Patent Application
20100320309
Wire and cable for installation in residences and buildings typically comes on cable reels. The types of wire and cable are numerous and include 110V three-conductor wire, “Romex”, and dozens of different kinds of low-voltage, multiconductor insulated communications cable, such as that used for setting up Ethernet networks, intercom systems, entertainment systems and the connection of security sensors and devices. A new building under construction will need many kinds of these cables, and several reels of cable will be used by an installer or systems integrator on-site.
One known technique is to provide coils of such cable in boxes and to create a hole in a front or top panel of the (typically cardboard) box for pulling out a desired length of cable. This conventional method has a drawback in that the cable may kink inside of the box or otherwise resist being pulled out of the box to such an extent that a cable installer or technician finds that he or she is pulling the box across the floor. Further, the installer has to install several different lengths of cable on a single run. To do this, the installer has had to identify which kinds of cable he or she needs, individually pull cable out of separate boxes, and estimate as best as he or she can the amount of cable so pulled.
Different cables are typically packed in separate boxes or reels which are often large, heavy, and cumbersome and typically contain long lengths of cable. As a result, the installer has to move multiple large boxes around the job site to install the cables. Moreover, the desired length of each cable for a particular job is usually much shorter than the length of cable in the cartons, so the installer wastes time and energy transporting multiple boxes or reels with too much cable around the job site. The cost for the labor to install this cable typically far exceeds the cost of the cable itself. Anything which can be done to minimize this labor cost conveys a distinct technical advantage. A need, therefore, persists for more efficient methods and apparatus for packing and dispensing cable.
A container for the dispensing of wound cable or wire on reels comprises a carton having a plurality of panels including a front panel having bottom, left and right sides. A bottom panel extends from the bottom side of the front panel and has an upper surface. A left panel extends from the left side of the front panel so as to be orthogonal to the bottom panel and a right panel extends from the right side of the front panel so as to be parallel and spaced from the left panel.
A plurality of reels of cable is rotatably mounted in the carton, so that multiple kinds and/or lengths of cable can be dispensed out of the same carton at the same time. The plurality of reels includes a first reel having a hollow spindle having a right spindle end, a left spindle end, a first spindle length, a left reel flange on the first spindle end, and a right reel flange on the second spindle end. The right and left reel flanges each have a first flange radius.
A second reel includes a second hollow spindle having a right spindle end, a left spindle end, a second spindle length, a left reel flange on the first spindle end, and a right reel flange on the second spindle end. The right and left reel flanges have a second flange radius.
First and second axles are supported between a first support panel and a second support panel. Each axle has a first end, a second end, and a length between the first and second ends that is longer than the first and second spindle lengths. The first support panel is disposed near, to the right of, and parallel to the left panel and has a first set of axle holes. Each axle hole is adapted to receive the first end of an axle and the axle holes are spaced apart from each other by at least the first flange radius plus the second flange radius. Each axle hole is spaced from the panels such that the flange does not contact the panels.
Further, the container has a second support panel disposed near, to the left of, and parallel to the right panel and has a second set of axle holes with each axle hole being adapted to receive the second end of an axle. The second set of axle holes is equal in number and spacing to the first set of axle holes. The first and second reels are rotatably mounted on the first and second axles between the first and second support panels. Preferably, the axles are parallel to one another when inserted into the first and second sets of axle holes.
Additionally, a method for packing cable to increase the ease of simultaneous installation of multiple cables comprises the steps of custom winding a plurality of cables onto a plurality of reels with each reel having a hollow spindle and opening a dispensing carton. The method further comprises installing a first vertical support panel having a first set of axle holes into the dispensing carton and installing a plurality of axles, each axle having a first end and second end, by inserting the first end of each axle into the first set of axle holes. The method further comprises installing the reels into the carton by slipping the hollow spindle of each reel onto an axle, installing a second support panel having a second set of axle holes in the dispensing carton by slipping the second end of each axle into the respective axle hole in the second support panel, and closing the dispensing carton.
The different embodiments of the invention may be used with other systems fro dispensing wire or cable from reels such as those described in U.S. application Ser. No. 12/103,790, now U.S. Published Patent Application No. 2008/0191436 to Galgano et al., the disclosure of which is expressly incorporated by reference.
A carton insert for adapting a carton to contain a plurality of cable reel comprises a first support panel disposed near, to the right of, and parallel to a left panel of a carton and having a first support rod hole, a plurality of sides, and a first set of axle holes. Each axle hole in the first set is adapted to receive a first end of an axle and is spaced a first predetermined distance away from the closest side. Each axle hole is also spaced at least twice the first predetermined distance away from the nearest other axle hole and at least a second predetermined distance from the first support rod hole.
A second support panel is disposed near, to the left of, and parallel to a right panel of the carton and has a second support rod hole, a plurality of sides, and a second set of axle holes. Each axle hole in the second set is adapted to receive a second end of an axle, is at least twice the first predetermined distance from the nearest other axle hole, and is at least the second predetermined distance from the second support rod hole. The second set of axle holes are a mirror image of the first set of axle holes.
Finally, a container for the dispensing of a cable wound on a cable reel comprises a carton having a plurality of panels including a front panel having bottom, left and right sides. A bottom panel extends from the bottom side of the front panel and has an upper surface. A left panel extends from the left side of the front panel so as to be orthogonal to the bottom panel and a right panel extends from the right side of the front panel so as to be parallel and spaced from the left panel. A left panel arbor hole is formed in the left panel about an axis and a right panel arbor hole is formed in the right panel around the axis.
Additionally, a plurality of reels is disposed to be adjacent to one another inside the carton and a plurality of reel caddies is disposed in the carton. Each reel caddy supports an end of a reel.
In a preferred embodiment, a first caddy is disposed in the carton adjacent the left panel and to extend upwardly from an upper surface of the bottom panel. A substantially cylindrical bushing of the first caddy extends inwardly toward the right panel and is formed around the axis that is parallel to the bottom panel. The axis is disposed at a first distance measured orthogonally from the upper surface of the bottom panel with the bushing being formed substantially at a first radius from the axis. A hole is formed in the first caddy to be radially inward from an exterior surface of the bushing thereof.
Similarly, a second caddy is disposed in the carton to be left-facing and to extend upwardly from the upper surface of the bottom panel. A substantially cylindrical bushing of the second caddy extends toward the left panel and is formed around the axis. The bushing of the second caddy is formed substantially at the first radius from the axis and a hole being is formed in the second caddy to be radially inward from an exterior surface of the bushing thereof.
A third caddy is disposed in the carton to be right-facing and adjacent to the second caddy and extends upwardly from the upper surface of the bottom panel. A substantially cylindrical bushing of the third caddy extends toward the right panel and, like the previous bushings, is formed around the axis. The bushing of the third caddy is formed substantially at the first radius from the axis and a hole is formed in the third caddy to be radially inward from an exterior surface of the bushing thereof.
A fourth caddy is disposed in the carton to be left-facing and to extend upwardly from the upper surface of the bottom panel. A substantially cylindrical bushing of the fourth caddy extends inwardly toward the left panel and is formed around the axis. The bushing of the fourth caddy is formed substantially at the first radius from the axis and a hole is formed in the fourth caddy to be radially inward from an exterior surface of the bushing thereof.
Further, the container further comprises a first reel having spaced-part left and right first reel flanges with the right and left first reel flanges, each having a central hole. The first reel flanges are joined by a first spindle. The central holes of the left and right first reel flanges are each formed around the axis and have a second radius which is greater than the first radius. Thus, the bushing of the first caddy may be received in the central hole of the left first reel flange and the bushing of the second caddy may be received in the central hole of the right first reel flange. The largest radius of either the left or right first reel flanges are less than the first distance, thereby permitting the first reel to rotate around the axis inside the carton.
Similarly, a second reel has spaced-part left and right second reel flanges, each second reel flange having a central hole and being joined by a second spindle. The central holes of the left and right second reel flanges are each formed around the axis and have a third radius which is greater than said first radius. The bushing of the third caddy may be received in the central hole of the left second reel flange and the bushing of the fourth caddy may be received in the central hole of the right second reel flange. As above, the largest radius of either second reel flange is less than the first distance so as to permit the rotation of the second reel around the axis inside of the carton.
Further aspects of the invention and their advantages can be discerned in the following detailed description, in which like characters denote like parts and in which:
Referring to
Additionally, the container 100 comprises a plurality of reels including a first reel 120 having a first hollow spindle 122 with a left spindle end 124, a right spindle end 126, and a first spindle length 128. The first reel also has a left reel flange 130 on the first spindle end 124 and a right reel flange 132 on the second spindle end 126 with both the right and left reel flanges 130, 132 having a first flange radius 134. Further, the container 100 includes a second reel 136 having a second hollow spindle 138 having a left spindle end 140, a right spindle end 142, and a second spindle length 144. Also, the second reel 136 has a left reel flange 146 on the first spindle end 140 and a right reel flange 148 on the second spindle end 142 with both the right and left reel flanges 146, 148 having a second flange radius 150. In a preferred embodiment, each flange is made of two layers of cardboard joined to each other and to the spindle as by adhesive.
Referring to
Further, the container has a second support panel 220 disposed near, to the left of, and parallel to the right panel (116 of
The left panel 114 (
Additionally, one or more handles 156 may be formed into a panel 116 of the carton 102 and at least one panel 104 has at least one hole or elongated slot 158. The slot 158 preferably has a width that is approximately equal to the length 128, 144 of the spindles 122, 138 to permit the dispensing of cable 164 out of the carton 102 across substantially the entire spindle length 128, 144 without impinging on the panel 104. Further, the elongated slot preferably is sized to be approximately equal to two thirds of the diameter of the flange. Again, this prevents impingement on the front panel 104 and reduces friction.
Preferably, the carton 102 contains at least one slot 158 per reel. As shown in
Referring back to
In a preferred embodiment, the first set 210 of axle holes comprises four axle holes 210A-D that are equidistant from the left arbor hole (152 of
Referring to
The distance “d” between axle holes is at least twice the first predetermined distance “r,” which is the maximum size of reel flanges and is shown in broken line. Further, the second predetermined distance “x” between the axle hole and the support rod holes is greater than the first predetermined distance “r” and the distance “s” between the axle hole and the nearest panel of the carton is greater than the predetermined distance “r.”
Similarly, the second support panel 220 further comprises a fourth flap 406 having a second set 222 of axle holes 222A-D and a fifth flap 408 joined to the fourth flap 406 and folded so as to space the fourth flap 406 from the right panel (not shown) of the carton 102 such that the fourth flap 406 supports the second ends 206, 216 of the axles 202, 216. Further, a sixth flap 412 is joined to the fourth flap 406 on a first side 416 opposite the fifth flap 408, the fifth and sixth flaps 408, 412 together forming a second support rod hole 430A, B and a fourth set 420 of axle holes 420A-D positioned such that the fourth set 420 of axle holes aligns with the second set 222 of axle holes when the fifth and sixth flaps 408, 412 are folded to be adjacent to the fourth flap 406. As above, the fifth and sixth flaps 408, 412 space the fourth flap from the next adjacent panel of the carton 102 when folded back into a single plane. Additionally, a spacing flap 422 may be joined to the first flap 400 along a second side 401 of the first flap 400. Preferably, the spacing flap 422 is shorter in length by approximately four cardboard thicknesses than the depth of the carton 102. In addition, the spacing flap may be joined to the fourth flap 406 along a second side 414 of the second support panel 220.
It is contemplated that the spacing of the first set 210 of axle holes and the second set 222 of axle holes can be arranged in any pattern around the arbor holes 152, 154 such that the reel flanges 130, 146 do not contact one another or the panels of the carton 102, and do not occlude the linear path between support rod holes 218, 224. Thus, as shown in
Further, the container may comprise a fifth reel 510 having a fifth flange radius 512 and supported on a fifth axle 518 which is, in turn, supported by a fifth axle hole 210E in the first support panel 200 and a fifth axle hole 222E in the second support panel 220. The fifth axle hole in each support panel is spaced from the nearest adjacent axle hole by at least the fifth flange radius plus the flange radius of the nearest adjacent reel and is spaced from its respective support rod hole and from the panels by at least the fifth flange radius 512.
As described above, the reels need not have the same type of cable or even the same flange radii. In fact, the present invention permits the housing of different cable types used in the same job in one carton. For example, a door entry wiring for a home security system comprises four different types of cables: 22 gauge, 6 conductor shielded cable for use with a card reader; 18 gauge, 4 conductor stranded cable to supply power; 22 gauge, 2 conductor wire for use with the door contact; and 22 gauge, 4 conductor wire for use as a spare. Typically, a single carton can carry 125 feet to 500 feet of cable per reel.
Referring to
Further, the method comprises installing (614) a second support panel and affixing (616) a pull line to the cable ends, closing (618) the carton, and affixing (620) the carton to a structure. The step of affixing (620) the carton to a structure may comprise the substeps of inserting (622) an axial support member through the left arbor hole, passing (624) the axial support member through the carton and the right arbor hole, and attaching (626) the axial support member to a structure. The support structure may be an anchor but is preferably a vehicle such as a cart dolly, or a hand truck.
Referring to
A plurality of reels 958, 964, 992 are disposed in the carton 902, the reels being adjacent to one another, and a plurality of reel caddies 920, 930, 940, 950, 976, 984 are disposed in the carton, with each reel caddy supporting an end of a reel.
Preferably, a first caddy 920 is disposed in the carton 902 adjacent the left panel 916 and to extend upwardly from an upper surface 914 of the bottom panel 912. A substantially cylindrical bushing 922 of the first caddy 920 extends inwardly toward the right panel 918 and is formed around the axis 924 that is parallel to the bottom panel 912. The axis 924 is disposed at a first distance 999 measured orthogonally from the upper surface 914 of the bottom panel 912 with the bushing 922 being formed substantially at a first radius from the axis 924. A hole 926 is formed in the first caddy 920 to be radially inward from an exterior surface 928 of the bushing 922 thereof.
Similarly, a second caddy 930 is disposed in the carton 902 to be left-facing and to extend upwardly from the upper surface 914 of the bottom panel 912. A substantially cylindrical bushing 932 of the second caddy 930 extends toward the left panel 916 and is formed around the axis 924. The bushing 932 of the second caddy 930 is formed substantially at the first radius from the axis 924 and a hole 934 is formed in the second caddy 930 to be radially inward from an exterior surface 936 of the bushing 932 thereof.
A third caddy 940 is disposed in the carton 902 to be right-facing and adjacent to the second caddy 930 and extends upwardly from the upper surface 914 of the bottom panel 912. A substantially cylindrical bushing 942 of the third caddy 940 extends toward the right panel 918 and, like the previous bushings, is formed around the axis 924. The bushing 942 of the third caddy 940 is formed substantially at the first radius from the axis 924 and a hole 943 is formed in the third caddy 940 to be radially inward from an exterior surface 946 of the bushing 942 thereof.
A fourth caddy 950 is disposed in the carton to be left-facing and to extend upwardly from the upper surface 914 of the bottom panel 912. A substantially cylindrical bushing 952 of the fourth caddy 950 extends inwardly toward the left panel 916 and is formed around the axis 924. The bushing 952 of the fourth caddy is formed substantially at the first radius from the axis 924 and a hole 954 is formed in the fourth caddy 950 to be radially inward from an exterior surface 956 of the bushing 952 thereof.
Further, the container further comprises a first reel 958 having spaced-part left and right first reel flanges 960, 962 with the right and left first reel flanges each having a central hole. The first reel flanges 960, 962 are joined by a first spindle 964. The central holes of the left and right first reel flanges 960, 962 are each formed around the axis 924 and have a second radius which is greater than the first radius. Thus, the bushing 922 of the first caddy may be received in the central hole of the left first reel flange 960 and the bushing 932 of the second caddy 930 may be received in the central hole of the right first reel flange 962. The largest radius of either the left or right first reel flanges 960, 962 are less than the first distance 999, thereby permitting the first reel 958 to rotate around the axis 924 inside the carton 902.
Similarly, a second reel 964 has spaced-part left and right second reel flanges 966, 968, each second reel flange having a central hole and being joined by a second spindle 970. The central holes of the left and right second reel flanges 966, 968 are each formed around the axis 924 and have a third radius which is greater than said first radius. The bushing 942 of the third caddy 940 may be received in the central hole of the left second reel flange 966 and the bushing 952 of the fourth caddy 950 may be received in the central hole of the right second reel flange 968. As above, the largest radius of either second reel flange 966, 968 is less than the first distance 999 so as to permit the rotation of the second reel 964 around the axis 924 inside of the carton 902.
As described above, the left and right panels 916, 918 of the carton each have an arbor hole 970, 971 formed around the axis 924 and, preferably, the first and second spindles 964, 970 each have an axial passageway 972, 974 for communicating the central holes of the right reel flanges 962, 968 and left reel flanges 960, 966. In one embodiment, the fourth caddy 950 is adjacent to the right panel 918 of the carton 902.
One embodiment of the invention houses only two reels (such as reels 958 and 964) side-by-side in carton 902, and carton 902 is accordingly not as long as the one shown. In the illustrated embodiment, however, a fifth caddy 976 is disposed in the carton 902 to be right-facing and adjacent to the fourth caddy 950 to extend upwardly from the upper surface 914 of the bottom panel 912, a substantially cylindrical bushing 978 of the fifth caddy 976 extending toward the right panel 918 and formed around the axis 924, the bushing 978 of the fifth caddy 976 being formed substantially at the first radius from the axis 924 and a hole 980 being formed in the fifth caddy 976 to be radially inward from an exterior surface 982 of the bushing 978 thereof.
Further, in the illustrated embodiment a sixth caddy 984 is disposed in the carton 902 to be left-facing and to extend upwardly from the upper surface of the bottom panel, a substantially cylindrical bushing 986 of the sixth caddy 984 extending inwardly toward the left panel 916 and formed around the axis 924, the bushing 986 of the sixth caddy 984 being formed substantially at the first radius from the axis and a hole 988 being formed in the sixth caddy 984 to be radially inward from an exterior surface 990 of the bushing 986 thereof.
A third reel 992 housed in carton 902 has spaced-part left and right third reel flanges 994, 996, with each third reel flange having a central hole. The third reel flanges are joined by a third spindle 997, preferably having an axial passageway 995 for communicating the central holes of the right and left third reel flanges 994, 996. The central holes of the left and right third reel flanges are each formed around the axis 924 and have a fourth radius which is greater than said first radius. Thus, the bushing 978 of the fifth caddy 976 may be received in the central hole of the left third reel flange 994 and the bushing 986 of the sixth caddy 984 may be received in the central hole of the right third reel flange 996. The greatest radius of either the right or left third reel flanges 994, 996 is less than the first distance so as to permit the rotation of the first reel 992 around the axis 924 inside of the carton 902. Thus, the sixth caddy 984 may be adjacent to the right panel 918 of the carton 902.
The back-to-back caddy pairs 930, 940; 950, 976 provide structural support columns inside the interior of carton 902. These columns will receive some of the load of the cable reels stored in carton 902 and insure that there is no catenary sagging of any support rod placed through the carton 902 along axis 924.
As above, the container preferably includes at least one elongated slot 998 formed in at least one panel of the carton in a direction parallel to the axis to permit the dispensing of cable out of the carton.
The embodiment illustrated in
In summary, the different embodiments of the invention find their utility by allowing an installer to pull a plurality of cables in a single pull out of one carton that has been custom wound with the desired types and lengths of cables. This reduces the amount of time and effort wasted transporting multiple heavier reels having longer lengths of cable, thereby decreasing labor costs and increasing the speed of the installation.
While illustrated embodiments of the present invention have been described and illustrated in the appended drawings, the present invention is not limited thereto but only by the scope and spirit of the appended claims.
