Patent Application
20080221482
This invention relates generally to the field of accessory tips, particular for assisting rods in traversing cavities. More specifically, the invention relates to steerable tips for flexible rods.
Flexible rods, typically made from pulltruded fiberglass, have been used for retrofit wire and cable installation applications to push and pull wires and cables inside wall spaces, in crawl spaces, though overhead ceiling spaces and other structural spaces. These flexible rods have generally replaced the use of metal “fish tape” which historically has been used for similar purposes. Such rods typically have threaded connectors at each end to allow numerous rods to be connected together to provide long lengths of 30 feet or more. Various accessory tips have been developed that can be connected to such rods to add versatility, and to accommodate special installation and method requirements.
One existing tip incorporates a metal “whisk” type structure having four evenly spaced steel wire legs extending in a curved fashion. The legs are soldered together at the distal end to form a blunt end, and the rod may be coupled to the proximal end. An example of such a tip can be found in the current Labor Saving Devices Inc. product catalog (Volume 24) on numerous pages, including pages 35, 38, 40, 43 and 44. The complete disclosure of this catalog is herein incorporated by reference.
While such a tip has proven to be commercially acceptable, improvements are still desired. Hence, this invention relates to steerable tips with various novel features.
The invention provides various steerable tips for use with flexible rods. In one embodiment, a steerable tip comprises a rigid tip body having a proximal end, a distal end and a plurality of radially extending fins. Also, at least one of the fins includes at least one through hole. Also, a proximal connector is operably coupled to the proximal end of the tip body, and the proximal connector is adapted to couple the tip body to a rod. A distal connector is operably coupled to the distal end of the tip body. This permits other accessories or components to be coupled to the tip.
In some cases, one or more of the fins could include a slot which may be curved in geometry and include a sharpened edge. This slot may be useful in cutting into a wire or cable jacket to “capture” it from a distance, thus permitting the wire to be pulled toward the user. To remove the wire, it is simply pulled out of the slot.
In one particular arrangement, a pair of spaced apart through holes may be included in one or more of the surfaces. In this way, the wire may be threaded through both holes and then bent back and twisted onto itself to secure the wire to the tip. In some cases, one of the through holes may be elongate to allow the wire's jacket to lay close to the find to provide a low profile and reduce catching on other surfaces, such as ceiling tiles.
In one aspect, the tip body has a central axis extending between the proximal end and the distal end, and the fins extend radially outward from the central axis. In another aspect, the tip body includes three, four or more equally spaced apart fins.
In some cases, the tip body is constructed of a unitary piece of molded plastic, such as ABS. In other cases, the tip body may be constructed from aluminum alloys, biodegradable materials such as fiberboard, recyclable plastics, or composites, such as graphite, Kevlar and the like or various combinations thereof. In a further aspect, the tip body, or parts thereof, may be constructed of a luminescent material.
In a particular arrangement, each fin tapers outward from the proximal end toward the distal end, and is rounded at the distal end. In one particular arrangement, the fins have a length in the range from about two inches to about four inches and radially extend up to a distance in the range from about ½ inch to about 1½ inches.
According to one aspect, the proximal connector has a proximal end that may include a female end or a male threaded end. Also, the proximal connector may have a knurled distal end. Further, the knurled distal end may be molded into the tip body. Further, the distal connector may have a threaded end and a knurled end, and the knurled end may be molded into the tip body. However, the invention is not intended to be limited to such ends and may have other ends, such as threads that are internally fabricated within the tip body (at either the proximal end, the distal end, or both), other integrally formed connections, and the like
In a further embodiment, the invention provides a method for steering a rod. The method utilizes a steerable tip comprising a rigid tip body having a proximal end, a distal end and a plurality of radially extending fins. At least one of the fins defines a surface having at least one through hole extending through the surface, and a proximal connector is operably coupled to the proximal end of the tip body. Further, a distal connector is operably coupled to the distal end of the tip body. As part of the method, a rod is coupled to the proximal connector of the steerable tip. Also, the rod is grasped and manipulated to steer the rod through a cavity using the steerable tip.
In another step, a flexible cord is coupled to the tip through the through hole. Further, a tool may be coupled to the distal connector of the steerable tip.
In yet another embodiment, the invention provides a steerable tip system comprising a rigid tip body having a proximal end, a distal end and a plurality of radially extending fins. At least one of the fins includes at least one through hole. A proximal connector is operably coupled to the proximal end of the tip body. A distal connector is operably coupled to the distal end of the tip body. A flexible rod is also included in the kit and is configured to be coupled to the proximal connector. In some cases, the rod is constructed from fiberglass. In other cases, the rod may be constructed of other composite, plastic, nylon or other suitable flexible material.
The invention provides various steerable tips, methods for their use and wire and cable installation systems. The steerable tips are configured to be coupled to flexible rods and have various rigid fins to assist in moving the rod through various cavity configurations. The fins act as a series of supports when the rod is laying on its side to lift the distal end up and provide sufficient structure to allow the tip to longitudinally slide up and over small protrusions or irregularities on a surface. The fins also help to prevent the distal end of the rod from snagging or otherwise getting lodged in a corner, in insulation or in other materials.
In use, the rod is steered by rolling the rod (or rods if multiple rods are connected together), and therefore the tip, along its axis where the fins of the tip walk the distal end to either side depending upon the direction of rotation. The tip may also have a shape similar to a light bulb which allows the tip to travel across edges and irregularities longitudinally.
To provide such features, the tip is constructed of strong, yet lightweight material. Light weight is critical since the rods used for wire and cable installation are generally highly flexible to enable bending around angles of 90 degrees or greater and other contours. If the tip is too heavy, the weight may cause the rod to bend or sag, thereby compromising the necessary tactile positioning control needed by the installer/user to maneuver the rod to the desired position quickly and accurately.
Another feature is the use of one or more through holes in the fins. This permits a light weight nylon (or other material) “pull line” to be tied to the tip and pushed or pulled through a desired structure. This pull line is then used to actually pull the wire or cable being installed, thus avoiding loading the tip with the wire or cable itself. Alternatively, a wire or cable could be tied to the through hole directly.
The steerable tips of the invention may be constructed as a solid structure made from plastic or other stiff, durable, light weight material. The tips may be made of injection molded ABS plastic or other suitable materials and may have three or more fins. At least one of the fins defines a surface that may have one or more through holes or voids which extend through the surface to permit attachment of wire or cables to the tip by twisting or tying the stripped or jacketed wire through the hole and onto the tip. In one particular embodiment, the tip may be molded of a single piece and may incorporate four symmetrically spaced fins to provide a stable and balanced platform when lying on it side. However, other numbers of fins could be used as well. Multiple holes or other cut-outs can be provided in the fins to minimize weight providing the resultant fin structure provides adequate strength and streerability side to side. In addition, the fins surfaces of one or more of the fins provide an area to print, etch or cut out a logo, product part number or other identifier on the tip. This permits the ability to provide promotional identifiers, ownership identifiers or other materials to be placed onto the tip.
In one particular arrangement, the tip includes a connector on the proximal end to permit a tool or other attachment, such as a rod, sensor, magnet or accessory to be coupled to the tip. The proximal connector may be molded into, or as part of, the tip to provide increased strength and durability.
The plastic may be selected or formulated to incorporate a luminescent or glow-on-the-dark material to allow the tip to absorb light energy and emit the light in dark spaces, thereby allowing the user to easily see the location of the distal end of the rod in dark spaces, such as in crawl spaces, false ceilings, conduits, cable raceways, attics and the like.
The tips may also include a connector for connecting additional accessories and tips to the distal end of the tip. Such a connector may use a female threaded connector molded into the distal tip. Other mechanical connectors such as clevis pin, biased detent and capture window, friction fit, or other suitable mechanical connecting means could also be used. The distal connector permits additional accessories, attachments or tools, such as magnets, sensors, lights and various mechanical accessories, such as a j-shaped extension or other extension or embellishment to be attached to the distal tip to add functionality.
Although ABS plastic is one exemplary material to construct the tip, a variety of other materials may be used, such as lightweight 6061 aluminum, other suitable lightweight alloys, composites, such as carbon fibers, graphite, Kevlar or the like, or biodegradable materials such a fiber pulp resin matrix, fiberboard or the like. Alternatively, the steerable tips of the invention may incorporate a combination of materials assembled, affixed or molded together to form the desired solid structure. The materials may be ferrous or non-ferrous. Also, the connectors may be made as a friction fit or a snap together multi-component structure to allow easy disassembly and reduce space in storage.
In another aspect, the tips may include a hollow longitudinal channel to permit the rod to be inserted into the tip and be removably attached at the extreme distal end of the tip using a mechanical connector at that extreme distal end. In some cases, the channel permits the tip to function as a sleeve, i.e., the tip may be affixed or removably positioned at different points along the rod or may even float along the length of the rod to provide a movable attachment point for a wire.
A further aspect is that the tip may be covered with an airtight bladder that can be inflated to allow the tip to perform as a float when it is desired to position the rod across water or other fluid and avoid submerging. Another option is to place a foam material in between the fins to provide buoyancy. For example, the spaces between the fins may be filled or partially filled with a closed cell foam or other material to provide buoyancy. Also, this foam material may be luminescent.
Referring now to
Steerable tip 10 further includes a proximal connector 22 which is illustrated in greater detail in
Distal end 26 of proximal connector 22 includes threads that permit proximal connector 22 to be coupled to one or more flexible rods. In this way, steerable tip 10 may easily be coupled to a flexible rod so that steerable tip 10 may be employed to help steer the rod when passing through a cavity. Also shown with a threaded end, it will be appreciated that proximal connector 22 may have a variety of coupling mechanisms, such as quick connects, snap fit connections, detent connections, friction fit connections, and the like. Some specific examples will be described hereinafter.
Tip body 12 may be constructed from essentially any suitable material that is light weight, durable and generally rigid. In some cases, tip body 12 could even be somewhat flexible. One particular material that may be used is an ABS plastic. However, a variety of other materials may be used, such as light weight metals, alloys, rigid or resilient composites, rubbers or plastics, and the like.
In some cases, fins 18 may have a length from proximal end 14 to distal end 16 that is in a range from about two inches to about four inches, and in some cases from about one inches to ten or more inches. Further, each fin 18 may radially extend out to about 0.5 inches to 1.5 inches, and in some cases from about one inches to five or more inches. The general angle of outward taper from proximal end 14 may be in the range from about 14 degrees to about 16 degrees, and in some cases from about 10 degrees to about 45 degrees. This taper may be made linear or nonlinear.
Through holes 20 and 21 may be provided through each fin 18, or only certain of the fins. In some cases, through holes 20 may have a circular diameter to facilitate ease of manufacture with a diameter in the range from about 0.125 inches to about 0.5 inches, and in some cases from about 0.0625 inches to about 0.5 inches or more. However, it will be appreciated that other shapes may be used, such as oblong, angular, geometric, or other various shapes providing the chosen shape comprises a void aperture of at lease 0.0625 inches in diameter. Also, while shown near distal end 16, it will be appreciated that through holes 20 and 21 may be provided at other locations within fin 18. Also, in some cases multiple through holes, of the same or varying shapes and sizes, may be provided in each fin 18.
One particular advantage of constructing tip body 12 of a light weight material is that it may be fabricated as a single body. For example, an injection molding process may be used to construct tip body 12 or a unified component having both tip body and proximal connector 22. In this way, steerable tip 10 may be manufactured in a relatively inexpensive manner, while still being light weight and durable.
In use, a flexible rod may be coupled to proximal connector 22 by screwing it to proximal end 26. Steerable tip 10 is then inserted into a structural space or cavity, and the rod is manipulated to move tip 10 through the cavity to a desired distal location. If needed, the rod may be rotated to permit steerable tip 10 to “walk” side-to-side across a surface through the cavity where the steerable tip, and therefore the distal end of the flexible rod attached to it, can be accurately positioned at a precise distal location around or behind structures. Also, before insertion into the cavity, a string, cord, wire, cable or the like may be coupled to tip body 12 through one or more of holes 20 so that it may be pulled through the cavity to physically connect a beginning or entry point to a desired end or exit point within a structure of cavity. When reaching the desired distal location, the string, cord, wire or cable may be uncoupled from tip 10 if in the desired final location, or may be tied, taped or otherwise secured to another usually heavier wire or cable so that it may be pulled through the cavity. In this way, new wire or cable can be installed in existing structure without the need to tear out wall surfaces or other structures in order to position the wire or cable through them. In another use, steerable tip 10 is used in a similar fashion to be able to retrieve a string, cord, wire or cable from a distant location. In this application, steerable tip 10 is used in conjunction with a flexible rod to position the distal end of steerable tip to a location within a structure or cavity where a string, cord, wire or cable can be retrieved and pulled back to the proximal end of the rod.
Another feature of steerable tip 10 is that distal end 16 is rounded or curved in order to facilitate movement of steerable tip 10 longitudinally over bumps, ridges, or the like. However, it will be appreciated that other shapes may be used at distal end 16. For example, distal end 16 could be more pointed, or in some cases the radius of curvature could be increased to flatten distal end 16 to provide more of a directional or pointed distal end 16 to enable distal end 16 to move through, or pierce, material such as insulating material or moisture barriers within structural walls and cavities, or to anchor the distal end 16 into such materials for later retrieval.
Referring now to
Proximal connector 32 may be constructed of a metal or other rigid material and includes an opening 40 and a through hole 42 which extends through a sidewall of proximal end 36. With such a configuration, proximal connector 32 may be coupled to a shaft which has a distal end that may fit within opening 40. Also, the distal end of the rod may include a detent, projection, or the like that is spring biased outwardly so as to snap within through hole 42 after passing beyond proximal end 36. To remove the rod, the detent may be depressed and then the rod may be pulled from proximal connector 32.
Although not shown, it will be appreciated that proximal opening 62 and distal opening 64 could be configured as an elongated channel extending entirely through tip body 52. In this way, tip body 52 would include a hollow longitudinal channel to allow a rod to be inserted completely through tip 50 to allow tip 50 to be positioned at different points along the rod.
Distal end 86 includes a blunt nose 92 which smoothly transforms into fins 88. Blunt nose 92 may be useful in helping tip 80 to traverse through tortuous cavities. Proximal end 84 further includes an opening 94 and a side wall through hole 96 similar to that described in connection with the embodiment illustrated in
It will be appreciated that the steerable tips of the invention may take on a variety of other shapes. Some examples of such shapes are illustrated in
One feature of tip 250 is that the fins 254 each include a slot 256 having a sharpened edge 258 on one side of the slot. Sharpened edges 258 act as a knife edge that cuts into the jacket surrounding the wire or cable. This permits a user to cut into and “capture” a wire from a distance, allowing the user to pull it towards him without losing the grip. To release the captured wire, it is simply pulled out of the slot 256.
Tip 250 inches a series of through holes which may be used in a manner similar to the through holes of other embodiments. For examples, through holes 260 may be included in each fin 254. Alternatively, or in addition to, one or more of the fins 254 may include a set of spaced apart through holes 262 and 264. In some cases, through holes 264 are elongate in geometry. Through holes 262 and 264 permit wire, cables and the like to be easily tied to tip 250. This is illustrated in greater detail in
Tip 250 may also include distal and proximal connectors at a distal end 270 and a proximal end 272 similar to other embodiments. Also, a lumen could extend between distal end 270 and proximal end 272 similar to other embodiments.
The invention have now been described in detail for purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims.
