Abstract:
Disclosed are disposable reels and assemblies for holding a cable, thereby aiding the craft in routing cables such as fiber optic drop cables. The reel has a first flange having at least one first tab and at least one first tab slot and a second flange having at least one second tab and at least one second tab slot. First flange is attached to the second flange to form the disposable reel by at least one first tab engaging at least one second tab slot and at least one second tab engaging the at least one first tab slot, thereby forming a hub for the disposable reel that has an accessible space therein. Additionally, fiber optic cable assemblies can further include a connector on one or more ends.

Description:
RELATED APPLICATIONS 
     The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/004,453 filed Nov. 27, 2007 titled “Drumless Cable Reel,” which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to reels for fiber optic cables and assemblies. More specifically, the present invention relates to a small form factor reel that is easy to assemble and use for providing the craft with a packaged solution for fiber optic cable and/or assemblies. 
     TECHNICAL BACKGROUND 
     Fiber optic cables are being routed deeper into communication networks for increasing the bandwidth available to the subscriber. For instance, fiber optic cables are being routed to the premises of subscribers for fiber to the home (FTTH) applications. Currently, fiber optic drop cables are wound on relatively large drums during manufacturing and the like, then removed therefrom as a relatively large coil such as a 16″ coil, which is a limitation of the equipment rather than a coil limitation of the fiber optic cable.  FIG. 13  depicts the relatively large 16″ coil used currently for shipping fiber optic cables and/or assemblies with a connector such as hardened connector and the smaller diameter that the fiber optic cable and assemblies can form. 
     Consequently, the fiber optic drop cables are currently being supplied to customers without reels in relatively large loose coils that range in length from about 15 feet to about 2500 feet for FTTH applications. The large loose coils can be difficult to manage in the field and/or factory. For instance, pulling length from the loose coil imparts a twist in the cable. The cost of providing a conventional reel having a solid drum for each these loose coils adds considerable expense for manufacturing the fiber optic cable and/or assembly. Moreover, the craft would have to either dispose or return the conventional reels, which would take up considerable space in vehicles. Due to the increasing volume of fiber drop cables produced annually and the explosive growth of FTTH, a low cost, easily deployable package for fiber optic drop cables is desirable. 
     SUMMARY 
     Disclosed are disposable reels and assemblies for holding a cable, thereby aiding the craft in routing cables such as fiber optic drop cables. The reel has a first flange having at least one first tab and at least one first tab slot and a second flange having at least one second tab and at least one second tab slot. Before assembly, the respective tabs on the first flange and second flange are disposed generally in same respective planes of the first flange and the second flange. To assemble the reel, the respective tabs of the flanges are pushed outward (i.e., folded out) from the respective planes of the first flange and second flange. Thereafter, the first flange is attached to the second flange to form the disposable reel by at least one first tab engaging at least on second tab slot and at least one second tab engaging the at least one first tab slot, thereby forming a hub for the disposable reel that has an accessible space therein. Additionally, fiber optic cable assemblies can further include a connector such as a hardened connector or a non-hardened connector on one or more ends. 
     It is to be understood that both the foregoing general description and the following detailed description present embodiments of the invention, and are intended to provide an overview of framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principals and operation of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  shows a plan view of exemplary flanges for constructing a reel according to the present invention. 
         FIG. 2  shows a side view of one of the flanges of  FIG. 1  having its tabs pushed out prior to assembly according to the present invention. 
         FIG. 3  is an enlarged plan view of the tab of one flange of  FIG. 1  showing the cutout shape for the same. 
         FIG. 4  is a plan view showing the exemplary flanges of  FIG. 1  assembled together for making a reel according to the present invention. 
         FIGS. 5 and 6  are side views of the assembled reel of the  FIG. 1  from different angles. 
         FIGS. 7-10  are various views of the assembled reel of the  FIG. 1  having a fiber optic cable or fiber optic assembly disposed thereon. 
         FIGS. 11-12  are various views of the fiber optic cable on an assembled reel with a cable tie for securing the fiber optic cable. 
         FIG. 13  shows a plan view of fiber optic cable assemblies wound in large diameter as shipped currently and the smaller diameter that the fiber optic cable assembly can form. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, like reference numbers will be used to refer to like components or parts.  FIG. 1  depicts a plan view for a set of exemplary flanges  10  for constructing a reel  100  (i.e., a first flange and a second flange assembled together) according to the present invention. As shown, flanges  10  are similar in shape and size such as round, but other shapes or sizes are possible. As shown, flanges  10  are identical (but could be similar or dissimilar) circular flanges stamped from corrugated plastic, cardboard, solid plastic, corrugated paper, or other suitable material for making reel  100 . Each flange  10  has a plurality of tabs  12  such as two tabs punched into flange  10  and a plurality of tab slots  14  (i.e., knockouts) that are matched to the spacing on the tabs (e.g., about 180 degrees for two, about 120 degrees for three, etc.). By way of example, exemplary flanges  10  have tab slots oriented 90 degrees from tabs  12  and on approximately the same arc (i.e., about the same distance from the center). In other words, tabs  12  are about 180 degrees apart and tab slots  14  are about 180 degrees apart with a radial spacing so that tabs  12  and tab slots  14  engage to assemble reel  100  after tabs are folded back. 
     For assembly, flanges  10  are pushed out as shown in  FIG. 2  and then folded to a protruding position and a first flange is rotated 90 degrees to align and engage corresponding tab slots  14  on second flange and vice versa. In other words, before assembly the respective tabs on the first flange and second flange are disposed generally in same respective planes of the first flange and the second flange. To assemble the reel, the respective tabs of the flanges are pushed outward (i.e., folded out) from the respective planes of the first flange and second flange. Thereafter, the two flanges  10  are pushed together, thereby forming reel  100  as shown in  FIG. 4 . When the reel  100  is assembled, cable, wire, or the like can wound thereon. If desired, one could also place a coil of cable on one flange and then could attach the other flange, to form the reel. Reel  100  can also be easily collapsed after usage for re-use or disposal. Reel  100  is relatively inexpensive to manufacture and assembly compared with conventional reels for fiber optic cables. 
       FIG. 3  illustrates an exemplary end-shape  12   a  for creating a locking effect when engaging tabs  12  with tab slots  14 . End-shape  12   a  (e.g., width and notches) of tabs  12  allows them to be inserted and secured into the slots. As shown, end shapes  12   a  of tabs  12  have a slight leading edge taper, which could be larger or non-existent. Other shapes are also possible for tabs  12  and/or end-shapes  12   a  such as shown by  FIG. 4 . A folding location (not numbered) along with a length for tabs  12  respectively influence a hub diameter and a reel width for reel  100 . More specifically, the position of the folding location (i.e., the start point of tab  12 ) influences the minimum diameter of the hub portion (i.e., the hub created by tabs  12 ). Smaller diameters for the hub portion can accommodate longer lengths of fiber optic cable, but the diameter of the hub portion should not be smaller than a bend limitation for the intended cable. Likewise, the length of tab  12  influences a width for reel  100  since it determines the spacing between flanges  10  and is one factor influencing the length of fiber optic cable that will fit on reel  100 . For example, a reel having a wider width can accommodate longer lengths of fiber optic cable. 
     Furthermore tabs  12  and tab slots  14  should be orientated onto the material of flanges  10  to provide suitable strength for reel  100 . By way of example, if flanges  10  are made from a corrugated plastic or cardboard, the alignment of tabs and tab slots  14  could be orientated parallel, perpendicular, or other variation to the corrugations depending on the impact to the integrity and strength of flange  10  for the given material, ease of assembly, and the like. In other variations, tabs  12  can protrude through the tab slot  14  of the opposing flange and have the end inserted back into a second slot closer to the center of the opposing flange. This “double insertion” tab may provide improved attachment between the flanges, but it increases the complexity of the flanges and assembly for the reel. 
     Assembled reel  100  is lightweight yet strong even though it does not include a solid drum like conventional reels. Instead, the fiber optic cable is wound onto the four tabs  14  of the two cooperating flanges  10  that form reel  100  as shown in  FIGS. 7 and 8 . The use of a plurality of tabs  14  advantageously creates an accessible space within the hub of reel  100  for storing and protecting connectors such as hardened connectors or the like on the ends of the cable ( FIG. 10 ) and the like. In other words, the accessible space within the hub allows the preconnectorized first end of the fiber optic cable to be routed into the center of the reel with ease. This protects the connector while on the reel, facilitates spooling, and provides easy access to both ends of the cable for testing. 
     Using an open hub to create an access space instead of a solid drum enables another advantage of the invention. Specifically, the open hub/removable flange allow the factory or craft to easily secure a cable tie  80  to the fiber optic cable for securing it in a coil. Additional openings could also be die-cut into flange(s)  10  to allow for the insertion of cable ties into the flange and around the cable as shown in  FIGS. 11 and 12 . This feature allows the factory or craft to install cable ties around the remaining cable on the reel prior to disassembly of the flanges. This will decrease time required by the installer for slack management. 
     Simply stated, reel  100  can be advantageously assembled using two similar pieces cut from the same die to form reel  100  (instead of three or more pieces) which is economical and makes it easy to assemble or disassemble. However, the concepts of the invention can also include other variations that are not identical or similar. By way of example, all of the tabs could be located on the first flange and all the tab slots could be located on the second flange. 
     Additionally, the two piece design enables a coil of the fiber optic cable to be placed onto one flange of the reel before or after assembly of the reel, thereby increasing productivity and flexibility in manufacturing. Likewise, the fiber optic cable can be loaded (i.e., coiled) onto the reel  100  before loading onto automation equipment for preconnectorization or the like. By way of example, reel  100  has a plurality of windows  18  exposed on each flange  10  that are created after tab  12  is folded inward. Windows  18  give access for allowing components of manufacturing equipment to engage/grab/support the inside surface of tabs  12  on one or both flanges  10  such as during cable coiling. Simply stated, coiling equipment can engage and support tabs  12  through windows  18  to inhibit crushing forces on the hub from back-tension, while also providing a rotation force to reel  100 . Simply stated, the fiber optic cable tension applied to reel  100  when coiling fiber optic cable can create significant crushing forces that could deform or crush a reel if tabs were not supported during coiling. By way of example, two opposing coiling heads having a suitably sized U-shape driving mechanism can engage reel  100  from each flange  10  and support tabs  14  while turning the reel for coiling the cable thereon. Once the fiber optic cable is loaded onto reel  100 , the back-tension is removed and any pressure is equalized so that the coiling heads may disengage and retract from reel  100  with no issues. Likewise, windows  18  provide grabbing locations for other manufacturing operations. For instance, windows  18  also allow for easy reel placement of the reel and cable onto an automation line. Because windows  18  create a distinct punched out pattern, an automation tray could integrate a similar u-shaped device for allowing an accurate, easy and quick swap out of loaded cable reels either pre- or post-termination onto automation cells. Additionally, flanges  10  of reel  100  may also include an arbor hole (not shown) disposed near the center for winding and/or unwinding the fiber optic cable in the field. 
     Further, reel  100  advantageously provides a quick and easy disassembly with the fiber optic cable and/or assembly thereon for speedy slack storage of the excess length when installing the same. More specifically, one or more tabs may be removed or one of the flanges that form the drum can easily be pulled off to expose the fiber optic cable coil while maintaining the integrity of the coil. Moreover, cable ties can be secured to the fiber optic cable intended for slack storage. This allows the craft technician to remove the coil from the reel and insert the coil directly on or into the slack storage device without the needing to recoil the fiber optic cable. This results in a significant time savings for the craft by eliminating the need to wind the cable for slack storage. 
     As best shown in  FIGS. 7 and 9 , flanges  10  can include backlash tabs  13  that are punched out near the perimeter of flanges  10  to act as a deterrent for inhibiting cable from spooling off the reel due to the nature of the cable to uncoil itself. As shown by  FIGS. 8 and 9 , each flange  10  has one or more backlash tabs  13  that end up being at about the same location when the reel is assembled. Consequently, the potential energy stored in the cable coil is inhibited from unspooling cable on the reel. Additionally, as shown one or more ends of the fiber optic cable may protrude out of one of the backlash tabs  13  to make an end easy to locate, but the cable end may protrude from other portions of the reel. 
     Reels of the invention also offers an integrated stack lock feature by permitting multiple reels to be stacked one on top of the other. This is achieved by the tab and slot design configuration. Because the tabs and slots are 90 degrees opposed and aligned, when multiple assembled reels are stacked upon one another, the tab which protrudes past the slot will protrude into the tab cutout of the reel just above or below the reel. This integrated feature allows multiple reels to be stacked with ease and strengthens a bulk package of assembled reels. This feature eases the ability to pack and ship multiple reels using a larger box, crate, wrap, or the like. 
     Reels may also include features for identifying the cable/connector thereon. For instance, flange  10  could include identifying features such as printing, marking and/or a decal suitable for marking so the factory could indicate the length of cable and/or the type of connector on the end of the cable. Likewise, a pull-out tab, knockout or the like could be a portion of one of the flanges, which is useful for identification of the cable/connector on the reel, thereby eliminating the need for markers or pens to identify the cable length or connector type. 
     Many modifications and other embodiments of the present invention, within the scope of the claims will be apparent to those skilled in the art. Although the invention was described with respect to fiber optic cables, the concepts can be applied to other types of cable such as copper communication cables, copper data cables, wires, electrical cables, etc. Thus, it is intended that this invention covers these modifications and embodiments as well those also apparent to those skilled in the art.