Patent Publication Number: US-10322868-B2

Title: Cable assembly dispenser systems and associated methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to a U.S. provisional patent application entitled “Cable Assembly Delivery System and Associated Methods,” filed with the U.S. Patent and Trademark Office on Mar. 15, 2013, and assigned Ser. No. 61/793,395. The entire content of the foregoing provisional patent application is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to cable assembly dispenser systems and methods and, in particular, to cable assembly dispenser systems for efficient packaging and payout of cables. 
     BACKGROUND 
     Cables, e.g., patch cords, Category 5, Category 6, Category 6A, fiber optic cables, cables with plug and/or jack connectors, and the like, are generally used in a variety of settings to create electrical connections for communication between electronic devices, e.g., networking between switches, servers, data storage devices, and the like. In packaging/supplying cables to the trade, manufacturers generally package cables individually, e.g., in plastic packaging. Cables are generally also grouped together in large boxes when shipped from the manufacturer and can contain a variety of cables in each box. In addition, the site preparation prior to installation of cables generally requires an inventory of necessary cables to be allocated, the cables to be sorted, removed from their unit packaging, unbundled, and finally uncoiled in order to make the connection. Thus, large amounts of material are typically wasted in packaging cables and a large amount of time can be spent in identifying specific cable types when multiple cable types are implemented during the installation, thereby slowing the installation process and generally inconveniencing the installer. In an industry where large numbers of different cables may be required for installation at one time, individually removing each cable from the packaging and identifying whether the correct cable has been selected can lead to lengthy installation times. 
     Thus, a need exists for cable assembly dispenser systems that facilitate cost effective packaging and/or efficient cable access and installation in the field. These and other needs are addressed by the cable assembly dispenser systems and associated methods of the present disclosure. 
     SUMMARY 
     In accordance with embodiments of the present disclosure, exemplary cable assembly delivery systems are provided that generally include at least one cable, a support element and a coupler element. The at least one cable generally includes an elongated cord and, optionally, a first connector mounted with respect to one end of the elongated cord. The support element can be configured and dimensioned to support the at least one cable thereon. The coupler element can detachably secure the at least one cable to the support element. 
     The at least one cable generally includes a second connector mounted with respect to an end of the elongated cord opposing the first connector. The first and second connector can be, e.g., a plug, a jack, and the like. In some embodiments, rather than including a second connector, the at least one cable includes a bare cable end at an end of the elongated cord opposing the first connector. In some embodiments, rather than including first and second connectors, the at least one cable can include first and second bare ends on opposing ends of the elongated cord. The support element can be fabricated from, e.g., a cardboard material, a plastic material, and the like. In some embodiments, the support element can be collapsible. Further, the support element can define, e.g., a planar surface, a stiff surface, combinations thereof, and the like. The coupler element can be one or more of, e.g., a wrapping, a cable tie, adhesive tape, a spring-loaded clip or clamp, and the like. 
     In accordance with embodiments of the present disclosure, exemplary methods of cable assembly delivery are provided that generally include providing at least one cable that includes an elongated cord and, optionally, a first connector mounted with respect to one end of the elongated cord. The methods generally include providing a support element configured and dimensioned to support the at least one cable thereon. The methods further include detachably securing the at least one cable to the support element with a coupler element. 
     In accordance with embodiments of the present disclosure, exemplary cable assembly dispenser systems are provided that generally include at least two cable assemblies. Each of the at least two cable assemblies generally includes a least one cable that includes an elongated cord. In some embodiments, each of the at least two cable assemblies includes at least one connector mounted with respect to the elongated cord. In some embodiments, each of the at least two cable assemblies includes at least one bare end at an end of the elongated cord. Each of the at least two cable assemblies also includes a support element configured and dimensioned to support the at least one cable thereon. The support element defines, e.g., a planar surface, a stiff surface, and the like. Each of the at least two cable assemblies further includes a coupler element for detachably securing the at least one cable to the support element. 
     The systems generally include a housing configured and dimensioned to receive the at least two cable assemblies, e.g., in a stacked configuration. The stacked configuration can be a vertically stacked configuration and/or a horizontally stacked configuration. The housing includes at least one opening for dispensing each of the at least two cable assemblies. In general, dispensing a first cable assembly of the at least two cable assemblies from the at least one opening repositions, e.g., automatically, manually, combinations thereof, and the like, a second cable assembly of the at least two cable assemblies adjacent to the at least one opening. 
     In some embodiments, the systems include a mechanism, e.g., a spring-loaded mechanism, for repositioning the second cable assembly of the at least two cable assemblies adjacent to the at least one opening. The mechanism can impart and maintain a force on the second cable assembly in a direction of a position aligned with the at least one opening. In some embodiments, the mechanism automatically repositions the second cable assembly of the at least two cable assemblies adjacent to the at least one opening. In some embodiments, the mechanism is actuated manually to reposition the second cable assembly of the at least two cable assemblies adjacent to the at least one opening. In some embodiments, rather than or in combination with the spring mechanism, removing one cable assembly from the opening can automatically reposition the second or subsequent cable assembly adjacent to the opening due to gravity. 
     In some embodiments, the systems include a mechanism, e.g., a spring-loaded mechanism, for at least partially dispensing the first cable assembly of the at least two cable assemblies from the at least one opening when the first cable assembly is positioned in a position aligned with the at least one opening. The mechanism imparts a force in a direction of the at least one opening. In some embodiments, the systems include a counter positioned on the housing for sensing and indicating a number of cable assemblies remaining in the housing. 
     In accordance with embodiments of the present disclosure, exemplary methods of cable assembly dispensing are provided that generally include providing at least two cable assemblies. Each of the at least two cable assemblies includes at least one cable that includes an elongated cord. Each of the at least two cable assemblies further includes a support element configured and dimensioned to support the at least one cable thereon. The methods include providing a housing configured and dimensioned to receive the at least two cable assemblies, e.g., in a stacked configuration. The housing includes at least one opening for dispensing each of the at least two cable assemblies. The methods include dispensing a first cable assembly of the at least two cable assemblies from the at least one opening of the housing. The methods further include repositioning, e.g., automatically, manually, and the like, a second cable assembly of the at least two cable assemblies adjacent to the at least one opening. 
     In some embodiments, repositioning the second cable assembly of the at least two cable assemblies adjacent to the at least one opening includes imparting a force with a mechanism, e.g., a spring-loaded mechanism, on the second cable assembly in a direction of a position aligned with the at least one opening. In some embodiments, repositioning the second cable assembly of the at least two cable assemblies adjacent to the at least one opening includes imparting a force, e.g., a gravitation force, separate from or in combination with a force imparted by the mechanism. In some embodiments, dispensing the first cable assembly of the at least two cable assemblies from the at least one opening includes imparting a force with a mechanism, e.g., a spring-loaded mechanism, on the first cable assembly in a direction of the at least one opening to at least partially dispense the first cable assembly from the at least one opening. 
     In accordance with embodiments of the present disclosure, exemplary cable assembly dispensing systems are provided that generally include at least two cable assemblies. Each of the at least two cable assemblies includes an elongated cord. The systems generally include a housing configured and dimensioned to receive the at least two cable assemblies, e.g., in a stacked configuration. The housing includes at least one opening for dispensing each of the at least two cable assemblies. Dispensing a first cable assembly of the at least two cable assemblies from the at least one opening of the housing repositions, e.g., automatically, manually, and the like, a second cable assembly of the at least two cable assemblies adjacent to the at least one opening. 
     Each of the at least two cable assemblies can include a binding element for binding the elongated cord relative to itself and/or the first connector. Each of the at least two cable assemblies can include a support element configured and dimensioned to support one of the at least two cable assemblies thereon. The system generally includes a coupler element for detachably coupling one of the at least two cable assemblies to the support element. 
     Other objects and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To assist those of skill in the art in making and using the disclosed cable dispensers and associated systems and methods, reference is made to the accompanying figures, wherein: 
         FIG. 1  is a perspective view of an exemplary cable assembly dispensing system, including an exemplary cable assembly and a cable assembly dispenser according to the present disclosure; and 
         FIG. 2  is a perspective view of an exemplary cable assembly dispensing system, including an exemplary cable assembly and a cable assembly dispenser according to the present disclosure. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENT(S) 
     With reference to  FIG. 1 , a perspective view of an exemplary cable assembly dispensing system  100  (hereinafter “system  100 ”), e.g., a cable assembly packaging and payout system, is provided that includes an exemplary cable assembly  200  and a cable assembly dispenser  300 . The cable assembly  200  generally includes at least one cable  202 . In some embodiments, the cable assembly  200  can include multiple cables  202  secured relative to each other with coupler elements, e.g., clips, tape, cable ties, and the like. The cable  202  includes an elongated cord  204  which defines two opposing ends, e.g., a first end  212  and a second end  214 . At least one of the first end  212  and second end  214  includes a connector  206 ,  208  mounted to the elongated cord  202 . The connector  206 ,  208  can be, e.g., a plug, a jack, and the like. The plug can be, e.g., an RJ 45 type plug, a Category 5 plug, a Category 6 plug, a Category 6A plug, a fiber optic plug, and the like. In some embodiments, at least one of the first end  212  and the second end  214  defines a bare cable end, e.g., without the connectors  206 ,  208 . In some embodiments, both the first and second ends  212 ,  214  define a bare cable end. 
     The cable assembly  200  can include a support element  210 , e.g., a cardboard support element, a plastic support element, and the like. The support element  210  can be configured and dimensioned to support the cable  202  thereon. In particular, the support element  210  can be configured as, e.g., rectangular, square, circular, oval, and the like, as long as the support element  210  completely supports the cable assembly  202  thereon. In some embodiments, the support element  210  can define a substantially planar surface. In other embodiments, the support element  210  can define a curved surface. For example, the support element  210  can define a central groove configured and dimensioned to receive therein the cable  202  to ensure that the cable  202  does not fall off the support element  210 . In some embodiments, the support element  210  can include side walls for housing the cable  202  to ensure that the cable  202  does not fall off the support element  210 . 
     At least one coupler element  216 , e.g., a wrapping, a cable tie, adhesive tape, a spring-loaded clip or clamp, and the like, can be used to detachably secure the cable  202  to the support element  210 . The wrapping can be a plastic wrapping. In some embodiments, the wrapping can be transparent. In embodiments implementing a cable tie, the support element  210  can include one or more holes passing the thickness of the support element  210  to allow passage of the cable tie therethrough for detachably securing the cable  202  to the support element  210 . 
     With reference to  FIG. 1 , the cable  202  is shown detachably secured to the support element  210  with an adhesive tape coupler element  216 . In some embodiments, a binding element  218 , e.g., a wrapping, a cable tie, adhesive tape, and the like, can be used to bind the elongated cord  204  of the cable  202  relative to itself and/or the connectors  206 ,  208 . In particular, the cable  202  can be wound or coiled into, e.g., a circular configuration, an oval configuration, and the like, and a binding element  218  can be used to maintain the cable  202  in the wound configuration. In some embodiments, the cable  202  can be wound or coiled into, e.g., a circular configuration, an oval configuration, and the like, and the coupler element  216  can be used to detachably secure the cable  202  to the support element  210  and maintain the cable  202  in the wound configuration without the use of a binding element  218 . It should be understood that alternative configurations of winding or coiling the cable  202  are within the scope of the present disclosure. 
     Packaging the cable assemblies  200  with only the support element  210 , a coupler element  216  and, optionally, a binding element  218 , can decrease costs associated with production of the cable assemblies  200  and reduce installation times by necessitating less materials to be removed for installation of the cable  202 . For example, once dispensed from the dispenser  300 , the cable assembly  200  can be unwound or uncoiled by removing the coupler element  216  and, optionally, tearing or breaking the binding element  218 . Thus, rather than removing cables  202  from multiple packaging materials, the cable  202  can be ready for installation within a shorter period of time by necessitating a lesser amount of materials to be removed to unwind the cable  202 . 
     Still with reference to  FIG. 1 , the system  100  generally includes a cable assembly dispenser  300  (hereinafter “dispenser  300 ”). The dispenser  300  includes a housing  302  which can be defined by a top wall  308 , a bottom wall  310 , a rear wall  314 , a front wall  312  and side walls  318 . In some embodiments, the housing  302  can be configured as, e.g., a cylindrical housing, a rectangular housing, and the like, depending on the configuration of the support element  210 . In some embodiments, the housing  302  can include a handle  326 , e.g., one or more openings configured and dimensioned to receive a user&#39;s fingers, a strap, and the like, for lifting or moving the system  100 . The housing  302  defines an interior space  304  configured and dimensioned to receive a plurality of cable assemblies  200 . In particular, the top wall  308  of the housing  302  can include a lid which can be opened to insert the plurality of cable assemblies  200  into the housing  302 . The housing  302  can receive the cable assemblies  200  in a stacked configuration, e.g., vertically stacked in a top wall  308  to bottom wall  310  direction. In particular, the cable assemblies  200  can be stacked one on top of another until the top wall  308  is reached. For example, as shown in  FIG. 1 , the dispenser  300  can accommodate up to six cable assemblies  200  in first, second, third, fourth, fifth and sixth positions  306   a - 306   f , respectively. However, it should be understood that in some embodiments, the dispenser  300  can accommodate any number of cable assemblies  200 . In some embodiments, the housing  302  can be flipped on one of the side surfaces  318  or can be oriented such that the cable assemblies  200  are horizontally stacked in a direction perpendicular to the direction of dispensing. 
     The housing  302  includes at least one opening  316 , e.g., an exit slot, for dispensing each of the cable assemblies  200  individually from the interior space  304 . In particular, the opening  316  can be located near the bottom wall  310  of the housing  302  and can be substantially aligned with the first position  306   a  for a cable assembly  200 . The opening  316  can be configured and dimensioned to allow the passage of one cable assembly  200  at a time when the cable assembly  200  positioned in position  306   a  is pulled out of the housing  316  in the direction A as shown in  FIG. 1 . 
     When a cable assembly  200  positioned in the first position  306   a  inside the housing  302  is dispensed and/or pulled out of the opening  316 , a cable assembly  200 ′ positioned immediately above the dispensed cable assembly  200  in the second position  306   b  can be automatically repositioned into the first position  306   a  adjacent to the opening  316 . In particular, when a cable assembly  200  positioned in the first position  306   a  inside the housing  302  is dispensed and/or pulled out of the housing  302 , all of the cable assemblies  200  positioned above the cable assembly  200  recently dispensed automatically move down one position in a direction B within the housing  302 . For example, with reference to  FIG. 1 , when cable assembly  200  is pulled out of the opening  316  in the housing  302  as shown, cable assembly  200 ′, which was positioned immediately above cable assembly  200 , can move down to the first position  306   a  in the direction B. 
     In some embodiments, the dispenser  300  can include a spring-loaded mechanism  320 , e.g., a spring-loaded surface, secured to the interior surface of the top wall  308 . The mechanism  320  can impart a force in the direction B, e.g., in the direction of the bottom wall  310 , on the cable assemblies  200  located within the housing  302 . Thus, when a cable assembly  200  positioned in the first position  306   a  inside the housing  302  is dispensed and/or pulled out of the opening  316  in the housing  302 , the mechanism  320  can impart a force onto the cable assemblies  200  remaining in the housing  302  to force and/or aid the movement of the cable assemblies  200  in the direction B such that the subsequent cable assembly  200  is positioned in the first position  306   a  and ready for dispensing. Although illustrated above the cable assembly  200 ′ for clarity, it should be understood that the mechanism  320  can be positioned against and provide a force to the top cable assembly  200  in the stack of cable assemblies  200  within the dispenser  300 . 
     In some embodiments, rather than automatically moving the subsequent cable assembly  200  from the second position  306   b  to the first position  306   a  when the cable assembly  200  has been dispensed from the first position  306   a , the mechanism  320  can be manually actuated by a user with, e.g., a switch, to force the subsequent cable assembly  200  in the B direction. In some embodiments, rather than a using a mechanism  320 , the cable assemblies  200  remaining in the housing  302  can be moved in the direction B by gravitational forces due to the weight of the stacked cable assemblies  200 . 
     In some embodiments, the dispenser  300  can include an alternative spring-loaded mechanism  322 , e.g., a spring-loaded surface. The mechanism  322  can be secured to the rear wall  314  of the dispenser and can impart a force in the direction A, e.g., in the direction of the opening  316 , on the cable assembly  200  positioned in the first position  306   a . Thus, when a cable assembly  200  is moved down from the second position  306   b  to the first position  306   a  inside the housing  302 , the mechanism  322  can automatically force and/or aid in at least partially dispensing the cable assembly  200  out of the opening  316 . In some embodiments, rather than automatically dispending the cable assembly  200  out of the opening  316 , the mechanism  322  can be manually actuated by a user with, e.g., a switch, to at least partially dispense the cable assembly  200  out of the opening  316 . Once the cable assembly  200  has been partially dispensed from the opening  316 , the mechanism  322  can automatically reset to a position adjacent to the rear wall  314  to permit the subsequent cable assembly  200  to be moved down into the first position  306   a.    
     In some embodiments, rather than positioning and/or dispensing only one cable assembly  200  at a time, the dispenser  300  can include, e.g., a switch, to allow selection of the number of cable assemblies  200  to be positioned in the first position  306   a  or to be dispensed from the opening  316 . For example, the first position  306   a  and the opening  316  can be dimensioned to receive one or more cable assemblies  200  at one time. Thus, if a user requires more than one cable assembly  200  for installation, rather than dispensing each cable assembly  200  individually, several cable assemblies  200  can be dispensed at one time. 
     When a portion or all of the cable assemblies  200  have been dispensed from the dispenser  300 , the dispenser  300  can be reused by refilling the dispenser  300  with additional cable assemblies  200 . The outer surfaces of the housing  302  can include information about the cable assemblies  200  within the housing  302 , e.g., logos, the cable type, the connector type, the number of cables in the dispenser  300 , and the like. In some embodiments, the housing  302  can be fabricated from, e.g., a plastic material, a glass material, a metal material, and the like. In some embodiments, the housing  302  can be collapsible. In some embodiments, the housing  302  can be translucent. In addition, the dispenser  300  can include a counter  324  on an outer surface of the housing  302  for sensing and indicating the number of cable assemblies  200  remaining in the housing  302 . The counter  324  can be reset when the dispenser  300  is refilled with additional cable assemblies  200 . The system  100  can therefore be used for effectively and/or efficiently packaging, organizing, identifying, accessing and/or dispensing a variety of cables. 
     Turning now to  FIG. 2 , a perspective view of an exemplary cable assembly dispensing system  400  (hereinafter “system  400 ”), e.g., a cable assembly packaging and payout system, is provided that includes an exemplary cable assembly  500  and a dispenser  300 . In particular, the dispenser  300  of system  400  can be substantially similar in structure and function to the dispenser  300  of system  100  shown in  FIG. 1 . The cable assembly  500  of system  400  can be substantially similar to the cable assembly  200  of system  100  shown in  FIG. 1 , except that the cable assembly  500  does not include a support element  210 . The cable assembly  500  of system  400  generally includes at least one cable  202  that includes an elongated cord  204  and can include connectors  206 ,  208  at the first and second ends  212 ,  214 . In some embodiments, at least one of the first and second ends  212 ,  214  can define a bare cable end. The cable  202  can be wound or coiled in, e.g., a circular configuration, an oval configuration, and the like, and can be bound by one or more binding elements  218 , e.g., a wrapping, a cable tie, adhesive tape, and the like. For example,  FIG. 2  illustrates cable  202  wound in a circular configuration and bound by adhesive tape. 
     Packaging the cable assemblies  500  without the support element  210  can further decrease costs associated with production of the cable assemblies  500  and reduce installation times by necessitating less materials to be removed for installation of the cable  202 . For example, once dispensed from the dispenser  300 , the cable assembly  500  can be unwound or uncoiled by tearing or breaking the binding element  218 . Thus, rather than removing cables  202  from multiple packaging materials, the cable  202  can be ready for installation within a shorter period of time by necessitating a lesser amount of materials to be removed to unwind the cable  202 . 
     Similar to system  100 , the cable assemblies  500  of system  400  can be vertically stacked within the housing  302  of the dispenser  300  such that when a cable assembly  500  positioned in the first position  306   a  is dispensed and/or pulled out of the opening  316  in the housing  302  in the direction B, any cable assemblies  500  positioned above the dispensed cable assembly  500  automatically move down one position in the direction B toward the bottom wall  310  and adjacent to the opening  316 . For example, the cable assembly  500  was positioned in the first position  306   a  of the housing  302  and was pulled out of the opening  316  in the direction A. The cable assembly  500 ′ was positioned directly above cable assembly  500  in the housing  302 . Thus, when cable assembly  500  is pulled out of the housing  302 , the cable assembly  500 ′ automatically moves in the direction B from the second position  306   b  to the first position  306   a  adjacent to the opening  316 . 
     In some embodiments, a spring-loaded mechanism  320  can be used to force the cable assembly  500 ′ in the direction B. In some embodiments, the mechanism  320  can be actuated manually by a user with, e.g., a switch. In some embodiments, the cable assembly  500 ′ can be forced in the direction B only by a gravitational force. The repositioning of the cable assemblies  500  located above the dispensed cable assembly  500  advantageously positions the next available cable assembly  500  to be dispensed, thereby decreasing installation times. As discussed above, the dispenser  300  can include a spring-loaded mechanism  322  aligned with the first position  306   a  and the opening  316  to at least partially dispense the cable assembly  500  from the housing  302  when the cable assembly  500  is repositioned into the first position  306   a . In some embodiments, the dispenser  300  includes a counter  324  on an outer surface of the housing  302  for sensing and indicating the number of cable assemblies  500  remaining in the housing  302 . The system  400  can therefore be used for effectively and/or efficiently packaging, organizing, identifying, accessing and/or dispensing a variety of cables. 
     While exemplary embodiments have been described herein, it is expressly noted that these embodiments should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention.