APPARATUS, SYSTEM, AND METHOD FOR WIRE STABILITY AND PROTECTION

It is common to bundle plural conductor wires (e.g., via cable tie) when conductor wires are run collectively some distance (e.g., from the back of a computer tower to related devices (e.g., mouse, monitor)). Oftentimes bundled conductor wires are broken or damaged—potentially posing a shock hazard—when conductor wires are bundled too tightly or bent at too extreme an angle. These concerns are exacerbated in long runs of conductor wire in enclosed spaces where friction and strain relief also become concerns—for example, in large scale applications where tall, substantially hollow poles contain long runs of conductor wire which connect devices at or near the top of the pole to devices at or near the bottom of the pole. Disclosed herein are apparatus and methods of supporting runs of conductor wire in a manner that overcomes the above deficiencies, and further provides stability and protection.

TECHNICAL FIELD OF INVENTION

The present invention generally relates to apparatuses, systems, and methods of supporting runs of wire (e.g., by providing strain relief, in situ positioning, bundling, reducing friction). More specifically, the present invention relates to providing stability and protection to long runs of conductor wire (e.g., dozens of feet) which (i) electrically conductively (e.g., via electrical current or power transmission)connect geographically remote devices and/or (ii) provide a route for or otherwise facilitate/conduct signal transfer (e.g., via control, monitoring, sensing, feedback, communication, or other information transmission).

BACKGROUND OF THE INVENTION

It is common to bundle plural conductor wires (e.g., via cable tie) when wires are run collectively some distance; for example, from the back of a computer tower to related devices such as a mouse or monitor. As is well known, care must be given to avoid bundling conductor wires too tightly or bending said wires at too extreme an angle—wires can be broken or damaged, or wire insulation can be compromised thereby posing a shock hazard. Often conductor wires will also be protected with some means (e.g., tubing, conduit) which can be used in conjunction with said bundling so to create a cable management system which addresses, to some degree, the need for both stability and protection of wires. This is both well-known and widely practiced across the electrical arts whether residential or commercial, indoor or outdoor.

For large scale applications such as that illustrated inFIGS. 1A-Cproviding stability and protection is not merely a matter of adding more bundles or conduit to accommodate longer lengths of conductor wire; there is also the issue of addressing concerns with strain relief and wire isolation. Consider a lighting installation in which a target area5is illuminated by arrays1of lighting fixtures2which are spaced about and elevated above target area5by poles6. Electrical power9is delivered to the site (e.g., via utility company), transported via conductor wiring10to a power distribution cabinet11where power is metered out, and further transported via conductor wiring12to each pole6where power is conditioned for the load (here, one or more LED lighting fixtures2) at one or more electrical enclosures13(here, at one or more drivers/power means3). This is well known in the art of lighting (particularly sports lighting), though U.S. Pat. No. 8,537,516, incorporated by reference herein, provides additional background information specific to outdoor lighting applications such as that inFIGS. 1A-C.

Once metered and conditioned power leaves electrical enclosure13as a bundle of conductor wires it travels more or less vertically via conductor wires14(illustrated inFIG. 1Cas a single conductor wire for clarity) through many feet of substantially hollow pole6—which could be a single pole or in sections, a single diameter or tapered, or even comprise an elongated structural member that can elevate devices or components (but is not a hollow pole as illustrated in the Figures)—where it is bent or otherwise manipulated near a removable pole cap20and routed through a substantially hollow crossarm7where it is portioned out to each fixture2through an electrical connection in each associated knuckle4. As may be appreciated, for the scenario just described not only must conductor wires be bundled and guided along the substantial length of pole6(e.g., dozens of feet, including 24 feet to a hundred or more feet), and not only must conductor wires be positioned in situ (e.g., to power fixtures2), but conductor wires may need to be identified and isolated at different lengths at different vertical and horizontal positions in an array1(e.g., to provide power to upper and lower crossarms7). All of this is in addition to requirements for strain relief for conductors run vertically (see, e.g., National Electric Code (NEC) 300.19, 2017 version).

Further, the available space within pole6is limited, and as each fixture2requires dedicated conductor wiring14, and as there is generally a need to add as many lighting fixtures as a pole can safely support to reduce project cost, there can be a significant amount of friction between conductor wires14in the limited space along the vertical span of pole6. Also, for long lengths of conductor wire (see, e.g., the table of aforementioned NEC 300.19) a mid-point handhole15must be added to pole6for access to the interior space of the pole for the sole purpose of allowing a contractor to install a strain relief device; seeFIG. 1B. Not only does the addition of handhole15add cost to any project, failure to correctly install the mid-point strain relief device (which often happens) places undue stress on any strain relief device at the top of the pole (e.g., accessed via pole cap20)—which can damage wiring at the top of the pole and reduce integrity thereof beyond what would have existed with no strain relief means at all.

The art would benefit from improved means of supporting long runs of conductor wire which provide needed stability and/or protection. The art would further benefit if the aforementioned could be applied to longer lengths of conductor wire than what is possible using state-of-the-art systems. Further still, the art would benefit if all of the aforementioned could be applied while remaining below threshold loads carried by the conductor wires such that devices such as handholes15currently needed—see applicable NEC and Underwriters Laboratories (UL) codes—could be eliminated and, therefore, cost reduced.

Thus, there is room for improvement in the art.

SUMMARY OF THE INVENTION

When connecting long runs of conductor wire (e.g., dozens to more than 100 feet) between geographically remote devices (e.g., lighting fixtures at the top/distal end of a pole and power means at the bottom/proximate end of said pole), a number of stability and protective means are required. Conductor wires are more stable and easily managed in situ when bundled, and conductor wires are more protected when contained in conduit, for example. That being said, oftentimes a lack of space (e.g., in the interior of a substantially hollow pole) creates friction between conductor wires—between a conductor wire and the internal surface of a pole at a gap in the conduit, or between two conductor wires when one is bent and routed in a different direction from the rest of the bundle, for example—when conventional means are used. Further, said conventional means of providing stability and protection to long runs of conductor wire can actually compromise the integrity of the conductor wire (to the point of inoperability) if done incorrectly or incompletely (e.g., when forgetting to install mid-point strain relief devices).

It is therefore a principle object, feature, advantage, or aspect of the present invention to improve over the state of the art and/or address problems, issues, or deficiencies in the art.

Envisioned are apparatuses, systems, and methods of providing stability and protection to long runs of conductor wire, and in a manner that improves upon the state of the art by reducing both potential cost (e.g., by eliminating mid-point pole handholes) and potential error in installation (e.g., by reducing steps or connection points required of a contractor/installer).

In one aspect of the invention, a method for creating a wire support system for a run of conductor wire comprises winding, braiding, or twisting one or more conductor wires together with a support wire to create an intermediate wire bundle to minimize interaxial gaps between any of the one or more conductor wires or between any of the one or more conductor wires and the support wire; wrapping the intermediate wire bundle with a tape to create a final wire bundle; cutting the final wire bundle to a desired length having opposite ends; and clamping a sleeve along the length of and around the cut final bundle at or near both of the opposite ends of the cut final wire bundle.

In another aspect of the invention, an apparatus comprises a wire support system comprising a run of one or more conductor wires wound, braided, or twisted together with a support wire to create a wire bundle to minimize interaxial gaps between any of the one or more conductor wires or between any of the one or more conductor wires and the support wire.

In another aspect of the invention, the apparatus above could further comprise a spiral wrap of the wire bundle with a tape to bind the bundle along its length.

In another aspect of the invention, the apparatus of a twisted bundle of conductor and support wires, wrapped with tape, could further comprise a clamping sleeve at one or both ends of the run to hold the twisted wires from longitudinal axially movement relative to one another.

In another aspect of the invention, the apparatus can be incorporated into a combination of a structural member with a stabilizing point, the twisted and/or wrapped wire bundle connected to the stabilizing point, and the opposite ends of selected wires of the wire run operatively connected to first and second electrical devices. In one example, the first and second electrical devices are lighting fixtures and electrical power, respectively, or a sensor device (e.g., light, moisture) and a receiving device (e.g., radio, gateway, processor), respectively.

In another aspect of the invention, the apparatus can be included in a plurality of structural members. One example is a plurality of poles with elevated lighting fixtures at spaced apart positions around a common illumination target, such as a sports field, each lighting fixture having an associated wire support system, all the wire support systems run to a common location (e.g., power distribution cabinet).

These and other objects, features, advantages, or aspects of the present invention will become more apparent with reference to the accompanying specification and claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

To further an understanding of the present invention, specific exemplary embodiments according to the present invention will be described in detail. Frequent mention will be made in this description to the drawings. Reference numbers will be used to indicate certain parts in the drawings. Unless otherwise stated, the same reference numbers will be used to indicate the same parts throughout the drawings.

Regarding terminology, reference is given herein to power means and lighting fixtures as examples of geographically remote devices which may benefit from aspects according to the present invention; here “geographically remote” can mean a distance of a few inches or many dozens of feet, or some other greater distance, for example. Geographically remote devices can be other than power means and lighting fixtures as well; geographically remote devices could be a receiver coupled with a sensor or other device which communicates a signal to the receiver, or power means with a control circuit, for example. Reference is also given herein to the “top” of a pole and the “bottom” of a pole, the former also being referred to herein as the “distal end” and the latter also being referred to herein as the “proximate end”; it is important to note that these terms are relative to the application and orientation of wires, devices, etc., and none are intended to impart any limitations not explicitly stated herein. For example, an application may not use a pole at all (e.g. using instead some other sort of structural member such as a truss), or an application may run wire in a horizontal direction and therefore have a “left” and “right”, but no “top” and “bottom”. All are possible, and envisioned, according to aspects of the present invention.

Further regarding terminology, terms such as “device”, “component”, “means”, “portion”, “part”, and “apparatus” may be used herein to describe various aspects according to the present invention, any of which might be combined or otherwise form part of a larger system. While specific reference is given herein to protective means, some examples of which are tubing and conduit, and specific reference is given herein to stability means some examples of which are strain relief, in situ positioning, and bundling, generally speaking, the aforementioned terms are used by way of convenience, and none are intended to impart any limitations not explicitly stated herein.

With further regards to terminology, it is important to note that terms such as “tape”, “wrap”, and “tape wrap” are used interchangeably herein to describe a part (see reference no.30); this is for purposes of illustration, example, and to cover a variety of manners in which said part might be referenced in industry. This is true also of the terms “contractor’” and “installer” as examples of those who may practice the invention; again, these are non-limiting examples using different terms that one may encounter in industry. This approach to terminology can be further extended to the use of the terms “conductor”, “wire”, “wires”, “cable” and “wiring”. While specific reference is given to “conductor wire” or “conductor wiring” (see reference no.14) which is electrically conductive effective for such things as electrical power or current transmission (including low voltage or high voltage), control or signal transmission, data transmission, multiplex transmission (including power and signal transmission simultaneously), or other electrically interconnecting functions, and while specific reference is given to “support wire” (reference no.26) to denote a wire, strand, elongate, or multi-strand that exhibits one or more of strength and durability over large temperature range, resistance to corrosion, and resistance to abrasion both of itself and of surfaces or components it may come into contact (but is not required to conduct power or a signal), generally speaking, the aforementioned terms are used by way of convenience, and none are intended to impart any limitations not explicitly stated herein.

However, it is of note that irrespective of which term is used to describe what is understood in the industry as a slender rod or filament of material (often drawn material), the figures typically illustrate for clarity a single wire. That being said, a wire could be a single wire or multiple wires, one or more wires including multiple strands, or even wire-like components (e.g., fiber) in any material, bundling arrangement, or gauge. Wire can be bare or surrounded by another layer or layers of material (e.g. shielding, insulation, jacketed, coated, etc.). Said wires could be very long (e.g., many dozens of feet) or simply an inch or so, and may be referred to as “runs” and “bundles” regardless of length, number of wires, etc. Also, with respect to said runs or bundles of wiring, the term “gap” is used herein; this term generally refers to an interaxial spacing that is more than slight separations between the cross-sectional perimeters of adjacent wires. In essence, a gap in a wire bundle refers to larger separations where one or more wires are not in abutment with other wires or an enclosure in all transverse directions, examples of which are shown inFIGS. 3Dand E. Of course, other terms (e.g., “void”) might describe the same phenomenon, what generally constitutes a “gap” might differ from application to application (e.g., depending on a ratio of empty space to wire across a bundle cross-section). All of the aforementioned terms and options are possible, and envisioned.

Returning now to the outdoor lighting application ofFIGS. 1A-C, consider how conductive wiring is stabilized and protected according to state-of-the-art practices; this is illustrated inFIGS. 2Aand B. As can be seen fromFIG. 2A, conductive wire (also sometimes referred to as a conductor)14is routed along the internal space of hollow pole sections6and isolated at different points to be routed through hollow crossarms7to power lighting fixtures2at connection points8which are embedded in knuckles4; additional information regarding making electrical connections at knuckles (also referred to as adjustable armatures) can be found in U.S. Pat. No. 8,337,058 incorporated by reference herein. Multiple conductive wires may be bundled via cable ties19and protected via flexible or semi-rigid conduit17(e.g., any model of corrugated tubing available from OEM/Miller, Aurora, Ohio, USA). Some degree of strain relief might be provided by affixing a cable tie19to a stabilizing point21via a snap-type hook18(e.g., any commercially available stainless steel snap hook with sufficient loading capacity (e.g., ˜250 lbs)). In other situations, no strain relief may be present; this is illustrated inFIG. 2B, which is a side view in partial cutaway of the pole and lighting fixture arrangement ofFIG. 1C. Of course, no strain relief means (as inFIG. 2B) is not preferable for long runs of conductive wire, nor is a strain relief means that places significant stress on a single point of a conductive wire (as inFIG. 2A).

FIGS. 3A-Eillustrate an improvement over the systems ofFIGS. 2Aand B, but a state-of-the-art approach that is not without deficiencies. As can be seen fromFIGS. 3Aand C, additional support for conductive wiring can be provided by extending conduit17along more of the length of pole6; this can be in addition to bundling via cable ties19. In this sense, a more stable and protected run of conductive wire exists from the top of the pole to the bottom of the pole. In terms of strain relief, strain relief means22are an improvement insomuch that stress is spread out across conductor wires14(i.e., via a wire matrix which encloses all conductive wires and terminates in a loop which is hooked to stabilizing point21via snap-type hook18) rather than at a single point (as inFIG. 2A).

While the wire support system ofFIGS. 3A-Eis certainly an improvement over the systems illustrated inFIGS. 2Aand B for long runs of conductive wire, in the event a contractor forgets to attach strain relief means22at the pole mid-point (see handhole15ofFIG. 3A), strain relief means22at the poletop position can actually become overloaded and cut into the insulation of conductor wires14and ultimately, cause device and/or conductive wiring failure. Additionally, conduit17which is intended to provide stability by keeping conductive wire bundles intact and improve the ease of in situ positioning can actually decrease the integrity of the conductive wiring in some situations. If conductive wire bundles have a gap (as inFIG. 3Dwhere the entire cross-sectional area inside conduit17is not substantially occupied by conductive wire(s), in this example leaving a gap in the middle, or otherwise where the interaxial spacing between any conductor wires14in the conduit17has gaps such that the conductor wires14are not all in abutment with other conductive wires or any encasement (e.g., conduit17) in all directions), conductive wires can be damaged (e.g., pinched as inFIG. 3E) when uneven forces are applied to the conductive wire bundle (e.g., when pulling through a pole or crossarm or when isolating conductive wire sections at the top of the conductive bundle to power lighting fixtures).

So as can be seen, state-of-the-art practices can be improved upon with respect to wire support systems. By way of convenience and comparison, and not by way of limitation, the following discusses exemplary apparatuses, systems, and methods which set forth such improvements in the context of a large scale, outdoor sports lighting system such as that illustrated inFIGS. 1A-C.

B. Exemplary Method and Apparatus Embodiment 1

A first embodiment according to aspects of the present invention addresses improved stability and protection of long runs of conductive wiring by reducing the number of strain relief connection points thereby providing a potential cost savings (e.g., by eliminating a handhole) and reducing potential installation error, with improved bundling which, among other benefits, reduces friction.

Apparatus

According to the present embodiment and with particular reference toFIGS. 4A-I, a support wire26(e.g., any nylon coated304stainless steel wire)—which unlike conductor wiring14is not designed to carry power or a signal—is placed at or near the perimeter of a group of conductor wires14so to create a preliminary wire bundle. Support wire26and conductor wires14are wound, braided, or otherwise twisted together (at least in some cases), run at least a substantial length of a pole6, and connected to aforementioned stabilizing point21via an eye end fitting27(e.g., any stainless steel model available from Loos & Company Inc. Cableware Division, Naples, Fla., USA). The placement of support wire26together with the winding efforts provides both improved protection and stability—as opposed to burying support wire26in the center of intermediate bundle14/26—since (i) with regards to the former, more of the overall exterior surface area of the run of intermediate bundle14/26is support wire26, and so in the event of a sharp or abrasive surface (e.g., in the interior of a pole) it is more likely support wire26will absorb the damage than conductor wires14; and (ii) with regards to the latter, more support wire26is used and its position in intermediate bundle14/26is varied over the increased run length of the bundle, which allows more distribution of forces along the run of the bundle. The pitch, slope, and radius of the helical or spiral twisted wire can vary according to the wire and its application, and the direction of twist into the helical or spiral shape can be either right-handed or left-handed. In the case of braiding (not illustrated) the tightness and type (e.g., single, double) of the braid can vary according to the wire, number of wires, and its application.

Protection and stability can be further enhanced by then wrapping intermediate bundle14/26with a component or material that at least partially covers and may also cinch or provide inward radially forces to reduce or hold individual conductor wires14and26of bundle14/26together without any gaps. In this embodiment wrap30is a flat braided nylon tape (e.g., model NOF150W available from Western Filament, Inc., Grand Junction, Colo., USA—minimum break 135 lb., elongation 40%, width 0.180 inch min. to 0.220 inch max., thickness 0.013 inch min. to 0.019 inch max., melts at 480° F. to 500° F., excellent resistance to mildew, aging, and abrasion) so to create a final bundle; as can be seen inFIGS. 4A, B, D, H, and I tape wrap30in this embodiment is wound in the opposite direction (e.g. left-hand direction if support wire26twist is right-handed direction; right-hand direction if support wire26is left-handed) of support wire26around the outside/perimeter of the bundle (thereby creating two opposite-running spirals or helixes). Again, the pitch, slope, and overlap or spacing of turns of the helical or spiral wrap30can vary according to the bundle that is being wrapped, the wrap itself, and the application. Likewise, if braiding tape30into bundle14/26the tightness and type (e.g., creating a rope braid if intermediate bundle14/26is twisted together, creating a double braid if bundle14/26is braided together) of the braid can vary according to the wire, number of wires, and its application.

In the example illustrated inFIGS. 4A-I, the helical or spiral pitch relative to tape width is such that there is no overlap of tape edges, and portions of support wire26are exposed, though tape30could have edges closer or even overlapping, if desired or needed. Irrespectively, both ends of final bundle14/26/30are run through the center of a sleeve31(here, as a non-limiting example, a cylindrical aluminum sleeve having a thickness on the order of 0.10″ surrounding a rubber sleeve/grommet having a thickness on the order of 0.10″ with an overall length on the order of 2.25″ and an inner diameter (i.e., aperture) on the order of 0.35″) which is then crimped in place thereby securing tape30, support wire26, and conductor wires14in situ and preventing unraveling of any component. Sleeve31provides sufficient radial forces to resist any longitudinal movement of individual conductor wire(s)14or support wire26relative to others in the bundle. It essentially is a mechanical clamp to hold all wires in the bundle in that same longitudinal position relative to each other. Any final connectors23,24are added to either or both ends of component14/26/30/31so to create an envisioned wire support system1000.

As can be seen fromFIGS. 4A-Ifriction is reduced because twisted bundled conductor wires14are bound along substantially the entire length (with the exception of a secondary length, later discussed) and do not rub against one another even when one or more conductor wires14are split off (e.g., by keeping all wires fixed at a common point at the top and bottom of the pole); note that inFIGS. 4A, B, and D twisted bundled conductor wires14are not individually shown for clarity, but support wire26is shown to illustrate its relative position along the twisted wire bundle14and its direction of twist. Also, there is no pinching or distortion of wires (as may be the case in using conduit of a fixed size/diameter) since support wire26and tape30conform to the shape of conductor wires14, and in any event are fixed at sleeve31(thereby also ensuring compact bundling). Tape30is shown individually to illustrate its relative position along twisted conductor wires14and support wire26, as well as its different direction of twist. As can be seen, wrap30does not necessarily cover all of twisted intermediate bundle14/26; this can aid in providing binding to avoid gaps, make the bundle easier to handle (e.g., by adding some rigidity which makes pulling runs of wiring easier), and protect the bundle, but also save costs by less wrap material in final bundle14/26/30. Lastly, strain relief means are provided along the entire length, yet only one connection (see reference no.27) need be made by a contractor—this eliminates the need for handhole15(seeFIG. 3A).

As will be appreciated by those skilled in the art, benefits according to one or more aspects of the invention could be achieved by the following combinations in addition to what has already been described and illustrated:a. Just one or more conductor wires14with a support wire26twisted along the longitudinal length of the assembly. If the one or more conductor wires14is more than one wire, they might not be twisted but rather simply be parallel, but support wire26twisted around them. As such, this combination provides a support wire26along the length for strength and durability, but does not use wrap30or sleeves31.b. One or more conductor wires14with support wire26and wrap30, without sleeves31. This combination provides support wire26for its purposes but adds wrap30to pull together the bundle14/26along its length, adds rigidity, and provides anti-friction areas along the length.c. One or more conductor wires14with support wire26and wrap30, with a sleeve31at one end of the length. This combination provides support wire26and wrap30for their purposes, but adds at least one sleeve31at an end of the length for its assistance in deterring longitudinal movement of individual conductor wires14in the bundle relative to others, and allowing one or more wires14/26in the bundle to extend from the sleeve as discussed in the exemplary embodiments.d. One or more conductor wires14and support wire26and at least one sleeve31, but not wrap30. This combination provides support wire26with at least one sleeve31for their purposes but without wrap30.

As indicated, the combination of all features can provide enhancements individually and collectively, but combinations of less than all features are possible according to need or desire.

Method

In practice, wire support system1000ofFIGS. 4A-Imay be produced according to method5000ofFIG. 5. According to a first step5001conductor wires14are gathered along with a support wire26; the precise number, gauge, and material of wires14/26will depend on the application, number of geographically remote devices being connected, etc. In this embodiment, conductor wires14and support wire26are gripped and twisted as they are fed from their respective spools. This intermediate bundle is then gripped and wrapped in a similar fashion (but in opposite direction) with nylon tape30according to step5002, thereby creating a final bundle having two opposite running spirals and no gaps between wires. In practice, the same machine is used for steps5001and5002—and depending on fabrication capabilities, steps5001and5002could be done more or less concurrently.

According to a third step5003, final bundle14/26/30is cut to a defined length. Here care must be taken to not only account for the length needed between geographically remote devices (e.g., fixtures2and power means3), but also (i) an extra length of conductor wires14to extend out of sleeve31so to make necessary connections, and (ii) a length of support wire26so to allow for connection for strain relief (see, e.g., see exposed portion of support wire26connected to fitting27,FIG. 4D, which is placed in operative connection with part21to provide strain relief). In the case of a single crossarm or geographic location, extra length of conductor wire14may be a fraction of an inch (see, e.g., small amounts of conductor wires14in connector half23,FIG. 4D). For the example of devices on a lower crossarm or multiple geographic locations (see, e.g., pole6and crossarm7in broken line inFIG. 4A), extra length of conductor wire14may be many inches long (see, e.g., conductor wire14in broken line inFIGS. 4Aand B). Though the exact length of components may vary from application to application, in all cases final bundle14/26/30has a primary length running the span of a pole, and splitting off (if any) of any of wires14and/or26for connections or otherwise (i.e., a secondary length) is done after strain relief means at the pole top (unlike in some state-of-the-art practices).

When an adequate length of final bundle is measured and cut, both ends of said primary length are fitted with sleeves31and secured by crimping (e.g. using hand force with manually-operated tools or with automatic or semi-automatic tools or machines) (step5004)—the goal being to secure wires, but not to pinch wires as inFIG. 3E, and to leave sufficient length of wires14/26(e.g., for connectors, for running to different locations for connection to geographically remote devices). The correct amount of pinching can be established by trial and error, and is dependent upon the physical characteristics of sleeve31and the physical characteristics of wires14and26.

As a final step5005, connectors and/or connector halves (see, e.g., reference nos.23/24) and/or fittings (see, e.g., reference no.27) are connected to portions of selected wires14/26extending past sleeves31, and wire support system1000is ready for use in a variety of applications;FIG. 6illustrates one possible method6000of implementation for the specific case of a large scale, outdoor lighting system such as that illustrated inFIGS. 1A-C.

As a first step6001, power wiring12is connected below grade at a pole location (e.g., at base16,FIG. 1B) where a substantially hollow pole6is to be assembled and installed; typically pole6is laid horizontally on the ground near base16at this early stage. Following this, wire support system1000is pulled through pole6(e.g., via commercially available fish wire-type wire pulls)—step6002. At this point in situ positioning is secured, at least in part, by attaching strain relief device26/27to stabilizing point21(step6003); note that this is the only strain relief (and snap-hook type) connection required of a contractor, and that there is a visual cue to complete the connection by presence of strain relief device26/27when a contractor accesses connectors via pole cap20(unlike the mid-point strain relief device of the prior/current art which provides no such visual cue when pulling wire).

Once wire support system1000is pulled and positioned, a distal end (i.e., the end at or near pole top) is connected to mating connector halves23/24(seeFIG. 4A) according to step6004; similarly, a proximate end (i.e., the end at or near the bottom of the pole) is connected to connector halves23/24according to step6005. Again, if there are multiple connections to be made along the vertical length of the pole (e.g., lighting fixtures on lower and upper crossarms), each conductor wire14(which will likely be labeled with some indicia on or near its connector half which matches up with indicia on its mating connector half at or near knuckle interface8) must be isolated and routed accordingly. This is likewise true at the proximate end where connector halves may need to be mated at specific drivers or landed at specific ports in enclosure13. As a result, there may be different lengths of wires14/26extending outwardly from sleeve31at either end of wire support system1000; put differently, the secondary length (i.e., the length of conductors past sleeve31) could, in practice, vary depending on the number and purpose of wires14/26.

A full electrical connection is made at the distal end when fixtures are snapped into place according to step6006(see again U.S. Pat. No. 8,337,058 for details); of course, if the application is different (e.g., connecting a cellular antenna at a top of a pole to a control device at the bottom of a pole) step6006could be different, or omitted entirely. At this point pole6(which to this point has been lying on the ground) is stood, elevated, and placed on pole base16as inFIG. 1B. Final electrical connections (e.g., landing main power at a main disconnect) are made at the proximate end (step6007) to complete the circuit and, ultimately, connect geographically remote devices (which in one example, results in powering plural (e.g., three) lighting fixtures2(step6008)). Method6000would then be repeated for each pole location at each target area until all lighting fixtures are connected and powered.

As will be appreciated by those skilled in the art, methods5000and6000could be modified in any of the ways discussed in the Apparatus section, supra. For example, embodiments of the invention may not include twisting of conductor wires14, use of wrap30, use of sleeve(s)31, or could include some or all of them.

C. Options and Alternatives

The invention may take many forms and embodiments. The foregoing examples are but a few of those. To give some sense of some options and alternatives, a few examples are given below.

Several figures illustrate wiring14or26as a single wire, but it is important to note that aspects according to the present invention could be applied to a single wire, multiple wires, wires of varying materials and gauges, wires intended to power devices, wires intended to carry a signal (even if referred to as a conductor), or wires intended to both power devices and carry a signal (e.g., powerline communications). Both conductor wire14and support wire26can very in gauge, length, material, quantity in a bundle—and may be braided, wound, twisted, or some combination thereof (e.g., conductor wires twisted to each other and then braided with one or more support wires26).

Cross-sections of devices have illustrated some parts as greatly exaggerated in thickness; for example, in part30ofFIG. 4C. It is important to note that in addition to wires14/26, these other parts may differ in quantity, thickness, and shape—and that aspects according to the present invention could be applied to all. Further, while geographically remote devices have been illustrated as including lighting fixtures and remotely located power means, aspects of the present invention could apply to other electrical devices (e.g., antennas, radios, communication stations, monitors, computer towers). Also, connection means have been generally illustrated herein as a hook with associated device (e.g., eye end fitting), but any means of connecting a wire bundle to a point could be used (e.g., a loop of support wire26hooked on hook21). As another example, poles6could be formed from multiple sections or be a single section, may be only a few feet tall or many feet tall, and include a taper or be slip-fit, or otherwise—or in some cases may not be a pole or have hollow support members (e.g., a solid bar truss). As yet another example, various stability and protection means could be combined; for example, a primary length of wiring may be such as described in Embodiment 1, but a secondary length of wiring may be secured with cable ties (as is common in the state of the art). All of the aforementioned options are possible, and envisioned, according to aspects of the present invention.

It is also important to note that an application benefitting from aspects of the present invention may be other than a large scale, outdoor lighting application, and that methods5000and6000may differ accordingly. Depending on the needs of the application, the type of wiring, and the nature of the geographically remote devices being connected (as an example), methods5000and6000may include more, fewer, or different steps than those illustrated and described herein. For example, method6000may omit step6006if the electrical device does not require an intermediate connection point (see reference no.8). As another example, at least some wires14/26in a final wire bundle may not have any connectors connected according to step5005, and therefore steps6005and6007may be omitted for at least some wires14/26. This may be useful, for example, if there is not a current need for a conductor wire, but there is an anticipated future need for the conductor wire (e.g., if adding lighting fixtures or poletop sensors like photocells); in this sense the conductor wires need only be bundled and run once but connectors could be added as needed—even well after installation—without compromising the integrity of the bundle or having to re-run wiring again.

Even if the application is a lighting application (indoor or outdoor, large scale or small scale), methods5000and6000may differ from that described and illustrated herein. For example, steps6001,6004, and6005could be reordered for a more intuitive approach to completing an electrical circuit. As another example, a pole may be stood up and installed prior to pulling wires (i.e., occurring before step6002instead of before step6007as described). Again, all of the aforementioned are possible, and envisioned, according to aspects of the present invention.