Patent Publication Number: US-2009223025-A1

Title: Support chord protector

Description:
BACKGROUND 
     1. Field 
     The preferred embodiments of the present invention relate to supporting objects and, preferably, to supporting objects having corners or bents via a support chord (e.g., a wire, rope, cable, chain, tether, strap, belt or the like). 
     2. Background Discussion 
     In lifting and supporting various objects via a chord or strap (such as, e.g., a wire, a rope, a cable, a tether, a chain, a strap, a belt or the like [collectively, broadly referred to herein as encompassed within the term “support chord”]) containing corners or bends, there has existed the problem of putting additional stress on the corners of the object while supporting it. Putting additional stress on corners or bent portions can cause several problems. The corners of the object to be supported are more likely to deform because of the greater pressure placed upon them. Furthermore, the support chord used to support said object could also receive additional stress. For example, the corner of the supported object can, essentially, dig into the support chord, increasing the risk that the chord could suffer damage. 
     Previously, corner protectors have been employed in limited circumstances that would surround a corner of the object, thereby alleviating the stress placed upon the corner and/or the support chord. However, the existing corner protectors have had substantial limitations and deficiencies. Among other things, such existing corner protectors were unwieldy and difficult to install. 
     There has been a need to provide a system and/or method to overcome the above and/or other problems in the background art. 
     SUMMARY 
     The present invention overcomes the above and/or other problems in the background art. 
     The preferred embodiments pertain to a device for protecting or isolating an object and/or a supporting chord that is used to retain or support the object. The device can include, e.g., an extruded plastic member having a flexible base portion that extends around an object and a channel portion that fixedly receives the support chord (e.g., via a snap-fit engagement). In some preferred embodiments, the channel portion is substantial rigid and the base portion is more flexible. In some preferred embodiments, the channel portion includes slits to separate it into a plurality of segments so as to facilitate bending of the device. 
     According to the preferred embodiments, a support chord protector assembly includes: a generally flat and flexible base portion configured to bend around a corner of an object to be supported, a chord holder extending along the base portion and having a higher rigidity than the base portion to retain a support chord, and the chord holder having a channel portion with an opening in the channel portion configured to receive the support chord. 
     According to some examples, the base is made from a flexible PVC material and the chord holder is made from a generally rigid PVC material. In some examples, the chord holder has slits extending generally perpendicular to a length of the support chord protector so as to facilitate bending around a corner of an object. In some other examples, the assembly further includes a support chord and the chord holder being configured to fixedly receive the support chord. In some examples, the chord holder is configured to fixedly retain a support chord. In some examples, the assembly further includes a support chord and the chord holder being configured to fixedly snap-fit to the support chord. 
     According to some other embodiments, a method of using at least one support chord protector includes: providing at least one protective strip having a flexible base portion and a engagement channel portion along the base; aligning the engagement channel portion with a support chord such that the support chord extends generally parallel to the engagement channel portion; laterally moving the support chord into the engagement channel portion such that the engagement channel portion fixedly retains the support chord; and supporting an object via the support chord with the protective strip situated between the object and the support chord. In some examples, the method further includes having the protective strip distribute a load to or from the object. In some examples, the method further includes having the protective strip isolate vibration, heat or electric flow to or from the object. In some examples the method further includes that the step of providing at least one protective strip having a flexible base portion and an engagement channel portion includes providing the flexible base portion with a more flexible material than the engagement channel portion. In some examples, the method further includes providing the at least one protective strip by extruding elastomeric material. In some examples, the method further includes providing the at least one protective strip by co-extrusion a more flexible base portion and a more rigid channel portion. 
     According to some other embodiments, a method of making an elastomeric support chord protector having a base portion and a chord holder portion includes: co-extruding a unitary elastomeric support chord strip having a generally flat base portion and a chord holder portion extending along the base portion, with the base portion having a higher flexibility than the chord holder portion. In some examples, the method further includes cutting the unitary elastomeric support chord strip into individual support chord protectors. In some examples, the method further includes cutting slits into the chord holder portion with the slits being generally perpendicular to an extrusion direction of the support chord protector. In some examples, the method further includes forming the chord holder portion with a channel that is configured to fixedly receive a support chord therein. 
     The above and/or other aspects, features and/or advantages of various embodiments will be further appreciated in view of the following description in conjunction with the accompanying figures. Various embodiments can include and/or exclude different aspects, features and/or advantages where applicable. In addition, various embodiments can combine one or more aspect or feature of other embodiments where applicable. The descriptions of aspects, features and/or advantages of particular embodiments should not be construed as limiting other embodiments or the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         FIG. 1  is a perspective view of a support chord protector according to a first embodiment of the invention; 
         FIG. 2  is an end view of the support chord protector shown in  FIG. 1  according to some embodiments; 
         FIG. 3  is an end view of a support chord protector shown in  FIG. 2  with a support chord inside of a support chord holder; 
         FIG. 4  shows a support chord and a plurality of support chord protectors used to retain a ventilation duct to a ceiling according to an illustrative implementation according to some preferred embodiments; 
         FIG. 5  is a perspective view of a support chord protector with a plurality of slits formed along a length thereof according to some illustrative embodiments; 
         FIG. 6  is a side view of the support chord protector shown in  FIG. 5  bent around the corner of an object, along with a support chord extending through the support chord protector; 
         FIG. 7(A)  is a perspective view of another embodiment of a support chord protector and a corresponding support chord; 
         FIG. 7(B)  is a perspective view of yet another embodiment of a support chord protector and a corresponding support chord; 
         FIG. 8  is an end view of another embodiment of a support chord protector; 
         FIG. 9  is a perspective view showing an illustrative method of extruding a support chord protector according to some embodiments; 
         FIGS. 10(A)-10(D)  show illustrative applications for a support chord protector according to the preferred embodiments, in which  FIG. 10(A)  shows application to a flat bad truck (e.g., supporting items, such as, e.g., lumber, bricks, boxes, pipes, etc.),  FIG. 10(B)  shows application to supporting items retained on pallets,  FIG. 10(C)  shows application to supporting freight and/or packaging (such as, e.g., crates, packing containers, boxes, etc.),  FIG. 10(D)  shows application to supporting a boat hull, and  FIG. 10(E)  shows application to supporting piping (such as, e.g., metal or plastic plumping and/or other pipes). 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein. 
     The preferred embodiments provide a support chord protector that can be used to facilitate supporting of a variety of objects such as, e.g., a) construction items, such as, e.g., ventilation ducts, pipes, beams and other construction items, b) packaging items, such as, e.g., pallets, crates, freight cargo boxes and other packaging items, c) support items, such as, e.g., boat hulls and other large support items, d) etc. 
     Among other things, a support chord protector can provide one or more of the following advantages: 1) protection of a supported item; 2) vibration isolating; 3) heat isolation; and/or 4) protection of the support chord supporting an item. 
     Referring now to  FIG. 1 , the figure shows a perspective view of a support chord protector  1 , in which a chord holder  2  is connected to base portion  3 . In some embodiments, the chord holder  2  has confronting inner sidewalls  8 . These inner sidewalls  8  have a curvilinear inner surface and define a hollow portion or channel  9 . The diameter d 1  of hollow portion  9  is preferably approximately the same size as the diameter of support chord  10 . Thus, when support chord  10  is placed inside of chord holder  2 , a snug fit is attained. 
     Chord holder  2  also includes lips  5  which are located at the top of chord holder  2  and have two confronting surfaces that are separated a distance d 2 . The distance d 2  is preferably smaller than the diameter of the support chord  10  so as to enable the support chord holder to fixedly retain the support chord  10 . Chord holder  2  is preferably made out of plastic or other suitable material, such that it may flex outward to receive the support chord and then to resiliently return inward upon receipt so as to retain the support chord  10  and to then flex outward to allow the support chord to be removed from hollow portion  9 . 
     In some preferred embodiments, the base portion  3  can be made out of a softer and more pliable material than chord holder  2 . For example, it is preferably in such instances more pliant and bendable (e.g., having a lower hardness). This is because base portion  3  is preferably able to bend around corners, while the chord holder  2  is preferably able to retain the support chord  10 . 
     In some embodiments, this dual material construction can be formed by co-extrusion in which the base portion  3  is formed of a first, more pliable material, and the chord holder  2  is formed of a second, more rigid, material, which materials are co-extruded together to form a unitary and integral piece. In some embodiments, the base portion  3  can bend around corners are an angle of up to about 150°. In some embodiments, base portion  3  can bend around corners up to about 120°. In some embodiments, base portion  3  can bend around corners up to about 90°. In some embodiments, base portion  3  can bend around corners up to about 60°. In some embodiments, base portion  3  can bend around corners up to about 30°. In many instances, the base portion  3  will bend around about a 90° corner, such as, e.g., around a ventilation duct, or other rectangular object. 
     As indicated above, it is preferable that chord holder  2  is made from a harder and less pliable material than base portion  3 . This is because chord holder  2  is preferably hard enough to receive support chord  10  without easily letting support chord  10  become disengaged from chord holder  2 . In some embodiments, the chord holder  2  should preferably allow support chord  10  to snap into place inside hollow portion  9  of chord holder  2  (i.e., providing a snap-fit connection). For example, in some illustrative non-limiting examples, the chord holder  2  can be between about  30  and  95  on a Shore hardness scale and the base portion  3  can be between 20 and 90 on a Shore hardness scale. 
     Among other things, the provision of a secure engagement between the chord holder  2  and the support chord  10  has a number of advantages. For example, this helps a user to secure the support chord protector  1  upon a support chord  10  and then to manipulate the combination of the support chord protector  1  and the support chord  10  with respect to the object to be retained, such as, e.g., a ventilation duct or other item. In some preferred embodiments, the support chord protector  1  can be slid along the support chord  10  after being secured thereto (such as, e.g., upon the application of a sufficient manual force upon the support chord protector  1  in the direction of the length of the support chord  1  to slide the protector there-along). 
     In some less preferred embodiments, if desired, an adhesive or tacky substance can be used to either help secure the support chord  10  to the support chord protector  1  or to secure the support chord protector  1  to an object (such as, e.g., upon the backside of planar base portion  3 ). For example, an adhesive can allow the support chord protector to maintain a fixed position on the corner of the object to be protected. An adhesive could also be placed inside chord holder  2 , along the surface of inner confronting walls  8 . This could help support chord  10  be stationary while inside chord holder  2 . 
     In some embodiments, a support chord protector  1  can be sized such that the width W of base portion  3  (see, e.g., dimension W shown in  FIG. 1 ) can be between about 1 and 6 inches, while in other embodiments, it can be between about 2 to 5 inches, while in other embodiments, it can be between about 3 to 4 inches. In some embodiments, a length L of the base portion  3  can be between about 2 to 12 inches, while in other embodiments, it can be between about 4 to 10 inches, while in other embodiments, it can be between about 6 to 8 inches. In some embodiments, the diameter d 1  of hollow portion  9  can be between about ⅛ inch to 1 inch, while in other embodiments, it can be between about ¼ inch to ½ inch. 
       FIG. 2  is an end view of the support chord protector  1  shown in  FIG. 1 . In this figure, the same reference characters refer to the same parts as described above.  FIG. 2  also helps to depict what sections of the device are deemed part of the chord holder  2  and the base portion  3  in some embodiments. In this regard, in this illustrative example, the chord holder  2  includes the portions of the device extending above the base  3  in the region A, while the base  3  includes the portions within the region B. As discussed herein-below, in some embodiments the base  3  and the holder  2  can be made with the same material and with the same properties, while in other embodiments the holder  2  and the base  3  can be made with different materials and/or properties (see, e.g., discussion below). 
       FIG. 3  is an end view of support chord protector  1  with support chord  10  positioned inside of the chord holder  2 . As noted above, it is preferable that hollow portion  9  be configured to securely retain the support chord. For example, this can be achieved by having hollow portion  9  sized with a cross-section that is approximately the same size as or slightly less than the support chord  10  so as to ensure a snug fit of support chord  10  inside chord holder  2 . As shown in  FIGS. 2 and 3 , the support chord  10  can be fixedly (in some embodiments, releasably) connected to chord holder  2 . 
       FIG. 4  shows an example of how a support chord protector  1  can be used to support an object having corners. In this illustrative example, a ventilation duct  21  is shown supported by a support chord  10  which can be, e.g., attached to a ceiling, and two support chord protectors  1  are located at corners of the duct, such that each corner of ventilation duct  21  and is protected and supported by a respective support chord protector  1 . 
     Among other things, the support chord protector  1  can help to distribute a load away from the corners of ventilation duct  21 , to the sides of the duct. Among other things, this can prevent damage of the support chord  10  and also can prevent the corners of ventilation duct  21  from bending under its own weight. 
     Furthermore, in the preferred embodiments, the support chord  10  snaps into chord holder  2  of support chord protector  1 . Among other things, the use of a snap-fit engagement can make installing support chord protector  1  much easier. For example, a single person could easily install the support chord protector  1 . During installation, the support chord protector  1  can be, e.g., positioned relative to the support chord  10  and snap-fit in place into chord holder  2  (i.e., such that the length of the support chord  10  is aligned generally parallel to the channel  9  and moved laterally into the channel  9 ). In addition, due to the engagement of the support chord  10  with the support chord protector  1 , their relative positions can be readily maintained while the two items are being manipulated around the duct for easy installment. 
       FIG. 5  shows another embodiment of the invention. In this exemplary embodiment, the chord holder  2  contains lateral slits  31  which allow support chord protector  1  to more easily bend around a corner of an object. As discussed above, in some preferred embodiments, base portion  3  can be made of a more pliable material than chord holder  2 . This combination readily allows for support chord protector  1  to easily bend around corners, while the chord holder  2  fixedly retains the support chord at a plurality of separated segments. 
       FIG. 6  is a side view of support chord protector  1  similar to that shown in  FIG. 5  including slits  31  that separate the chord holder  2  into a plurality of segments. As shown in  FIG. 6 , slits  31  allow chord holder  2  to easily bend around a corner. In  FIG. 6 , the support chord  10  is shown inside chord holder  2  and extending between segments of the chord holder  2 . As seen from the figure, the force of the support chord  10  is distributed by support chord protector  1 . 
       FIG. 7(A)  shows another embodiment of the invention. In this additional embodiment, instead of the hollow portion or channel  9 ′ being in a generally cylindrical shape, it is configured to retain a strap-like support chord. In the example shown in  FIG. 4 , hollow portion  9 ′ of the support chord holder  1 ′ is generally configured to have a rectangular cross-sectional shape which corresponds to the cross-sectional shape of the support chord  10 ′. In addition, overhanging portions  2   a  and  2   b  are provided to facilitate retention of the support chord  10 ′. 
       FIG. 7(B)  is a perspective view of yet another embodiment of a support chord protector and a corresponding support chord. In this example, the support chord protector  1 ″ includes a base portion  3 ″ having a chord holder portion  2 ″ extending downwardly therefrom rather than extending upwardly therefrom. It should be appreciated that the chord holder portion can extend along the base portion in these illustrative ways and in a variety of other ways in various embodiments of the invention. 
       FIG. 8  shows another embodiment of the invention. In this additional example, the chord holder  2 ′″ is connected to base portion  3 ′″ in a manner to have an exposed opening at one side proximate the base portion (i.e., close to the base portion). In this embodiment, the support chord  10  fits into hollow portion or channel  9 ′″, in between a single lip  5 ′″ and base portion  3 ′″. 
     In some embodiments, slits (as described above) can be included in the chord holder  2 ′″ shown in  FIG. 8 . It should be understood based on this disclosure that such slits can be employed in any of the embodiments of the invention. Among other things, the embodiment shown in  FIG. 8  can facilitate engagement of the support chord with the protector  1 ″ because the support chord  10  can be readily slid along the base  3 ′″ into the hollow portion or channel  9 ′″. That is, due to the wider base portion  3 ′″ adjacent the opening to the channel  9 ′″, it can be used to facilitate placement by sliding the chord  10  along the base  3 ′″ into the channel  9 ′″. 
     Various Implementations: 
     As discussed above, the preferred embodiments can be employed in a variety of implementations and for a variety of purposes. By way of example,  FIGS. 10(A)-10(D)  show illustrative applications for a support chord protector according to the preferred embodiments, in which  FIG. 10(A)  shows application to a flat bad truck (e.g., supporting items, such as, e.g., lumber, bricks, boxes, pipes, etc.),  FIG. 10(B)  shows application to supporting items retained on pallets,  FIG. 10(C)  shows application to supporting freight and/or packaging (such as, e.g., crates, packing containers, boxes, etc.),  FIG. 10(D)  shows application to supporting a boat hull, and  FIG. 10(E)  shows application to supporting piping (such as, e.g., metal or plastic plumping and/or other pipes). 
     Extruded Construction: 
     As indicated above, in the preferred embodiments, the base portion  3  and the chord holder  2  are preferably integrally formed as a single unitary member by extruding a plastic material through an extrusion die and cutting appropriate section lengths during the extrusion process, such as, e.g., shown generally in  FIG. 9 . 
     In order to achieve different levels of hardness of base portion  3  and chord holder  2 , as is desired in some preferred embodiments, a co-extrusion technique can be used in which two different plastics are extruded together to form one unitary and integral structure. 
     In some embodiments, the extrusion can be made with PVC, polypropylene, TPE, TPO and/or other suitable materials. In some co-extruded embodiments, the dual materials can include a rigid PVC for the portion  2  and a flexible PVC for the portion  3 . For reference,  FIG. 9  illustrates an exemplary cross-section of a co-extruded piece  1  drawn through a single extrusion die  90 . 
     For some illustrative and non-limiting background information on extrusion and co-extrusion, see, e.g., U.S. Pat. No. 3,773,882, incorporated herein by reference in its entirety. 
     Whether formed by extrusion or by other means the cross-sections of the support chord protectors  1  are preferably generally constant and continuous over the entire lengths of these members. However, this is not a fixed requirement in other embodiments. In addition, in some embodiments, the support chord protectors  1  can be formed by other techniques, such as, e.g., by injection molding, machining and/or other methods. In addition, while elastomers or plastics are preferred materials in some embodiments, other embodiments can be employed with other materials, such as, e.g., aluminum and/or other metals. 
     In some embodiments, extrusion provides a number of benefits over other methods of manufacturing the device. Extrusion is often a low cost, simple way to manufacture goods. A large quantity of goods can often be manufactured at one time in a short amount of time. 
     Support Chord and Channels: 
     In various other embodiments, it is contemplated that the support chords  10 , etc., and the channels  9 , etc., can have a variety of cross-sectional configurations in various embodiments, such as, e.g., circular, elliptical, rectangular, triangular, irregular, varied cross-sectional shape (such as, e.g., to accommodate a chain, rope, or other irregular cross-section along a length), etc. In addition, although the base portion  3 , etc., is depicted as being substantially flat, it is to be understood that the base portion does not need to be planar or linear, but can have a varied surface with some curvature or irregularity (e.g., considered herein as being encompassed by the terminology generally flat) and/or can otherwise be varied so as to meet a particular application at hand. Often, however, the base portion  3 , etc., can have a planar base surface to contact members that are substantially planar, such as, e.g., rectangular ducts, etc. 
     Broad Scope of the Invention: 
     While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. In the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” In this disclosure and during the prosecution of this application, means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects and embodiments), and should not be improperly interpreted as limiting the scope of the application or claims.