Box for payout of a filamentary product

A box for payout of a filamentary product such as cable or wire that is wound in a coil inside of the box. The box is constructed to retain the coil securely and utilize material in an efficient manner. Particularly, the box is adapted to retain a figure-eight coil of wire, which is often formed in an irregular shape. The box may include a payout tube that extends from a point outside of the box through a wall of the coil and into an interior point of the coil. The box serves to retain such a payout tube with an efficient amount of material and also provides for an improved method of assembling the box, the coil, and the payout tube.

BACKGROUND

The present invention relates to a box and payout tube construction designed to contain a coil of filamentary material for smoothly dispensing such filamentary material, and particularly to a box designed to contain a figure eight coil of filamentary material.

The figure eight coil arrangement has been in use in the wire and cable industry for many years to help payout at installation and to help prevent a cable from twisting when it is dispensed from the coil during an installation process. The figure eight coil generally includes loops of coil arranged between two divergent planes, crossing back and forth to define an opening through one side wall or edge of the coil. This creates a coil with one side that is wider than an opposing side. These coils of wire having sides of differing widths create problems for handling and packaging of the coil. Conventional coil packaging heretofore in use is comparatively expensive to make and often holds such coils inefficiently. Moreover, conventional packaging has problems paying out the wire, cable or other filamentary materials without kinks or knots. Conventional packaging, in attempts to overcome payout problems is complex, relatively weak, and occupies excessive space.

SUMMARY OF THE INVENTION

According to some embodiments of aspects of the inventions a box for paying out filamentary material from a coil of filamentary material contained in the box includes a pair of opposite faces and a front face with an aperture formed in the front face. The aperture is shaped and sized to permit payout of the filamentary material through the aperture, and the opposite faces are on divergent planes. The opposite faces each share an edge with the front face. The box may further include a second pair of opposite faces, wherein said second pair of opposite faces are trapezoid shapes. The box may not further include a payout tube extending from the aperture and through an opening formed through an edge of the coil for permitting payout of filamentary material. The payout tube may include a filament lock defined in a wall of the payout tube for retaining an outer end of the filamentary material. The filament lock may include an opening through the wall of the payout tube and retention fingers extending into the opening to hold the outer end of the cable. A flange may extend outwardly from an outer end of the payout tube and the payout tube flange may be secured to the front face. The payout tube may be tapered. The flange may be secured to the outside of the box. The payout tube may be a multifaceted wall of alternating flat and arcuate sections. The multifaceted wall may have four flat sections and four arcuate sections. A recess may be defined in the payout tube to engage an edge of the aperture. The recess may be a slot defined through a wall of the payout tube. Alternatively, the recess may be a groove defined around the payout tube near an outer end. The front face of the box may be formed of two overlapped flaps, one of which has a slot defined therein for receiving the payout tube radially to a central axis of the payout tube. The slot for receiving the payout tube may have tabs defined thereabout for retaining the payout tube. Alternatively, the slot may have a keyhole shape for retaining the payout tube. The box may be defined by two sheets of material. In that case, the second sheet of material may define the one of the flaps having the slot. Alternatively, the box may be defined by only one sheet of material. The opposite faces on divergent planes may be inner faces, and the box may further have a pair of outer faces on parallel planes outside of the pair of opposite faces on divergent planes.

The various embodiments of aspects of the invention may, except where clearly mutually exclusive, be freely combined by the skilled artisan. The box, loaded with a coil of filamentary material, for example wire, cable, optical fiber or the like, also embodies aspects of the invention.

DETAILED DESCRIPTION

The present invention will be better understood upon reading the following detailed description of various embodiments of aspects thereof in connection with the drawings.

Embodiments of aspects of the present invention may be found in a box including features for holding and stabilizing a figure eight coil using a minimum of materials and a minimum of assembly labor. Embodiments of aspects of the invention can be shaped for minimum, close-packed volume when finished cartons of filamentary material are palletized, thus increasing pallet capacity significantly over conventional packaging. For example, using an embodiment of aspects of the present invention to package 305 m. (1,000 ft.) coils of Category 5E cable, Nordx/CDT, Inc. can achieve a total capacity per pallet of 13,725 km. (45,000 ft.), compared with conventional packaging, which achieves a total capacity per pallet of only 10,980 km. (36,000 ft.), thus saving substantially on shipping costs.

Embodiments of some aspects of the invention are constructed using one sheet of single-wall corrugated cardboard, plastic, or other suitable material configured for high strength, in combination with a payout tube constructed of a single piece of plastic or other suitable material. The configuration is a single sheet of material cut and folded to have six sides, with two opposing faces lying on different planes. The sheet may be formed by any suitable method, such as die cutting. As will be explained below, in greater detail, one or more of the faces may be constructed of plural, overlapped flaps. In addition to providing structural integrity, the combination of shapes used results in a container that holds a figure eight coil of filamentary material with high stability, little movement and little deformation during shipping or transportation. The container has an inside shape that closely follows the contours of a figure eight coil packaged therein.

Other embodiments having similar characteristics to those described above can be constructed of two or more sheets of material. The faces lying on the divergent planes can be inner faces, surrounded by faces not lying on divergent planes.

When constructed as described using either a single sheet of material or plural sheets of material, where components of the box are joined using sliding tabs and slots as necessary, the use of glue and excess labor are advantageously avoided.

A figure eight coil has a generally circular profile (see for example, FIG.5,501), formed of loops of filamentary material that cross over from one side of the coil to the other, periodically switching in which direction they cross. In the coil's simplest form, the loops cross alternately in one direction and then the other, without crossing an opening formed at one edge of the coil. The edge at which the opening is formed is wider than the opposite edge, the entire coil being bounded by two divergent planes.

A first embodiment of aspects of the invention, as shown inFIG. 1, comprises a box100, preferably formed of corrugated cardboard or another suitable, stiff, light material. The material of which box100is formed should be selected to adequately support the contents for shipping. Corrugated cardboard is generally preferred for shipping wire and cable products because it is cheap, light and strong, although alternatively, other suitable materials may also be used.

Box100has six faces,101,102,103,104,105and106. For convenience, they will be referred to as top, bottom, left, right, front, and back, respectively, although in practice the box100may be oriented in any convenient direction, for example with top101downwardly facing and bottom102upwardly facing. Front face105has two apertures107and optionally108defined therethrough. A punch-out cover109or flap110may, optionally, temporarily cover the apertures107and108, respectively, until they are ready for use. Aperture107is for payout of the filamentary material carried in box100, while aperture108defines a handle for easy carrying of the packaged filamentary material. Cover109and flap110present entry into box100of foreign matter of debris, before a point in time when filamentary material is to be dispensed.

Faces103and104of box100define two divergent planes which preferably roughly coincide with the divergent planes bounding the coil to be carried therein. The generally circular profile of the coil can be bounded by four orthogonally located planes, e.g., the planes defined by faces101,102,105, and106. When placed in box100the opening formed in the edge of the coil, which is used for payout of the filamentary material, coincides with face105including aperture107. Prior to placement in the box100, a payout tube (FIG. 2,205) is inserted through the opening in the edge of the coil to hold it open for passage of the filamentary material as it is payed out.

Front side105is defined by two overlapping flaps, an outer flap111and an inner flap112. Inner flap112will now be described in further detail in connection withFIG. 2. A slot113at an edge of front face105and defined through inner flap112receives a tab114defined at an edge of outer flap111, so that when the box100is assembled, the outer flap111and inner flap112are securely joined.

As shown inFIG. 2, inner flap112has a large opening or slot201with tabs202,203, and204which secure a payout tube205in place. Payout tube205is slid through opening or slot201until tabs202,203and204grip payout tube205through slots206. Also seen in this view are slot113and aperture108. Note that aperture108is defined through both the outer flap111and the inner flap112.

Details of the construction of top101and bottom102, as well as other hidden flaps, is now discussed in connection withFIG. 3.

FIG. 3shows box100unfolded and laid flat as it would be prior to assembly. The surfaces seen in this view are generally interior surfaces. Outer flap111and inner flap112comprising front face105appear at the top and bottom, respectively, of the figure. Between outer flap111and inner flap112are disposed, in order, right face104, back106, and left face103. In the orientation shown in the figure, attached to left face103on its left are outer top flap301and inner top flap302, comprising top face101. Disposed to the right of left face103are outer bottom flap303and inner bottom flap304, comprising bottom face102. In order to retain the back face106and the inner front flap112in position when the box is assembled, flaps301and302wrap around large tabs305and306, while flaps303and304wrap around large tabs307and308. Assembled faces101and102are held in place by tabs309and310, which are retained in slots311and312, respectively.

After faces101,102,106and inner flap112are assembled as described above, a coil of filamentary material with a payout tube205inserted can be slid into place. As described above in connection withFIG. 2, the payout tube205is slid into opening201and retained by tabs202,203and204. Large tabs313and314are folded up and slid into box100between the coil of filamentary material and faces101and102, respectively, while large tabs315and316are slid between outer top flap301and large tab305and outer bottom flap303and large tab307, respectively. Finally, tab114is inserted into slot113, thus closing the box. Other means can be used to secure the box, either in addition to or instead of the tab114and slot113described. For example, glue, tape, or the like, can be used to secure the box closed. The box may be assembled as described by a progressive die folding machine, manually, or by any other suitable method.

An alternative embodiment of aspects of the invention is shown inFIG. 4. An openable face401is adjacent to the end402of the box400, although it could be on another side in other embodiments. The openable face401is used to insert the coil into the box400, and can also be used to access the inside of the box for any other reasons that might present themselves. The openable face401can comprise a single flap that substantially covers the side or, it may comprise multiple flaps as shown inFIG. 4. Embodiments of the invention may also have a second openable face401opposed to the openable face shown inFIGS. 4 and 5. The openable faces401of the box are also shown to be held in a closed position with the assistance of locking tabs403. These locking tabs403comprise portions of cardboard that fit between adjacent sides of the box to help retain the openable faces401in the closed position. Other embodiments may employ different types of locking means such as tape, glue, or other suitable means as the invention is not limited in this respect. Another feature depicted inFIG. 4is a handle404, shown as an opening which is disposed on the end402of the box. The handle404could also be located on any of the other walls of the box400and could comprise other suitable features, such as a strap that is fastened to the box as the invention is not limited in this respect.

FIGS. 4–6show a payout tube205situated in the end402of a box400.FIG. 7shows the same payout tube205, separate from the box400, andFIG. 8shows a cross-section of the payout tube taken along line8—8ofFIG. 7. The payout tube205extends from box wall402, through the coil of cable501and to a position inside of the coil of cable501to allow cable502to unwind from a position internal to the coil of cable501. To accomplish this effect, the payout tube205is placed through the opening503in the coil of cable501either while the cable502is being formed into a coil or after the coil of cable has been formed.

As shown inFIG. 7, the payout tube205has a tapered body701and a flange702. The tapered body701of the payout tube205facilitates insertion of the payout tube205into the coil501and also serves to minimize the amount of divergence required between the loops of cable within the coil501. Although the body701of the payout tube205is tapered as shown inFIGS. 4–8, the invention may also include payout tubes that are not tapered, as aspects of the invention are not limited in this respect. The flange702of the payout tube205is adapted to be disposed outside the end wall402of the box400when the box is assembled. The payout tube205shown inFIGS. 4–8is made of a plastic material, although other suitable materials can be used, such as cardboards, papers, metals, and composites.

The payout tube205shown inFIGS. 4–8has a body701of non-circular cross-section, and in particular, a tapered, cross-section with four substantially flat sides801and for arcuate sides802. The inventor has found that some payout tubes with circular cross-sections can deform when they are placed through an opening503in a coil501. The loops of coil forming the diverging planes can serve to apply compression forces against the body701of the payout tube205. These compression forces can deform a payout tube205that is not designed appropriately. For instance, the payout tube having a body with a circular cross-section may deform under such compression forces whether the body is tapered or not. To address these issues, the payout tube of the present invention has been constructed and arranged in a non-circular cross-sectional shape that resists compression forces. The particular cross-section shown inFIG. 8has four substantially flat sides801connected by arcuate side portions802, although other cross-sections such as square, diamond-shaped, or any other suitable shapes, may be used as the invention is not limited in this respect. Another feature that helps resist the compression forces is the reinforced lip803at the end of the body701opposite the flange702. The lip803shown in the figures comprises a reinforced section of plastic molded into the payout tube body. However, the lip may also comprise other materials such as wire, a separate piece of plastic, or a reinforced piece of cardboard as the invention is not limited in this respect. Both the non-circular shape and the lip may be used individually or in combination to resist compression forces that the payout tube205may be subjected to, particularly when placed into the opening of a coil.

Disposed on the body of the payout tube205and adjacent to the flange702are a plurality of recesses206that are adapted to receive protrusions (FIG. 6,601) in a panel forming wall402of the box400. The engagement between the recesses206and protrusions601retains the payout tube flange702against the panel forming wall402of the box400. This configuration allows the payout tube205to be held, in the embodiments ofFIGS. 4–6, by an end wall comprising only a single ply of cardboard. It also allows the payout tube205to be held without additional, reinforcing sheets of cardboard or similar materials. The flange702also helps prevent the payout tube205from being pressed further into the box400. Collectively, the flange702and the interaction between the protrusions601and the recesses206retain the payout tube in its position. While the illustrated embodiment shows four recesses206and four protrusions601, other embodiments of the invention may comprise a different number of protrusions and recesses.

As shown inFIG. 9, still other embodiments may have protrusions901on the body701of the payout tube205at a position inward from the flange702. These protrusions901on the payout tube205may interact with recesses in the large opening or slot (FIG. 2,201; orFIG. 11,1101), or simply with the aperture itself. Still other embodiments may accomplish the same effect with a different form of protrusions. For instance, as shown inFIG. 10, the payout tube may be held in the large opening or slot (FIG. 2,201; orFIG. 11,1101) by the interference of a recessed groove1001on an outer surface of the payout tube205near the flange702. Such a groove1001may accept the edges of the opening or slot and hold it rigidly in place. In this case, the large opening or slot405may have an end of a similar shape as the groove1001or may alternatively have a different shape such as a rectangular shape that will naturally have interference points with a circular groove. For example, as shown inFIG. 11, the slot1101may have a keyhole shape for retaining the payout tube205.

An adhesive sheet406, as shown inFIG. 4, may be applied to the end wall402of the box400over the surface surrounding the aperture405to further insure that the payout tube205is held in place, prevent foreign debris from entering the payout tube and/or, help retain an outer end (FIG. 5,504) of the cable502inside of the box when it is not being dispensed. The adhesive sheet406shown inFIG. 4is made of a clear plastic sheet, although other translucent or opaque sheets may be used. Such sheets may be made of any suitable material and may also be held to the box400by means other than adhesives, such as staples as the invention is not limited in this manner. Slits407may be placed in the adhesive sheet at a point over the aperture405in the end of the box as shown in the figures. Such slits allow a user to easily access inside the payout tube205when cable502is ready to be dispensed.

FIGS. 6 and 7show among other things, a cable lock602disposed inside of the payout tube body701. The cable lock602comprises a hole in the wall of the payout tube that is sized to hold the cable, wire, or other filamentary product. Adjacent to the hole are several slits603extending radially from the center of the hole. These slits603create compliant sections that serve to grasp a cable502that is larger in diameter than the hole itself. In addition to helping grasp the cable502, the compliant sections allow a wider range of cable diameters to be held in a given size cable lock602.

The following describe steps that may be taken to assemble the box and coil shown inFIG. 4. The box400can be formed from a sheet of cardboard or other suitable material by any suitable method, such as die cutting followed by folding by a progressive die folding machine, manually, or otherwise. An openable face401is either left in an open position or opened when the coil is ready to be inserted. The coil of cable501is wound on a cable winding machine in a figure-eight configuration. An opening503in a wide side505of the coil of cable is retained during the winding process by directing loops of cable in two diverging planes408and409. The coil is then placed inside of the box400through the openable face401. A payout tube205is inserted through the aperture405in the end402of the box400and then through the opening503in the coil. The protrusions601in the aperture are locked into the recesses206of the payout tube205, thereby holding the payout tube in place. The outer end504of the cable is then placed through the payout tube205in a position that may be reached by the user, such a position may include the cable lock602. The openable flaps401are then closed and locked into the closed position with locking tabs403or other suitable features. An adhesive sheet may be placed over the end402of the box. Slits may then be cut in the adhesive sheet at a point over the aperture, or alternatively such slits may be cut in the adhesive sheet406before it is applied to the box400.

While the invention has been illustrated and explained by descriptions of specific embodiments and examples of aspects thereof, many alternatives, modifications and variations will now be apparent to those skilled in the art. Accordingly, embodiments of the invention as set forth herein are intended to be illustrative, not limiting.