Abstract:
A dual swivel saddle spacer assembly for use in securing and spacing a first bundle to a second bundle in angular crossing relationship to another. The assembly includes at least one saddle support member supported by and rotatable relative to a pivot pin member. Two saddle supports may be interposed between a rotatable pivotal pin. The pivot pin may comprise a separate structure or it may be integral to one of the saddle support members. The assembly includes one or more elongate slotted openings for receiving a securing device such as a conventional cable tie.

Description:
RELATED APPLICATION  
       [0001]    This application claims the benefit of provisional application Serial No. 60/232,364, filed Sep. 14, 2000, which claims the benefit of provisional application Serial No. 60/184,297, filed Feb. 23, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    This invention relates generally to specialized supports for use with cable ties and, more particularly, to a pair of saddles that can be used, for example, with cable ties to secure wires cables, hoses and tubing, hereinafter referred to as bundles, in angular or crossing relationship to one another. The invention further prevents the crossing bundles from rubbing or abrading each other by providing spacing between the bundles.  
           [0003]    Molded plastic cable ties are known in the art and are used to secure wires, cables, hoses, tubing, or other elongate articles in tight bundles.  
           [0004]    Presently, spacing supports used in conjunction with cable ties are limited to configurations in which the bundles to be secured must be in parallel alignment. This alignment attitude is sufficient when the bundles are to be run along each other or a common parallel surface, such as a truck frame or tractor-trailer bed, however, spacing supports of this type are impractical when it is necessary to secure the bundles in a nonparallel orientation.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention seeks to solve the above-mentioned problems by providing a spacing support assembly for use in securing a first bundle to a second bundle in angular relationship. The assembly includes a pair of saddle support members. In one embodiment a rotatable pivot pin is formed in a first member. In another embodiment, each member is attached to a separate rotatable pivot pin or disc member. The saddle supports are preferably interposed between one bundles to be supported and the pivot pin or disc member.  
           [0006]    In the preferred embodiment the saddle support assembly is comprised of two members, each having a mating portion and at least one having a saddle portion. The first member has an integrally formed axially extending pivot pin and a primary, radially extending, flange portion, said pivot pin including, proximate to its distal end, a secondary radially extending flange portion or head. The second mating portion includes a centrally located undercut collar having a mating interior configuration to rotatably engage the head of the pivot pin. The saddle portion is provided with a slotted aperture adapted to receive a conventional cable tie having a longitudinal strap portion and a locking head portion. The strap portion is arranged to circumferentially wrap the bundle to be secured. The head portion of the cable tie includes at least one opening there through for receiving the strap and at least one pawl for securing the strap.  
           [0007]    In an alternate embodiment the saddle support member is provided with a centrally located undercut collar having a mating interior configuration to rotatably engage the head of a pivot pin. A disc member has an integrally formed axially extending pivot pin and a primary, radially extending, flange portion, said pivot pin including, proximate to its distal end, a secondary radially extending flange portion or head. The saddle portion is provided with a slotted aperture adapted to receive a conventional cable tie having a longitudinal strap portion and a locking head portion. The strap portion is arranged to circumferentially wrap the bundle to be secured. The head portion of the cable tie includes at least one opening therethrough for receiving the strap and at least one pawl for securing the strap.  
           [0008]    In an alternate embodiment, the assembly includes two saddle support members and a double pinned disc interposed therebetween. Each saddle support member is adapted to pivotally receive and attach to the pivot pin and flange portion of the disc member.  
           [0009]    The saddle support member of the present invention provides support surfaces. Each support surface is arranged to support and engage a bundle. This support surface is preferably curved to more effectively engage a curved bundle, however it is to be understood that other surface contours may be used if the object to be supported so dictates. In the preferred embodiment, recessed pockets are formed in the curved support surface to permit greater circumferential engagement of the cable tie when wrapped around smaller bundles. In the case of larger bundles, there are provided outwardly projecting side rails to provide better load distribution adjacent the support surfaces.  
           [0010]    The invention further includes a method of manufacturing a dual swivel saddle spacer comprising the steps of first molding a first saddle member including a pivot pin. Next, inserting the first saddle member into a second saddle member molding cavity and introducing a molding composition that is allowed to cure in the cavity thereby forming a second saddle member adjacent and interlocked to said pivot pin.  
           [0011]    Alternatively, the invention may be described as a method of manufacturing a dual swivel saddle spacer comprising the steps of first molding a disc member having a radially extending, flange portion that provides a tapered shut-off in the mold cavity. Next said molded disc member is inserted into a saddle support molding cavity. A molding composition is introduced and allowed to cure in said molding cavity to independently form said saddle support member adjacent and interlocked to the pivot pin. Upon removing said saddle support member and its retained disc member from said molding cavity, the dual swivel saddle spacer assembly is formed.  
           [0012]    Alternatively, the invention may be described as a method of manufacturing a dual swivel saddle spacer comprising the steps of a first molding a disc member having oppositely disposed, integrally formed axially extending pivot portions and a primary, radially extending, disk portion, said pivot portions including, proximate to the respective distal end of each pivot portion, a secondary radially extending flange portion; next locating said molded disc member within a molding cavity and wherein said cavity is configured to form a pair of facing support members each support member having a base surface including a re-entrant bore having an interior configuration adapted to receive and rotatably retain a respective pivot portion and its secondary flange; introducing and curing a molding composition into said molding cavity to independently form said pair of support members adjacent to a respective side of said disc member and surrounding said pivot portion; and removing said pair of support members along with the retained adjacent disc member from said molding cavity.  
           [0013]    It is an object of the present invention to provide a rotatable spacing support assembly that is convenient to use and economical in manufacture.  
           [0014]    It is a further object of the present invention to provide a rotatable spacing support assembly for use with conventional cable ties to provide spaced-apart, rotatable support of bundled articles.  
           [0015]    It is a further object of the present invention to provide a rotatable spacing support assembly to prevent bundles from rubbing against each other.  
           [0016]    It is a further object of the invention to provide a rotatable spacing support assembly for use in combination with conventional cable ties that reliably and effectively secures items such as wires into bundles in angular crossing relationship. 
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is a perspective view of the spacing support assembly including bundles surrounded with cable ties in phantom.  
         [0018]    [0018]FIG. 2 is a perspective view of the spacing support assembly showing rotational movement.  
         [0019]    [0019]FIG. 2 a  is a perspective view of the spacing support assembly showing the saddle support members in relative alignment and as molded.  
         [0020]    [0020]FIG. 3 is a side elevational view of the spacing support assembly.  
         [0021]    [0021]FIG. 4 is an end elevational view of the spacing support assembly.  
         [0022]    [0022]FIG. 5 is a longitudinal section view of the spacing support assembly and taken along lines  5 - 5  of FIG. 4.  
         [0023]    [0023]FIG. 5 a  is a longitudinal section view of an alternate spacing support assembly similar to the view of FIG. 5.  
         [0024]    [0024]FIG. 6 is a perspective view of an alternate spacing support assembly and showing the saddle support members in rotated relationship.  
         [0025]    [0025]FIG. 6 a  is a perspective view of the spacing support assembly seen in FIG. 6 but showing the saddle support members in relative alignment and as molded.  
         [0026]    [0026]FIG. 7 is a top plan view of the spacing support assembly shown in FIG. 6 a.    
         [0027]    [0027]FIG. 8 is a longitudinal section view of the spacing support assembly shown in FIGS. 6 and 6 a  and taken along lines  8 - 8  of FIG. 7.  
         [0028]    [0028]FIG. 9 is a cross sectional view of the mold cavities used to produce the disc member of the spacing support assembly.  
         [0029]    [0029]FIG. 10 is a sectional view of the mold used to form the saddle support member and showing an inserted pre-formed disc in place.  
         [0030]    [0030]FIG. 11 is a sectional, exploded view of the mold after injecting and further showing the completed spacing support assembly.  
         [0031]    [0031]FIG. 12 is a perspective view of another alternate embodiment, namely a two-piece spacing support assembly and showing the pieces in rotated relationship.  
         [0032]    [0032]FIG. 12 a  is a perspective view of the spacing support assembly seen in FIG. 12, but showing the saddle support members in relative alignment and as molded.  
         [0033]    [0033]FIG. 13 is a top plan view of the alternate embodiment spacing support assembly shown in FIG. 12 a.    
         [0034]    [0034]FIG. 14 is a longitudinal section view of the alternate embodiment spacing support assembly shown in FIGS. 12 and 12 a  and taken along lines  14 - 14  of FIG. 13.  
         [0035]    [0035]FIG. 15 is a perspective view of another embodiment of a two-piece spacing support assembly and showing the pieces in rotated relationship.  
         [0036]    [0036]FIG. 15 a  is a perspective view of the spacing support assembly seen in FIG. 15, but showing the saddle support members in relative alignment and as molded.  
         [0037]    [0037]FIG. 16 is a side elevational view of the alternate embodiment spacing support assembly shown in FIG. 15 a.    
         [0038]    [0038]FIG. 17 is an end elevational view of the alternate embodiment spacing support assembly shown in FIG. 15 a.    
         [0039]    [0039]FIG. 18 is a longitudinal section view of the alternate embodiment spacing support assembly shown in FIGS. 15 and 15 a  and taken along lines  18 - 18  of FIG. 17.  
         [0040]    [0040]FIG. 19 is a perspective view of the preferred embodiment of a two-piece spacing support assembly and showing the pieces in rotated relationship.  
         [0041]    [0041]FIG. 19 a  is a perspective view of the spacing support assembly seen in FIG. 19, but showing the saddle support members in relative alignment and as molded.  
         [0042]    [0042]FIG. 20 is a top plan view of the spacing support assembly shown in FIG. 19 a.    
         [0043]    [0043]FIG. 21 is a side elevational view of the embodiment spacing support assembly shown in FIG. 19 a.    
         [0044]    [0044]FIG. 22 is an end elevational view of the embodiment spacing support assembly shown in FIG. 19 a.    
         [0045]    [0045]FIG. 23 is a longitudinal section view of the embodiment spacing support assembly shown in FIGS. 19 and 19 a  and taken along line  23 - 23  of FIG. 21.  
         [0046]    [0046]FIG. 24 is a sectional view of the spacing support assembly shown in FIGS. 19 and 19 a  and taken along line  24 - 24  of FIG. 22.  
         [0047]    [0047]FIG. 25 is a cross sectional view of the mold used to form the first saddle support member.  
         [0048]    [0048]FIG. 25 a  is a cross section view of the saddle support member  12   a  including an undercut shut off.  
         [0049]    [0049]FIG. 25 b  is a cross section view of the saddle support member  12   a  including a vertical shut off and a core.  
         [0050]    [0050]FIG. 26 is a cross sectional view of the mold used to form the second saddle support member and showing an inserted preformed first saddle support member in place.  
         [0051]    [0051]FIG. 27 is a sectional, exploded view of the mold after injecting and further showing the preferred spacing support member. 
     
    
     DETAILED DESCRIPTION  
       [0052]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention that may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.  
         [0053]    Referring to the drawings, and, in particular to FIGS.  1 - 4 , a spacing support assembly  10  embodying the various features of the invention is shown. The assembly  10  functions to securely space and separate elongate articles, such as wires, cables, hoses, tubing, or other elongate articles into bundles  8  and to secure the bundles  8  in angular crossing alignment with either a second bundle or a supporting structure. It will be apparent that a “bundle” may comprise a bundle of individual wires or cables, rigid or flexible conduit, hot or cold fluid transporting tubes. The “bundle” may also be contained within the bore of a conventional tubular conduit. Referring specifically to FIG. 1, it can be seen that the bundles  8  may be of various sizes and yet be accommodated by the assembly  10 . As seen in FIGS. 1 and 2, the assembly  10  is particularly well suited for use in applications in which it is preferred or necessary to secure bundles  8  in a non-parallel manner, for example, at right angles.  
         [0054]    As illustrated in the view of FIG. 5, the assembly  10  includes, in the first embodiment, two principal components, namely a saddle support member  12  and a disc member  14 . The assembly  10  of this illustrated embodiment is adapted to receive a pair of crossing opposed bundles  8  gripped by conventional cable ties, seen referenced generally as  16  in FIG. 1, and each bundle  8  is supported and engaged by an individual saddle support member  12 . It can be further seen that the disc member  14  is integrally formed and comprises a centrally located pivot pin  18  and a primary, radially extending, flange portion  20 . The pivot pin  18  further includes a head portion  22  having an undercut collar  23  and a secondary flange portion  24 .  
         [0055]    The saddle support member  12  is adapted to be pivotally received and attached to the pivot pin  18  of disc member  14 . The saddle support member  12  is provided with a re-entrant bore  26  having an interior configuration adapted to receive and rotatably engage the head  22  of the pivot pin  18 . While the re-entrant bore  26  is shown to be centrally located, it is to be understood that it could be located anywhere along saddle support member  12 . The saddle support member  12  is further provided with a slotted aperture  28  arranged to receive a conventional cable tie  16 . As seen in FIG. 1, the cable tie  16  to be used with the assembly  10  includes a longitudinal strap portion  32  and a locking head portion  34 . The locking head  34  is provided with an aperture  36  to receive and retain the strap portion  32 .  
         [0056]    Preferably the components for the spacing support assembly  10  and cable tie  16  are each injection molded from a strong, durable plastic, such as Nylon 6/6. Further, it can be seen that each saddle support member  12  is integrally formed and comprises a first surface  38  and a second curved support surface  40 . The first surface  38  provides clearance between saddles for pivotally receiving and attaching the saddle member  12  to the disc member  14 , while the second curved surface  40  is a saddle or cradle arranged for supporting engagement of a bundle  8  (see FIG. 1). Seen best in FIG. 5, the first surface  38  transitions to the re-entrant bore  26  arranged to receive the pivot pin  18  in disc member  14 .  
         [0057]    In alternate embodiments, the saddle member  12  may have a second surface  40   a  conforming to the shape of the structure to be supported. As seen in FIG. 5 a , for example, the second support surface  40   a  may be relatively flat to accommodate a non-curved object (not shown).  
         [0058]    As viewed in FIGS.  6 - 8 , another embodiment of the spacing support assembly  10   a  is shown. In this embodiment, the second surface  40  is provided with at least one cut-away portion  42 . The cut-away portion  42  of the support surface  40  allows bundles  8  (not seen in this view) having small diameters to be better circumferentially wrapped with a cable tie  16  and be effectively secured to the support surface  40 . In this embodiment, the strap  32  of cable tie  16  can be drawn into a smaller loop, to accommodate bundles having a smaller diameter than those able to be supported by the support surface  40  of the first embodiment as shown in FIGS.  1 - 5 . Furthermore, the rails  41  extending from the support surface  40  provide additional support when large bundles are secured. The flaring out  43  best seen in FIG. 7 of the rails  41  increases the surface contact to spread the load distribution and reduce pinching.  
         [0059]    The spacing support assembly  10  is preferably injection molded in a two-step process. As seen in FIGS.  9 - 11 , the disc member  14  is formed prior and independently of the saddle member  12 . A disc mold  44  is injected with material, such as plastic. After cooling, the disc member  14  is removed from the disc mold  44  and placed in the saddle member mold  46 . While it is preferred that the disc member  14  be molded in this manner, it is to be understood that other production means may be used, including, but not limited to, metal casting, cold forming, formed with a lathe or screw machine, formed from powdered metal, glass, wood or other materials. The saddle support member  12  is formed around the pre-formed disc member  14  as the saddle member mold  46  is injected with material. The material may be the same as that used to form the disc member or may be a material having a lower melting temperature. As seen in FIG. 11, the saddle member mold  46  is parted and the spacing support assembly is complete.  
         [0060]    Another alternate embodiment spacing support assembly, referenced generally as  10   b , is shown in FIGS.  12 - 14 . In this embodiment, a pivot pin  18   a  is integrally formed on a saddle support member  12   a . Referring to FIG. 14, saddle support member  12   a  is integrally formed with the pivot pin  18   a , while a second saddle support member  12   b  is provided with a re-entrant bore  26 . As in the previously described embodiments, the pivot pin  18   a  further includes a head portion  22  having an undercut collar  23  and a secondary flange portion  24 . The re-entrant bore  26  has an interior configuration adapted to receive and rotatably engage the secondary flange portion  24  of the pivot pin  18   a . The saddle support members  12   a ,  12   b  are each preferably provided with a slotted longitudinal aperture  28  arranged to receive a conventional cable tie  16 .  
         [0061]    As shown in FIG. 14, a false flange portion  20   a  is also formed on saddle member  12   b . False flange  20   a  does not have a functional purpose. It is provided for aesthetic reasons only.  
         [0062]    Yet another alternate embodiment spacing support assembly, referenced generally as  10   c , is shown in FIGS. 15 through 18. Again in this embodiment, a pivot pin  18   a  is integrally formed on a first saddle support member  12   a . Second saddle support member  12   b  is provided with a re-entrant bore  26 . As in the previously described embodiment, the pivot pin  18   a  further includes a head portion  22  having an undercut collar  23  and a secondary flange portion  24 . The re-entrant bore  26  of saddle member  12   b  has an interior configuration adapted to receive and rotatably engage the secondary flange portion  24  of the pivot pin  18   a . As best shown in FIGS. 16 and 17, a smooth walled cylindrical off-set  50  is formed between the saddle members  12   a ,  12   b . The height of off-set  50 , or the distance between the saddle members, will determine the relative spacing of the bundles to be secured. The saddle support members  12   a ,  12   b  are each preferably provided with a slotted longitudinal aperture  28  arranged to receive conventional cable tie  16 .  
         [0063]    Again in this embodiment, surface  40  is provided with at least one cut-away portion  42 . The cut-away portion  42  of the support surface  40  allows bundles having small diameters to be better circumferentially wrapped with a cable tie and be effectively secured to the support surface  40 . As previously described, rails  41  extend from the support surface  40  provide additional support when large bundles are secured. The flaring out of the rails  41  increases the surface contact to spread the load distribution and reduce pinching.  
         [0064]    The preferred embodiment of the spacing support assembly, referenced generally as  10   d , is shown in FIGS. 19 through 24. Again in this embodiment, a pivot pin  18   a  is integrally formed on a first saddle support member  12   a . Second saddle support member  12   b  is provided with a re-entrant bore  26 . As in the previously described embodiment, the pivot pin  18   a  further includes a head portion  22  having an undercut collar  23  and a secondary flange portion  24 . The re-entrant bore  26  of saddle member  12   b  has an interior configuration adapted to receive and rotatably engage the secondary flange portion  24  of the pivot pin  18   a . As best shown in FIGS. 21 and 22, a smooth walled cylindrical off-set  50  is formed between the saddle members  12   a ,  12   b . The height of off-set  50 , or the distance between the saddle members, will determine the relative spacing of the bundles to be secured. The saddle support members  12   a ,  12   b  are each preferably provided with a slotted longitudinal aperture  28  arranged to receive conventional cable tie  16 .  
         [0065]    Again in this embodiment, surface  40  is provided with at least one cut-away portion  42 . The cut-away portion  42  of the support surface  40  allows bundles having small diameters to be better circumferentially wrapped with a cable tie and be effectively secured to the support surface  40 . As previously described, rails  41  extend from the support surface  40  provide additional support when large bundles are secured. The flaring out of the rails  41  increases the surface contact to spread the load distribution and reduce pinching.  
         [0066]    Similar to the previously discussed process, the preferred spacing support assembly  10   d  is preferably injection molded in a two-step process. As seen in FIG. 25, the first saddle member  12   a  is formed prior and independently of the second saddle member  12   b . A first member mold  54  is injected with material, such as plastic. After cooling, the first member  12   a  is removed from the disc mold  54  and placed in the second saddle member mold  56 . Referring to FIG. 25 a , saddle support member is preferably molded with an undercut shut off  70 . The undercut shut off  70  allows member  12   a  to be better retained and also prevents material from flowing into undesirable regions on member  12   a  during the over molding process discussed infra. Alternatively, and as shown in FIG. 25 b , a vertical shut off  72  may be formed. It is also contemplated that a core  74  may be formed in the pivot pin region to allow member  12   a  to cool faster. This may decrease the total time required to form a finished spacing support assembly  10   d.    
         [0067]    The second saddle support member  12   b  is over molded or formed around the pre-formed first member  12   a  as the second saddle member mold  56  is injected with material. The material may be the same as that used to form the first member or may be a material having a lower melting temperature. As seen in FIG. 27, the second saddle member mold  56  is parted and the spacing support assembly  10   d  is complete.  
         [0068]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.