Patent Publication Number: US-2022219847-A1

Title: Cable wrapping system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 17/491,772 filed on Oct. 1, 2021, which claims the benefit of U.S. Provisional Application Ser. No. 63/136,548, filed Jan. 12, 2021, both of which are incorporated herein by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to machines that bundle cables. More particularly, the present disclosure relates to a non-powered apparatus for bundling cables together. 
     BACKGROUND 
     Cables are often bundled when placed in trenches for underground placement. To ensure the cables remain grouped, they are bound together at regular intervals. For example, it is common to place a zip-tie or other tying device every three feet. Because the zip-tie is secured by hand, the process is tedious, time-consuming, and can lead to soreness and injury as a result of the constant bending to tie the cables together. Because tying is done by hand, the intervals may not be accurate and the cables may tend to bunch or loosen in unbound sections. Additionally, because of the time involved in hand tying the cables, the overall time to complete the project is lengthened, making it more expensive (e.g., increased labor). 
     As a result, there is a need for an apparatus that can efficiently wrap cables for in-ground placement, thereby more accurately securing the cables, reducing labor, and mitigating back injuries. Accordingly, the present disclosure seeks to solve these and other problems. 
     SUMMARY OF EXAMPLE EMBODIMENTS 
     In some embodiments, a cable wrapper comprises a carriage coupled to a main frame with a plurality of twine compartments coupled to the carriage, each twine compartment comprising a roll of twine. The twine of each twine compartment is fed into the carriage. A plurality of cables are pulled through the carriage and the twine of each twine compartment is secured to the cables. As the cable is then pulled through the carriage, the twine is pulled and, via one or more pulleys causes the carriage to rotate. As the carriage rotates, the twine from each twine compartment wraps the cables, ensuring they are secured together their entire length. 
     In some embodiments, a first twine compartment is coupled to the carriage proximate a first twine tensioner, a first guide first roller, a first v-belt pulley, and a first guide second roller. A first twine is threaded through the first twine tensioner, the first guide first roller, the first v-belt pulley, and the first guide second roller. A second twine compartment is coupled to the carriage proximate a second twine tensioner, a second guide first roller, a second v-belt pulley, and a second guide second roller. A second twine is threaded through the second twine tensioner, the second guide first roller, the second v-belt pulley, and the second guide second roller. A third twine compartment is coupled to the carriage proximate a third twine tensioner, a third guide first roller, a third v-belt pulley, and a third guide second roller. A third twine is threaded through the third twine tensioner, the third guide first roller, the third v-belt pulley, and the third guide second roller. The twine from the first twine compartment, second twine compartment, and third twine compartment passes through and exits the carriage at a second, back end, where each is coupled to a plurality of cables passing through the carriage from a first, front end to the second, back end. As the cable is pulled through the carriage, such as by pulling the main frame forward using a truck, the first twine, the second twine, and the third twine to wrap around the cables as the cables exit the carriage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a top, right front perspective view of a cable wrapper; 
         FIG. 2  illustrates a front elevation view of a cable wrapper; 
         FIG. 3  illustrates a top plan of a cable wrapper; 
         FIG. 4  illustrates a right side elevation view of a cable wrapper; 
         FIG. 5  illustrates a bottom plan view of a cable wrapper; 
         FIG. 6  illustrates a rear elevation view of a cable wrapper; 
         FIG. 7  illustrates a right, front detailed perspective view of a pulley system of a cable wrapper; 
         FIG. 8  illustrates a right, rear detailed perspective view of a pulley system of a cable wrapper; 
         FIG. 9  illustrates a left, front detailed perspective view of a pulley system of a cable wrapper; 
         FIG. 10  illustrates a left side elevational, longitudinal cross-section view of a cable wrapper; 
         FIG. 11  illustrates a left side perspective longitudinal cross-section of a cable wrapper; 
         FIG. 12  illustrates a detailed front left side of a cable wrapper; 
         FIG. 13  illustrates a rear left side perspective view of a cable wrapper; 
         FIG. 14  illustrates a rear elevation view of a cable wrapper; 
         FIG. 15  illustrates wrapped cable as exiting the cable wrapper; 
         FIG. 16  illustrates a detailed front view of a cable wrapper; 
         FIG. 17  illustrates a front, top right perspective view of a cable wrapper; and 
         FIG. 18  illustrates a detailed view of a pulley system of a cable wrapper. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The following descriptions depict only example embodiments and are not to be considered limiting in scope. Any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an embodiment,” do not necessarily refer to the same embodiment, although they may. 
     Reference to the drawings is done throughout the disclosure using various numbers. The numbers used are for the convenience of the drafter only and the absence of numbers in an apparent sequence should not be considered limiting and does not imply that additional parts of that particular embodiment exist. Numbering patterns from one embodiment to the other need not imply that each embodiment has similar parts, although it may. 
     Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad, ordinary, and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list. For exemplary methods or processes, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. 
     It should be understood that the steps of any such processes or methods are not limited to being carried out in any particular sequence, arrangement, or with any particular graphics or interface. Indeed, the steps of the disclosed processes or methods generally may be carried out in various sequences and arrangements while still falling within the scope of the present invention. 
     The term “coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other. 
     The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including, but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes, but is not limited to,” etc.). 
     As previously discussed, there is a need for an apparatus that can efficiently wrap cables for in-ground placement, thereby more accurately securing the cables, reducing labor, and mitigating back injuries. The cable wrapper disclosed herein solves these and other problems. 
     In some embodiments, as shown in  FIGS. 1-6 , a cable wrapper  100  comprises a carriage  102  coupled to a main frame  104  with a plurality of twine compartments  106 A-C coupled to the carriage  102 , each twine compartment  106 A-C comprising a roll of twine  108 A-C. The twine  108 A-C of each twine compartment  106 A-C is fed into the carriage  102 . A plurality of cables  110 A-D (as best seen in  FIGS. 12-15 ) are pulled through the carriage  102  and the twine  108 A-C of each twine compartment  106 A-C is secured to a first end of the cables  110 A-D. As the cables  110 A-D are then pulled through the carriage  102 , the twine  108 A-C is pulled and, via one or more pulley systems  112 A-C causes the carriage  102  to rotate. As the carriage  102  rotates, the twine  108 A-C from each twine compartment  106 A-C wraps the cables  110 A-D, ensuring they are secured together their entire length. 
     In some embodiments, as shown in  FIG. 7 , a first twine compartment  106 A is coupled to the carriage  102  and is coupled to a first pulley system  112 A. The first pulley system  112 A comprises a first twine tensioner  114 , a first guide first roller  116 , a first v-belt pulley  118 , and a first guide second roller  120 . The first roll of twine  108 A is fed out a front end  122  of the twine compartment  106 A, around the first twine tensioner  114 , around the first guide first roller  116 , around the first v-belt pulley  118 , returned around the first guide first roller  116 , and into the carriage  102  around the first guide second roller  120 . From there, the first roll of twine  108 A may be secured (e.g., tied, taped, interlaced, etc.) to the cables to be wrapped. As the cables  110 A-D (best seen in  FIGS. 12-15 ) are pulled through the carriage  102  with each roll of twine secured thereto as described above, the carriage  102  rotates, wrapping the cables  110 A-D with the twine  108 A-D. For example, the first pulley system  112 A drives a first wheel  124  via a first drive draft  126  coupled to the first v-belt pulley  118 . As twine is pulled through the first pulley system  112 A, the first wheel  124  rotates on the frame  104  in wheel channel  128 , causing the carriage  102  and the components coupled thereto (e.g., twine compartments  106 A-C, pulley systems  112 A-C) to rotate, thereby encircling (wrapping) the cables  110 A-D as they pass through the carriage  102 . 
     It will be appreciated that each pulley system  112 A-C comprises the components described above with regard to the first pulley system  112 A. As a result, fewer or more pulley systems may be used. For example, in one embodiment, only one twine compartment  106 A and pulley system  112 A is required. In other embodiments, a plurality of twine compartments  106 A-C and pulley systems  112 A-C may be used, which is not limited to three as shown. 
     In a cable wrapper  100  comprising three twine compartments  106 A-C, as best seen in  FIGS. 7-9 , a first twine compartment  106 A is coupled to the carriage  102  proximate a first twine tensioner  114  (which may be spring  115  controlled), a first guide first roller  116 , a first v-belt pulley  118 , and a first guide second roller  120 . A first twine  108 A is threaded through the first twine tensioner  114 , to the first guide first roller  116 , to the first v-belt pulley  118 , returned around the first guide first roller  116 , and to the first guide second roller  120 . As shown in  FIG. 8 , a second twine compartment  106 B is coupled to the carriage  102  proximate a second twine tensioner  130 , a second guide first roller  132 , a second v-belt pulley  134 , and a second guide second roller  136 . A second twine  108 B is threaded through the second twine tensioner  130 , to the second guide first roller  132 , the second v-belt pulley  134 , back around the second guide first roller  132 , and to the second guide second roller  136 . The second pulley system  112 B further comprises a second wheel  138  and drive shaft  140  coupled to the second v-belt pulley  134 . As shown in  FIG. 9 , a third twine compartment  106  C is coupled to the carriage  102  proximate a third twine tensioner  142 , a third guide first roller  144 , a third v-belt pulley  146 , and a third guide second roller  148 . A third twine  108 C is threaded through the third twine tensioner  142 , to the third guide first roller  144 , the third v-belt pulley  146 , back around the third guide second roller  148 , and to the third guide second roller  148 . It will be appreciated that, in some embodiments, each first roller  116 ,  132 ,  146  may have two channels to prevent the twine going in opposite directions thereon from tangling and binding. For example,  FIG. 18  illustrates a first roller  216  having two channels  250 A,  250 B separated by a divider  251 . 
       FIGS. 10-11  illustrate a longitudinal cross-section of the cable wrapper  100 .  FIG. 12  illustrates a plurality of cables  112 A-D entering the cable wrapper  100  at first, front end  152 . The cables are fed through an incoming cable indexer  154 . As shown throughout the FIGS., the indexer  154  may comprise one or more vertical rollers  156 A-D so as to maintain the cable  110 A-D orientation as they proceed to the carriage  102 . A second, funneling frame  158  funnels the cables  110 A-D into the carriage  102  in close proximity to one another so that they can be tightly wound. As shown in  FIGS. 13-15 , as the wrapped cables  110 A-D exit the cable wrapper  100  through outgoing roller  160 , which may comprise vertical rollers  162 ,  164 . The wrapped cables  110 A-D are then able to freely rest on the ground where desired. When the rolls of twine  108 A-C are depleted, a user may open the twine compartments  106 A-C via a rear access panel  166 A-C, which may be hinged. A new roll of twine may be placed in each for continued use. As shown in  FIG. 17 , the cable wrapper  100  may further comprise a safety cage  168 . It will be appreciated that the safety cage  168  prohibits items and users from coming into contact with the rotating components of the cable wrapper  100 . The safety cage  168  may be coupled to a safety frame  169  that is coupled to the main frame  104 . 
     Referring back to  FIG. 16 , a stationary roller race  172  comprises a vertical portion  174  and a horizontal portion  176 . The carriage  102  comprises a plurality of first bearings  178 A-B engaging the horizontal portion  176  and a plurality of second bearings  180 A-B engaging the vertical portion  174 . The plurality of first and second bearings  178 ,  180  ensure that the carriage  102  rotates smoothly and does not experience unexpected motion. In other words, with the wheels  124 ,  138  engaged in the wheel channel  128  and the first bearings  178  and second bearings  180  engaging the horizontal portion  176  and vertical portion  174 , respectively, the carriage  102  rotates smoothly and does not experience unexpected motion. 
     The cables  110 A-D described herein may be medium voltage cables or of any type desired to be bundled by a user. Additionally, as low as two cables  110 A-B may be wrapped and may include more, including more than the four described above herein. For example, the incoming cable indexer  154  may further comprise a horizontal roller  170 , allowing for six or more cables to pass therethrough. In some instances, the weight of the bundled cables  110 A-D is sufficient such that as a truck pulls the cable wrapper  100  forward (such as on a trailer), the twine  108 A-C and pulley systems  112 A-C are actuated—no external force or power is needed, which is an incredible improvement over the prior art. If the cables are not of sufficient weight, they may be tethered such that they remain in position as the truck pulls the cable wrapper  100  forward. Again, no motors or other power, is needed to separately actuate the cable wrapper  100 . As appreciated, the cable wrapper  100  may even be mounted to the same trailer that carries the spools of cables  110 A-D for wrapping. 
     Accordingly, the cable wrapper solves the problems in the art, namely, the need for an apparatus that can efficiently wrap cables for in-ground placement, thereby more accurately securing the cables, reducing labor, and mitigating back injuries. Further, due to the speed with which the cables  110 A-D may be placed, the overall construction is completed faster, allowing for greater profitability by the contractor and for quicker commercialization by the owner. 
     It will be appreciated that systems and methods according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment unless so stated. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure. 
     Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein. 
     Exemplary embodiments are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages herein. Accordingly, all such modifications are intended to be included within the scope of this invention.