
[0118] Referring back to FIGS. 32-41, in the example shown,
receptacles 1245 are provided on the first member 1241 of the
handle 1204. The receptacles 1245 include retaining structures 1244
mounted to an interior surface of the first member 1241. The
receptacles also define openings 1243 passing through the retaining
structures 1244. In one embodiment, the openings 1243 also pass
through an exterior of the first member 1241 of the handle 1204.
The retaining structures 1244 define inside shoulders 1249.
[0119] Referring to FIGS. 52-61, one example cover piece 1261 of
the insertion tool 1200 includes the second member 1251 of the
handle 1204. In the example shown, the second member 1251 defines a
cutout 1252 between legs 1256. As shown in FIGS. 21 and 22, the
cutout 1252 is sized and configured to accommodate the second
section 1222 of the support structure 1202. The legs 1256 cooperate
with the first member 1241 of the handle 1204 to enclose the hinge
structure 1225 within the insertion tool 1200. The legs 1256 of the
second member 1251 are accommodated by cutouts 1235 of the second
section 1222.
[0120] In certain embodiments, the second member 1251 includes
protrusions 1255 extending from an interior surface of the second
member 1251. The protrusions 1255 include flanges 1253 extending
outwardly from the second member 1251 and tips 1254 configured to
interact with the inside shoulders 1249 within the retaining
structures 1244 of the first handle member 1241. In the example
shown, the protrusions 1255 include spaced flanges 1253 that can
squeeze together when the tips 1254 are cammed into the retaining
structures 1244.
[0121] Systems and methods consistent with the disclosure make
possible the fabrication, installation, and use of extruded
cable/fiber carriers for optical networks. The foregoing
description of example features of the invention provides
illustration and description, but is not intended to be exhaustive
or to limit the invention to the precise form disclosed.
Modifications and variations are possible in light of the above
teachings or may be acquired from practice of the invention.
[0122] For example, implementations consistent with the principles
of the invention can be implemented using other types of
fabrication techniques, and assembly methods other than those
illustrated in the figures and described in the specification
without departing from the spirit of the invention. Furthermore,
additional features can be added, or removed, depending on specific
deployments, applications, and the needs of users and/or service
providers.
[0123] No element, act, or instruction used in the description of
the invention should be construed as critical or essential to the
invention unless explicitly described as such. Also, as used
herein, the article "a" is intended to include one or more items.
Where only one item is intended, the term "one" or similar language
is used. Further, the phrase "based on," as used herein is intended
to mean "based, at least in part, on" unless explicitly stated
otherwise.
[0124] The above specification, examples and data provide a
complete description of the manufacture and use of the composition
of the invention. Since many embodiments of the invention can be
made without departing from the spirit and scope of the invention,
the invention resides in the broad inventive aspects disclosed
herein.
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