Patent Description:
Payout tubes for performing the function of guiding filamentary material through payout holes of packages of wound coils are known to the art. For example, <CIT> and <CIT>, describe a payout tube for insertion in a radial hole of a wound coil of filamentary material, where the radial hole extends from the inner to the outer wind of the wound coil. The payout tube includes an entrance and an exit opening in coaxial and spaced relationship with one another. <CIT>) discloses a payout tube for enabling payout of a consumable filament from a consumable assembly that is configured for use with an additive manufacturing system, the payout tube comprising a tip end having an inlet opening, a base end having an outlet opening, and a tube body having an average effective outer diameter that is substantially greater than an effective inner diameter of the inlet opening. <CIT>) discloses a payout tube for containers that is used to package and store continuous lengths of materials is described. The payout tube is configured with a high degree of flexibility. With this flexibility, the continuous lengths of material (like communication cables) do not kink or tangle when being removed from the storage container through the payout tube. The payout tube can be provided with this flexibility by eliminating the rigidity of the payout tube without destroying the structure of the tube, such as by forming slots or corrugations in the portion of the payout tube that needs to be flexible.

Payout tubes are described for facilitating payout of filamentary material from a coil of filamentary material wound in a figure-eight configuration and defining a payout hole. The payout hole is generated in the figure-eight winding and extends from an inner wind layer of the coil to an outer wind layer of the coil. The claimed invention provides a payout tube according to independent claim <NUM>. The claimed invention provides a package of filamentary material wound in a figure-eight configuration according to claim <NUM>.

The payout tube includes an outer ring centered about a longitudinal axis and having a flange at an outer end of the payout tube. The payout tube also includes an inner ring having a rounded edge at an inner end of the payout tube, and a plurality of spaced pillars are provided extending longitudinally from the outer ring to the inner ring. The inner ring is aligned coaxially with the outer ring and is spaced longitudinally from the outer ring.

In embodiments, the rounded edge of the inner ring has a radius of between <NUM> and <NUM> inches (~<NUM> and ~<NUM>), e.g., <NUM> inch (~<NUM>) and may have a half-round profile. In embodiments, each pillar includes a stiffener which may have a tapered, e.g., substantially V-shaped profile. In embodiments, the substantially V-shaped profile protrudes from an exterior side of the pillar and is indented on an interior side of the pillar. The V-shaped profile tapers along a longitudinal direction of the pillar so that it is widest adjacent the outer ring and narrowest adjacent the inner ring. In embodiments, the payout tube includes two diametrically opposed pillars.

The package of filamentary material includes a box or other packaging defining a payout hole, a coil of filamentary material wound into a figure-eight configuration defining a diamond shaped payout hole in alignment with the payout hole of the box or other packaging, and the payout tube as described in appended claim <NUM>. In embodiments, a box having a length of <NUM> to <NUM> inches (~<NUM> and ~<NUM>), a width of <NUM> to <NUM> inches (~<NUM> and ~<NUM>), and height of <NUM> to <NUM> inches (~<NUM> and ~<NUM>) is provided without the payout hole located central to a rectangular side, although boxes of other dimensions may be provided.

The embodiments shown in <FIG>, <FIG> and <FIG> and described below do not fall within the scope of the claimed invention.

<FIG> shows a payout tube <NUM> in accordance with an aspect of the disclosure, which does not fall within the scope of the claimed invention. The payout tube <NUM> may be made from various materials, included plastic or pulp paper. The payout tube <NUM> has an outer end <NUM> and an inner end <NUM>. As used herein, "inner" and "outer" refer to location of the ends <NUM>, <NUM> when the payout tube <NUM> is inserted in a package including a coil of wound filamentary material. That is, when the payout tube <NUM> is inserted into a coil, the inner end <NUM> will be located in a space defined by the coil (i.e., interior of the coil), while the outer end <NUM> will be located outside (exterior) the coil. In preferred embodiments, the coil is a coil of filamentary material wound in a figure-eight configuration, such as described in <CIT> and <CIT>.

The payout tube <NUM> includes a flange <NUM> at the outer end <NUM>, and an elongated tubular body <NUM> that extends longitudinally from the flange <NUM>, along an axis A-A, to the inner end <NUM>. The flange <NUM> is coaxial with the tubular body <NUM>. In the embodiment shown, the tubular body <NUM> has a tapered wall 108a of uniform thickness, which may be about <NUM> inch (~<NUM>).

As shown in <FIG>, and <FIG>, the flange <NUM> extends radially outwardly from the body <NUM>. The flange <NUM> has an inner diameter that defines an exit opening <NUM> through which filamentary material passes during payout. In one embodiment, the diameter Dfi (<FIG>) of the exit opening <NUM> may be between <NUM> inches and <NUM> inches (~<NUM> and ~<NUM>), and the flange <NUM> may have an outer diameter, Dfo (<FIG>) of between <NUM> inches and <NUM> inches (~<NUM> and ~<NUM>). In the embodiment shown, the outer diameter Dfo of the flange <NUM> is approximately <NUM> inches (~<NUM>).

At the inner end <NUM> of the payout tube <NUM>, the wall 108a of the tubular body <NUM> is rounded radially inwardly towards the axis A-A forming a half-round profile or edge <NUM>, shown in greater detail in <FIG>. The radius of the profile may be between <NUM> inch and <NUM> inch (~<NUM> and ~<NUM>). In the embodiment shown in <FIG>, the radius of the profile is approximately <NUM> inch (~<NUM>). The half-round edge <NUM> defines an inlet opening <NUM> (<FIG>) at the inner end <NUM> of the payout tube <NUM>. In one embodiment, the inlet opening <NUM> may have an inlet diameter, Di (<FIG>), of between <NUM> inch and <NUM> inches (~<NUM> and ~<NUM>). In the embodiment of payout tube <NUM> shown in <FIG>, the inlet diameter, Di, is approximately <NUM> inch (~<NUM>). The inlet diameter, Di, is noticeably smaller (about <NUM>% smaller) than the inner diameter Db (<FIG>) of the tubular body <NUM> at the base <NUM> of the rounded edge <NUM>, which in the embodiment of the payout tube <NUM> is approximately <NUM> inches (~<NUM>).

During payout of filamentary material from a coil of filamentary material wound in a figure-eight configuration, the payout tube <NUM> sits in an opening formed in the coil and filamentary material enters the payout tube <NUM> through the inlet opening <NUM> and exits the exit opening <NUM>. The rounded edge <NUM> with a desired radius of between <NUM> and <NUM> inch (~<NUM> and ~<NUM>) at end <NUM> provides a smooth edge against which filamentary material contacts the payout tube <NUM> as it enters the inlet opening <NUM>. Because of the desired radius, the rounded edge <NUM> facilitates an easier sliding of the filamentary material along the edge <NUM> during payout. For example, some portions of filamentary material payed out may have small kinks or irregularities at locations along their length. Such kinks or irregularities may slide more easily over the rounded edge <NUM> of the desired radius than if the edge is sharper as in the prior art.

Standoffs <NUM> (<FIG>, <FIG>) may be located on an inner side of the wall 108a of the tubular body <NUM> and may be located at or near the inner end <NUM>. In the example embodiment shown, three standoffs <NUM> are included and are spaced circumferentially <NUM> degrees apart from one another about axis A-A. While three standoffs <NUM> are shown in the embodiment of the payout tube <NUM>, more or fewer standoffs may be present. The standoffs <NUM> maintain a certain amount of axial spacing between adjacent payout tubes <NUM> when they are stacked or nested one inside one another. This spacing can mitigate adjacent stacked payout tubes <NUM> from "sticking" or otherwise tightly wedging themselves together when stacked.

<FIG> show additional details of the payout tube <NUM> of <FIG>, which does not fall within the scope of the claimed invention. The payout tube <NUM> may have an axial length, L (<FIG>), of about <NUM> inches (~<NUM>). A taper angle Θ (<FIG>) of the body <NUM> is relatively shallow and may, in one embodiment, be less than <NUM> degrees. In the embodiment shown, the taper angle, Θ, of the body <NUM> is approximately <NUM> degrees. Also, in embodiments, the tubular body <NUM> tapers down to an outer diameter at the base <NUM> of the rounded edge <NUM> of about <NUM> to <NUM> inches (~<NUM> and ~<NUM>). In the embodiment shown in <FIG>, the tubular body <NUM> tapers to an outer diameter of approximately <NUM> inches (~<NUM>) at the base <NUM> of the rounded edge <NUM>.

Turning now to <FIG>, another payout tube <NUM> is seen. The payout tube <NUM> may be formed from plastic or pulp paper and may have a uniform wall thickness. Payout tube <NUM> may have a rounded edge <NUM>, which is the same as edge <NUM> of payout tube <NUM>, i.e., having a radius of between <NUM> and <NUM> inches (~<NUM> and ~<NUM>) such as <NUM> inch (~<NUM>). The overall dimensions of the payout tube <NUM> (e.g., length, inlet and outlet diameters, and taper angle) may be the substantially the same as those for payout tube <NUM>, although the payout tube <NUM> differs from payout tube <NUM> in other ways. In particular, the payout tube <NUM> includes an outer tubular ring <NUM> having a flange <NUM>, an inner tubular ring <NUM> having the rounded edge <NUM> or profile, and elongated pillars <NUM> connecting the outer and inner tubular rings <NUM> and <NUM> in coaxially spaced relation along axis B-B. Two diametrically opposed pillars <NUM> are shown in the embodiment in <FIG>, although additional spaced pillars may be used in other embodiments.

The pillars <NUM> are stiffened by substantially "V" shaped stiffening ribs 208a, which protrude along the outer surfaces of the pillars <NUM>, as shown in <FIG>. A corresponding substantially V-shape profile is indented on the inside surfaces of the pillars <NUM> so that a uniform wall thickness is maintained. The ribs 208a extend axially between the flange <NUM> and the rounded edge <NUM>, though the ribs 208a need not terminate at either the flange <NUM> or the rounded edge <NUM>. In the example embodiment, the indent of the substantially V-shaped profile extends to the flange <NUM> such that an inner edge 206a (<FIG>) of the flange <NUM> has diametrically opposed substantially V-shaped indents 206b (<FIG>) corresponding to the indented profiles on the inside surfaces of the pillars <NUM>. The substantially V-shaped profile of the ribs 208a is wider towards the flange <NUM> than towards the rounded edge <NUM>. The ribs 208a have a central ridge 208b which is rounded and not sharp. This rounded ridge 208b is intended to prevent any pinching or kinking of filamentary material in contact with the ridge 208b. It is noted that the substantially V-shaped tapered stiffening ribs do not taper to a point at the inner end, but rather have a narrow non-tapered end as seen best in <FIG>.

In addition to stiffening the payout tube <NUM>, the ribs 208a also provide a keyed locating feature for inserting the payout tube <NUM> into a payout hole of a figure-eight wound coil of filamentary material. Specifically, a wound coil that has been wound in a figure-eight configuration may have a diamond-shaped payout hole. The protruding V-shaped ribs 208a on the exterior sides of the pillars <NUM> are configured to vertically align with upper and lower vertices of a diamond shaped payout hole.

Standoffs <NUM> (<FIG>) may also be located on an inner side of the inner ring <NUM> and may be located at or near the rounded edge <NUM>. In the example embodiment shown, three standoffs <NUM> are included and are spaced circumferentially <NUM> degrees apart from one another about axis B-B. While three standoffs <NUM> are shown in the embodiment of the payout tube <NUM>, more or fewer standoffs may be present. The standoffs <NUM> maintain a certain amount of axial spacing between adjacent payout tubes <NUM> when they are stacked or nested inside one another. This separation can mitigate adjacent stacked payout tubes <NUM> from "sticking" or otherwise tightly wedging themselves together when stacked.

When the payout tube <NUM> is disposed in a payout hole of a coil of filamentary material wound in a figure-eight configuration, the filamentary material will typically compress into spaces between the inner ring <NUM>, the outer ring <NUM>, and the pillars <NUM>. Filamentary material located in these spaces, when eventually paid out, will have to move out of the spaces and contact an edge <NUM> (<FIG>) before being drawn through inlet opening <NUM> (<FIG>). The edge <NUM> is comprised of a compound curve having a convex portion 220a and a concave portion 220b. The convex portion 220a is located at a radially outermost location of pillar <NUM>, while the concave portion 220b is located radially closer to axis B-B, as shown in <FIG>. The edge <NUM> is thus gently curved and smooth so that the filamentary material in the spaces between inner and outer rings <NUM>, <NUM>, and the pillars <NUM> can more easily slide along the edge <NUM> without kinking or getting caught on the edge <NUM>.

As previously mentioned, some of the dimensions of the payout tube <NUM> may be the same as the dimensions as the payout tube <NUM>. For example, the inner edge 206a of the flange <NUM> defines an exit opening <NUM> having a diameter Dfi (<FIG>), which may have the same dimension as the diameter Dfi of the exit opening <NUM> of the payout tube <NUM>. Also, the inner and outer rings <NUM> and <NUM> are tapered and define a taper angle Θ (<FIG>) of the payout tube <NUM> that may have the same dimension as the taper angle Θ of the payout tube <NUM>. The rounded edge <NUM> defines an inlet opening <NUM> having a diameter Di (<FIG>), which may have the same dimension as the diameter Di of the inlet opening <NUM> of the payout tube <NUM>. An outer diameter Db (<FIG>) of the inner ring <NUM> at the base <NUM> of the rounded edge <NUM> may have the same dimension as the outer diameter Db of the tubular body <NUM> at the base <NUM> of the rounded edge <NUM> of the payout tube <NUM>. Also, the payout tube <NUM> has a length L (<FIG>) measured along axis B-B, which may have the same dimension as the length L of the payout tube <NUM>.

The payout tube <NUM>, when compared to payout tube <NUM>, eliminates a significant amount of material from the body <NUM>. <FIG> (which is not within the scope of the claimed invention) shows payout tube <NUM> inserted into a coil <NUM> of filamentary material <NUM> wound in a figure-eight configuration. As shown in <FIG>, because the wall 108a of body <NUM> is solid, the filamentary material <NUM> cannot be located in the space occupied by the payout tube <NUM>. As a result, the coil <NUM> (and its box) is dimensioned to be wider than necessary to accommodate the width of the payout tube <NUM>. In contrast, as shown in <FIG>, when the tube <NUM> is inserted into a coil <NUM> of filamentary material <NUM>, the coil width can be narrower than the width of the coil shown in <FIG>, because filamentary <NUM> material can be located in the open spaces around the pillars <NUM> of the payout tube <NUM> which spaces are otherwise closed for payout tube <NUM>. Indeed, when using the tube <NUM>, the coil <NUM> can compress significantly, and thus reduce the overall width of the coil and its box. The reduced dimensions of the box can allow for a <NUM> to <NUM> percent increase in shipping density depending on the size of the box. For example, a typical box that holds a figure-eight wound coil of Category 6A cable has dimensions of <NUM> inches x <NUM> inches x <NUM> inches (~<NUM> x <NUM> x <NUM>), and such coil can accommodate the payout tube <NUM> described above. The use of payout tube <NUM> allows for a coil (and box) of smaller dimension so that an additional <NUM> to <NUM> boxes per layer to be placed on a shipping pallet as compared to the example box.

Turning to <FIG>, packages <NUM>, <NUM>' are provided including boxes <NUM>, <NUM>' containing figure-eight wound filamentary material (not shown) into which payout tubes <NUM>, <NUM> are inserted. In <FIG> (which is not within the scope of the claimed invention), the filamentary material (not shown) is packaged in a box <NUM> having a length that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>), a width that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>), and height that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>). Boxes of other dimensions may be utilized. The box <NUM> may be constructed as described in <CIT> and <CIT>. <FIG> shows the box <NUM> defining a payout hole <NUM> in a rectangular side of the box <NUM>, and the payout tube <NUM>. The coil defines a payout hole that aligns with the payout hole <NUM> of the box <NUM> and with the axis A-A (<FIG>, <FIG>, and <FIG>) of the payout tube <NUM>. The inner end of the payout tube <NUM> is disposed in an interior of the coil and the flange <NUM> is located adjacent to the rectangular side of the box <NUM> (e.g., captured between two flaps of the rectangular side).

<FIG> shows a box <NUM>' (<FIG>) having a length that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>), a width that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>), and height that is <NUM> to <NUM> inches (~<NUM> and ~<NUM>). Boxes of other dimensions (e.g., smaller as noted above) may be utilized. The box <NUM>' may be constructed as described in <CIT> and <CIT>. Box <NUM>' defines a payout hole <NUM>' in a rectangular side of the box <NUM>' into which payout tube <NUM> extends. Figure-eight wound filamentary material (not shown) contained inside the box defines a payout hole that aligns with the payout hole <NUM>' of the box <NUM>' and with the axis B-B (<FIG>) of the payout tube <NUM>. The inner end of the payout tube <NUM> is disposed in an interior of the coil and the flange <NUM> is located adjacent to the rectangular side of the box <NUM>' (e.g., captured between two flaps of the rectangular side).

Claim 1:
A payout tube (<NUM>,<NUM>) for facilitating payout of filamentary material from a coil of filamentary material wound in a figure-eight configuration and defining a payout hole, the payout hole extending from an inner wind of the coil to an outer wind of the coil, the payout tube comprising:
an outer ring (<NUM>) having a flange (<NUM>, <NUM>) at an outer end (<NUM>) of the payout tube, the outer ring centered about a longitudinal axis;
an inner ring (<NUM>) having a rounded edge (<NUM>, <NUM>) at an inner end of the payout tube, wherein the inner ring is aligned coaxially with the outer ring and is spaced longitudinally from the outer ring; and
a plurality of pillars (<NUM>) spaced from one another and extending longitudinally from the outer ring to the inner ring.