Abstract:
A wire feed apparatus and method for wire pulling installations through conduit between two boxes. A preferred embodiment of the wire feed apparatus has an opening, preferably centrally located, through which the wires pass prior to entering the box. The apparatus is adapted to securely mount to the box for the pulling operation. Preferably, the apparatus includes mounting apertures or slots to accommodate mounting of the apparatus to boxes of various sizes and shapes. The opening provides wire guidance as the wires enter the box opening and conduit and thus eliminates or significantly reduces the possibility of damaging the wire insulation while also reducing the pulling force required to pull the wires. Preferably, the wire feed apparatus is manufactured from a durable, sturdy plastic material.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to pulling wires through a conduit, and more particularly, to a method and apparatus to assist in feeding the wires into an electrical box to which the conduit is attached.  
         [0003]     2. Description of the Related Art  
         [0004]     To accomplish the distribution of electricity, insulated electrical wire must be installed between the power source and power distribution box and routed to electrical boxes to supply the required electrical power to a device, such as an electrical outlet or lighting fixture. The size of the wire used is determined by the application and amount of current that will be carried by the wire. The size of wires or electrical conductors is expressed in either circular mils or more typically by a numbering system known as the American Wire Gage System. In the American Wire Gage System, the smaller the number the larger the wire diameter and vice-versa.  
         [0005]     In many instances, municipal codes require that electrical wires in buildings be routed through a pipe, typically referred to as conduit. Thus, electrical wires spanning between electrical boxes are contained in conduit attached to the electrical boxes. Electricians and technicians are routinely required to pull wires or cables through conduit extending between electrical boxes. It is not uncommon for such conduits to span several feet in length and contain one or more elbows and turns which increases the difficulty of pulling wires through the conduits. The conduit is hidden behind walls and above the ceiling in buildings. A device that is commonly used to pull wiring through conduit is referred to as a fish tape. One example of a fish tape is shown and described in U.S. Pat. No. 6,416,040, which is herein incorporated by reference in its entirety.  
         [0006]     A typical technique for pulling wires through a conduit entails initially pushing a length of resilient spring steel fish tape, wound on a reel, through an electrical box opening and the attached conduit. This initial location where the fish tape is initially inserted into the box is referred to as the “pull end.” The fish tape typically has a substantially rectangular cross-section which, in combination with its spring steel construction, allows it to bend around corners within the conduit while maintaining sufficient rigidity to be pushed a considerable distance. A flexible leader with a rounded tip is attached to a free end of the fish tape. The leader enhances the ability to negotiate comers as the fish tape is pushed through the conduit.  
         [0007]     After the leader reaches the terminal end of the conduit and the attached electrical box, referred to as the “feed end,” the required number and size of electrical wires are attached to the leader. The number and size of wires required depends on the specific application. The diameter of the conduit is sized to accommodate the required wires. For example, a conduit having a 1″ diameter can contain approximately 20 individual wires of a particular gauge whereas a ½″ diameter conduit can only accommodate 9 such wires. The fish tape and attached wires are then pulled back through the conduit until the leader and the end of the electrical wires exit the end of the conduit and the box at the pull end.  
         [0008]     It is very important that the insulation on the wires not be damaged during the pulling operation. Damage to the insulation can result as the wire passes through the box opening at the feed end. For example, the wires are typically pulled off of individual reels at a location proximate the feed end. The box may be mounted in the ceiling with the wire reels supported on the floor below and the conduit horizontally connected to the box. In this example, one can envision that during the pulling operation, the wires will come off the floor supported reels traveling upwardly to the ceiling before transitioning horizontally into the box opening and conduit. The potential exists for a burr or a sharp or abrupt edge of the box, particularly at the box opening leading to the conduit, to damage the integrity of the insulation. Rarely, if ever, will the wires be directly aligned with the box opening. This is unlikely to occur due to the plurality of wires that are typically being simultaneously pulled since each of the wires is stored on a separate reel and all wires converge in a box or conduit opening of approximately 1″ or less.  
         [0009]     At least partially due to the aforementioned problems, pulling the wires is generally a two person job. Typically, when pulling the wires, one person pulls the fish tape from the pull end while a second person at the feed end feeds the electrical wires into the second box at the other end of the conduit. Typically, the fish tape and the wires are pulled in increments or strokes of several feet at a time. The two people at the opposite ends of the conduit develop a rhythm which allows them to pull and feed wire at the same time, and this rhythm enhances the speed and ease by which the wire is pulled. As described, the wire pulling installation requires two persons consuming much time and manpower which translates into higher costs.  
         [0010]     It is desirable to optimize the wire pulling installation by reducing costs. It is also desirable to optimize the wire pulling installation by reducing the manpower required.  
       BRIEF SUMMARY OF THE INVENTION  
       [0011]     The present invention is a wire feed apparatus, known as a “Wire Pullin&#39; Genie”, and method adapted to assist in the wire pulling installation. The wire feed apparatus is designed for mounting to a box, typically an electrical box, at the feed end of the pull. Preferably, The wire feed apparatus is used in conjunction with a fish tape when pulling electrical wires. The present invention allows the installation to be performed by single person, thus eliminating the need for a second person.  
         [0012]     In a preferred embodiment, the wire feed apparatus has an opening, preferably centrally located, through which the wires pass prior to entering the box. The apparatus is adapted to securely mount to the box for the pulling operation. Preferably, the apparatus includes mounting apertures or slots to accommodate mounting of the apparatus to boxes of various sizes and shapes. The opening provides wire guidance as the wires enter the box opening and conduit and thus eliminates or significantly reduces the possibility of damaging the wire insulation while also reducing the pulling force required to pull the wires. Preferably, the wire feed apparatus is manufactured from a durable, sturdy plastic material.  
         [0013]     The wire feed apparatus is easily and quickly attached to a box at the feed end. Preferably, after mounting the wire feed apparatus to the box, a fish tape is run from the pull end to the box at the feed end. At the feed end, the end of the fish tape is extended through the opening of the wire feed apparatus and the wires to be installed are attached to the fish tape end. The wires are preferably stored on reels that are rotatably supported. The installer returns to the pull end and retrieves the fish tape which pulls the fish tape end with attached wires through the wire feed apparatus opening and box and into and through the conduit and finally through the box at the pull end. The fish tape is detached and a sufficient length of wires are left extending from the boxes at each end. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0014]     The objects, advantages and features of the invention will become more apparent by reference to the drawings which are appended hereto and wherein like numerals indicate like parts and wherein illustrated embodiments of the invention are shown, in which:  
         [0015]      FIG. 1  is a view of two boxes interconnected by piping or conduit;  
         [0016]      FIG. 2  is an enlarged view taken along lines  2 - 2  of  FIG. 1 ;  
         [0017]      FIG. 3  is a perspective view of a preferred embodiment of the wire feed apparatus;  
         [0018]      FIG. 4  is a plan view of the wire feed apparatus of  FIG. 3 ;  
         [0019]      FIG. 5  is a view taken along lines  5 - 5  of  FIG. 4 ;  
         [0020]      FIG. 6  is an elevation view of the preferred embodiment of the wire feed apparatus mounted to a box;  
         [0021]      FIG. 7  is a view taken along lines  7 - 7  of  FIG. 6 ;  
         [0022]      FIG. 8  is a plan view of a second embodiment of the wire feed apparatus according to the present invention;  
         [0023]      FIG. 9  is a plan view of a third embodiment of the wire feed apparatus according to the present invention;  
         [0024]      FIG. 10  is a section view of another embodiment of the wire feed apparatus according to the present invention shown mounted to a box with wires being pulled;  
         [0025]      FIG. 11  is a plan view of yet another embodiment of the wire feed apparatus according to the present invention; and  
         [0026]      FIG. 12  is a view of an embodiment of the wire feed apparatus of the present invention mounted to a box during a wire pull installation. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     A description of the wire feed apparatus of the present invention, generally referenced by numeral  30 , and the method of using the wire feed apparatus  30  will be described in detail with reference to the drawings.  
         [0028]      FIG. 1  illustrates in simplistic detail a first box B 1  connected to a second box B 2  with a string of piping C, typically conduit. The depiction of  FIG. 1  could be representative of two electrical boxes mounted in a ceiling for mounting light fixtures through which the electrical wiring must be installed in the conduit. Since boxes are available in many shapes and sizes, it is to be understood that boxes will generally be referred to as “box B.” 
         [0029]     As shown in  FIG. 2 , the box B 1  is a generally rectangular box having a plurality of “knockouts” K which are adapted to be removed or “knocked out” when desired to attach a conduit to the box from any of a variety of directions. In  FIG. 2 , a knockout has been removed to allow the conduit C to be attached to the box B 1 , typically with a connector C 1 .  
         [0030]     It is to be understood that the box B 1  and connector C 1  are merely for illustrative purposes and are not intended to limit the scope of the invention. Box B 1  comes in a variety of sizes, shapes and arrangements. For example, some boxes are round. There are boxes having various arrangements and sizes of knockouts K. Additionally, there are several different types of commercially available connectors C 1 . The various boxes and connectors are well known by a person of ordinary skill in the art.  
         [0031]     Still referring to  FIG. 2 , the box B 1  typically includes a back wall  10  and a peripheral side wall or walls  12  extending from the periphery of the back wall  10 . The side walls  12  terminate at an edge  14  defining a box opening  16 . One or more tabs  18  typically extend from the peripheral walls  12 . The tabs  18  typically include a threaded hole  20  adapted to threadedly engage a threaded member  22 , typically a screw.  
         [0032]     Referring to  FIGS. 3-5 , a preferred embodiment of the wire feed apparatus  30  is shown. The wire feed apparatus  30  preferably includes a plate-like member  32  having an opening  34 , preferably circular, extending through the member  32 . The opening  34  is preferably centrally located in the member  32 . The circular opening  34  preferably has a diameter in the range of 0.5″ to 2″, more preferably in the range of 1.0″ to 1.75″, and most preferably in the range of 1.25″ to 1.5″.  
         [0033]     As shown in  FIG. 5 , the member  32  has a first surface  36  and a second surface  38 . The first and second surfaces  36  and  38  may be planer and parallel to each other. It may be desirable, depending on the type of material used, to have the thickness of the wire feed apparatus  30  increase from a peripheral edge  40  towards the center of the wire feed apparatus  30 . In the preferred embodiment shown in  FIG. 5 , the second surface  38  is planer and the first surface  36  tapers away from the second surface from the peripheral edge  40  of the member  32  to the central opening  34 . In a preferred embodiment the thickness is approximately 0.25″ at the peripheral edge  40  and increases to a thickness of approximately 0.50″ at the wall  42  defining the central opening  34 .  
         [0034]     The member  32  has a wall  42 , preferably rounded or arcuate, from the first surface  36  to the second surface  38  defining the opening  34 . Preferably, the rounded wall  42  is smooth to avoid any sharp or blunt edges that could possibly damage the wire insulation as it passes through the opening  34  during the wire pulling and installation process. Preferably, the opening has a height of at least 0.2″.  
         [0035]     Since there are many different sizes and shapes of electrical boxes, the wire feed apparatus  30  could be made in several different sizes and shapes to accommodate each of the various boxes. However, this is neither preferable nor desirable. Preferably, the wire feed apparatus  30  is made so that one apparatus works with various sizes and shapes of boxes. In one preferred embodiment, the wire feed apparatus  30  is generally square in shape with each side measuring approximately 5.625″ in length.  
         [0036]     As shown in  FIG. 4 , the preferred embodiment of the wire feed apparatus  30  includes one or more mounting apertures  44 , preferably extending through the plate-like member  32 . The mounting aperture  44  is adapted to receive a screw  22  of the box B such that the wire feed apparatus  30  can be secured to the box B by the threaded engagement of the screw  22  and the threaded hole  20  as shown in  FIGS. 6 and 7 . The preferred embodiment of the wire feed apparatus  30  includes at least two mounting apertures  44 , one mounting aperture  44  for each screw  22  as boxes B typically include two screws  22 . Referring to  FIG. 4 , the preferred embodiment includes mounting apertures  46   a  and  46   b  and mounting apertures  48   a  and  48   b . It is to be understood that mounting apertures  48   a  and  48   b  are optional for reasons explained below.  
         [0037]     The mounting apertures  46   a ,  46   b ,  48   a  and  48   b  are shown as slots in the preferred embodiment of  FIG. 4 . The slots  46   a  and  46   b  are preferably adapted to accommodate the screw size of the box B. The slots  46   a ,  46   b  have a width greater than the screw diameter but less than the diameter of the screw head  24 . In the embodiment shown in  FIG. 4 , the slots  46   a ,  46   b  are preferably elongated and axially aligned with each other. In a preferred embodiment, each elongated slot  46   a ,  46   b  has a length of approximately 1.0″ to 1.5″. Preferably, the center of the opening  34  intersects the axis of the elongated slots  46   a ,  46   b . The elongated slots  46   a ,  46   b  allow the wire feed apparatus  30  to be mounted to a variety of sizes and shapes of boxes B having a screw spacing falling within the spacing range provided by the opposing slots  46   a  and  46   b.    
         [0038]     The mounting apertures  48   a  and  48   b  are shown in  FIG. 4  as elongated slots having a width slightly greater than the width of the slots  46   a ,  46   b . The elongated slots  48   a  and  48   b  are adapted to accommodate screws having a diameter larger than the width of the elongated slots  46   a ,  46   b.    
         [0039]     Referring to  FIGS. 6 and 7 , the wire feed apparatus  30  is shown mounted to a box B. In this embodiment, the screws  22  are first removed from the box B, and after positioning the wire feed apparatus  30  on the box B, the screws  22  are inserted through the mounting apertures  48   a ,  48   b  and threaded into the threaded hole  20  until the screw heads  24  firmly engage and secure the wire feed apparatus  30  in place, preferably centraliy over the box opening  16 .  
         [0040]     Referring to  FIG. 8 , a second embodiment of the wire feed apparatus, referred to as  30 ′, is shown having an enlarged portion  46   a ′,  46   b ′,  48   a ′ and  48   b ′ at one of the ends of the elongated slots  46   a ,  46   b ,  48   a  and  48   b , respectively. The enlarged portion  46   a ′,  46   b ′,  48   a ′ and  48   b ′ is larger than the head  24  of the screw  22  adapted to be received in the mounting aperture  44 . The wire feed apparatus  30 ′ is adapted to be mounted to a box B without removing the screws  22  from the box B. With the screws  22  threadedly retained to a position such that the heads  24  are at a distance from the tabs  18  greater than the thickness of the wire feed apparatus  30 ′ at the enlarged portion, one enlarged portion, such as  46   a ′, is positioned over one screw head  24  and the member  32  is moved towards the box B such that the one screw head  24  extends through the corresponding enlarged portion  46   a ′. The wire feed apparatus  30 ′ is then positioned so that the second screw head can be extended through the enlarged portion  46   b ′. It is to be understood that while the wire feed apparatus  30 ′ is positioned so that the enlarged portion  46   b ′ is over the second screw head  24 , the first screw  22  is received and maintained in the elongated slot  46   a  by the first screw head  24  being larger than the width of the elongated slot  46   a . The wire feed apparatus  30 ′ is preferably substantially centered over the box openingl 6  before tightening the screws  22  to firmly secure the wire feed apparatus  30 ′ to the box B.  
         [0041]     Referring to  FIG. 9 , a third embodiment of the wire feed apparatus, referred to as  30 ′, is shown having an enlarged portion  46   a ″ and  48   b ″ joined to the elongated slots  46   a  and  48   b , respectively. The enlarged portion  48   b ″,  46   a ″ is shown joined to the elongated slot  48   b ,  46   a , respectively, via a short slot  48   d ″,  46   d ″, respectively. The enlarged portion  46   a ″,  48   b  is larger than the head  24  of the screw  22  adapted to be received in the mounting aperture  44 . Mounting apertures  48   a ″ and  46   b ″ are elongated openings having a mouth  48   c ″ and  46   c ″, respectively, formed at the peripheral edge  40  of the member  32  of the wire feed apparatus  30 ″. The wire feed apparatus  30 ″ is adapted to be mounted to a box B without removing the screws  22  from the box B. With the screws  22  threadedly retained to a position sufficient to receive the required thickness of the member  32 , the wire feed apparatus  30 ″ is positioned so that a mouth, such as  48   c ″, receives one screw  22  in the elongated opening  48   a ″. While maintaining the first screw  22  in the elongated opening  48   a ″, the wire feed apparatus  30 ″ is then positioned so that the second screw head  24  can be extended through the enlarged portion  48   b ″. Preferably, the member  32  is moved such that the second screw  22  travels through the short slot  48   d ″ and into the elongated slot  48   b . The wire feed apparatus  30 ″ is then preferably substantially centered over the box opening  16  before tightening the screws  22  to firmly secure the wire feed apparatus  30 ″ to the box B.  
         [0042]      FIG. 10  is an alternative embodiment of the wire feed apparatus, referred to as  130 . The wire feed apparatus  130  is similar to the other embodiments of the wire feed apparatus  30 ,  30 ′ and  30 ″ and includes a feature that can be incorporated with any of the embodiments according to the present invention. The wire feed apparatus  130  has an opening  134 , preferably circular, extending through the plate-like member  32 . The opening  134 , preferably centrally located in the member  32 , preferably has a diameter in the range of 0.5″ to 2″, more preferably in the range of 1.0″ to 1.75″, and most preferably in the range of 1.25″ to 1.5″. The second surface  38  of the member  32  preferably includes an extending portion  135  extending from the perimeter of the opening  134 . Preferably, the extending portion  135  has a height H which extends into the box opening  16 . Preferably, the extending portion extends into the box opening  16  at least 0.25″ and more preferably in the range of 0.25″ to 0.75″. In the embodiment shown in  FIG. 10 , the extending portion  135  is continuous around the circular opening  134  and extends the height of the opening  134 . Preferably, the extending portion  135  has a rounded or arcuate portion  142  defining the opening  134  and the opening  134  has a rounded or arcuate portion  42  at the first surface  36 . Preferably, the arcuate portions  42  and  142  are smooth and continuous to avoid any sharp or blunt edges that could possibly damage the wire insulation as it passes through the opening  134  during the wire pulling and installation process.  
         [0043]     Still referring to  FIG. 10 , a plurality of wires W, typically insulated, are shown extending through the opening  134  of the wire feed apparatus  130  and into the conduit C. The arrow D indicates the direction from which the wires W are being pulled as will be further explained below. Preferably, the height H of the extending portion  135  facilitates the guidance and position of the wires W as they enter the conduit C and connector C 1 .  
         [0044]     Referring to  FIG. 11 , yet another embodiment of the wire feed apparatus, referred to as  300 , is shown as a round member  332  having a plurality of paired opposing mounting apertures  344 . The paired mounting apertures  344  are arcuate slots  346   a  and  346   b ,  348   a  and  348   b ,  350   a  and  350   b , and  352   a  and  352   b . Preferably, each pair of arcuate slots have a common radius of curvature R and are formed about a common point P.  FIG. 11  identifies the radius of curvature R for arcuate slot  346   b . It is to be understood that the paired arcuate slot  346   a  has the same radius of curvature R and arcuate slots  346   a ,  346   b  are formed about the common point P. It is also to be understood that while each of the other pairs of arcuate slots are formed about the common point P, each pair has its own radius of curvature. Preferably, each of the arcuate slots  346   a ,  346   b ,  348   a ,  348   b ,  350   a ,  350   b ,  352   a  and  352   b  include an enlarged portion  346   a ′,  346   b ′,  348   a ′,  348   b ′,  350   a ′,  350   b ′,  352   a ′ and  352   b ′, respectively, at one end of the arcuate slots. The enlarged portion  346   a ′,  346   b ′,  348   a ′,  348   b ′,  350   a ′,  350   b ′,  352   a ′ and  352   b ′ is larger than the head  24  of the screw  22  adapted to be received in the mounting aperture  344 .  
         [0045]     The wire feed apparatus  300  illustrated in  FIG. 11  has four pairs of mounting apertures  344 . Each pair of mounting apertures  344  have a unique spacing between the paired arcuate slots (for example, paired arcuate slots  346   a  and  346   b ) adapted to accommodate a particular screw spacing. Each unique spacing between the plurality of paired mounting apertures will facilitate mounting of the wire feed apparatus  300  on one or more types of boxes B. Still referring to  FIG. 11 , the wire feed apparatus  300  is shown having an opening, which for purposes of illustration and not limitation, is shown as the opening  134  having the extending portion  135  as described above with reference to the wire feed apparatus  130 .  
         [0046]     The wire feed apparatus  300  is adapted to be mounted to a box B without removing the screws  22  from the box B. For example, the wire feed apparatus  330  is mounted to a box B having a screw spacing corresponding to the spacing between paired mounting apertures  350   a ,  350   b  by aligning the enlarged portions  350   a ′,  350   b ′ with the box screw heads and positioning the wire feed apparatus  300  towards the box B so that the screw heads extend through the enlarged portions  350   a ′,  350   b ′. The wire feed apparatus  330  is then preferably rotated until the screws contact the opposite end of the arcuate slot  350   a ,  350   b . The screws (shown in phantom) are then tightened to firmly secure the wire feed apparatus  300  to the box B.  
         [0047]     The wire pulling and installation procedure is preferably accomplished using the wire feed apparatus of the present invention in conjunction with a wire pulling device, commonly referred to as a fish tape. Fish tapes for pulling wiring through conduits are well known in the industry as discussed in the “Background of the Invention.” 
         [0048]     Initially, the wire feed apparatus of the present invention is easily and quickly attached to a box located at the “feed end” of the wire pull procedure, referenced as box B 2  in  FIG. 12 . The wire feed apparatus is securely attached to box B 2  in one of the manners described above for the various embodiments of the invention. For purposes of explanation, the remaining procedure will be described with reference to wire feed apparatus  130 . The installer goes to the “pull end” and inserts an end of the fish tape (not shown) into a box B 1  and forces the fish tape, typically made of resilient spring steel, through the conduit C and into the box B 2 . The end of the fish tape is retrieved through the wire feed apparatus opening  134  and the desired quantity of wires W are attached to the fish tape end in the usual manner. After the wires W have been attached to the fish tape end, the installer goes back to the pull end at box B 1  and begins retrieving or pulling the fish tape with the attached wires W. Preferably, the wires W are on rotatably mounted reels R. As an example,  FIG. 12  shows a prior art wire reel support device S rotatably supporting three reels R of wire W. As shown in  FIG. 10 , the opening  134  of the wire feed apparatus  130  provides guidance and limits the angle of entry of the wires W into the conduit C and conduit connector C 1 . Preferably, the opening  134  is substantially centrally located in the box B so that upon passing through the opening  134  the wires W have a suitable distance to become generally aligned with the conduit C before entering the conduit connector C 1 . This not only protects against marring or cutting the wire insulation during the installation, but also serves to reduce the required pulling force during wire installation.  
         [0049]     It is to be understood that the wire feed apparatus is a compact device, preferably made of a durable, sturdy plastic, adapted to be attached to a box, typically an electrical box, and used in conjunction with a wire pulling tool to make it possible for one individual to pull electrical wiring, typically for outlets, fixtures, and other electrical devices, without the assistance of a second individual. It is also to be understood that the apparatus can be used for pulling various types of wires, including but not limited to, wires in the data/communication field.  
         [0050]     As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from the spirit of the present invention. The disclosed embodiments are, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within the meaning and range of equivalence of the claims are therefore intended to be embraced therein.