Cable mounts attached with a hot melt adhesive

Abstract

In accordance with aspects of the present disclosure, a cable mount for securing a cable to a mounting surface has a body with two ends, a top surface, and a contact surface. At least one cable grip extends away from the top surface and a dispensing port provides an opening through the top surface for dispensing a hot melt adhesive through the body to the contact surface. In accordance with yet other aspects, a cable mount for securing a cable to a mounting surface has a metal body with a top surface and a contact surface, and a hot melt adhesive pre-coated on the contact surface such that, when a power source is used to heat the metal body while the metal body is pressed against a mounting surface, the pre-coated adhesive is melted to form a bond between the cable mount and the mounting surface.

Description

Attorney Docket No.: HI24-035PCTCABLE MOUNTS ATTACHED WITH A HOT MELT ADHESIVECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 724,476, filed on November 25, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.BACKGROUND

[0002] This invention disclosure is related to the field of cable mounts and, more specifically, the ability to either vertically or horizontally secure a cable to a broad range of mounting surfaces. Broadly, a cable may consist of copper wire(s) or fiber optic fiber(s) or a combination of both. Cable products are conventionally mounted to a surface using either a pressure sensitive adhesive, epoxy-type adhesive, or mechanical anchors that must penetrate the surface for securement (e.g., nails, barbs, or screws).

[0003] A pressure sensitive adhesive (PSA) offers the advantage of quickly securing a cable mount. However, PSAs have limited load bearing capabilities, poor high-temperature performance, and require a clean and dry surface for attachment. Epoxies and similar two- part adhesives, or one-part moisture cure adhesives, provide a strong bond but require a significant amount of time to develop bond strength so that a cable mount can be secured. Flowable adhesives can perform well when the mounting surface is not entirely clean but typically will not develop sufficient bond strength on a moist or wet surface. Cable mounts that are secured using nails, screws or barbs provide significant load bearing capabilities and can be secured on both contaminated and wet surfaces. However, the securement techniques for these types of cable mounts are invasive and may damage the mounting surface.

[0004] Hot melt adhesives provide excellent, load-bearing capabilities under a wide range of environmental conditions (e.g., high temperature, low temperature, and moisture). A cable mount system is needed that utilizes a hot melt adhesive for securement.SUMMARY OF THE INVENTION

[0005] The disclosure is directed to uniquely fabricated cable mounts that can be secured quickly, safely, and effectively to a surface using a hot melt adhesive. In accordance with one embodiment, a cable mount utilizes a small port designed into the cable mount thatAttorney Docket No.: HI24-035PCT fits securely to a hot melt applicator tip. The cable mount may be pressed against a mounting surface using the hot melt applicator, followed by injecting the hot melt adhesive through the port and on to the contact surface of the cable mount. Unique features are introduced on the contact surface of the cable mount to provide flow characteristics that enable the hot melt adhesive to effectively cover adequate surface area to form a secure bond.

[0006] In accordance with yet other embodiments, a hot melt adhesive can be precoated on the backside of a cable mount base. The cable mount base is then placed against a surface and the topside of the base is heated to melt the adhesive. A secondary mount cap may be used to interlock with the mount base while simultaneously securing the cable via cable securement features.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to illustrate the embodiments of the invention more clearly.

[0008] FIG. 1 is a top perspective view of a cable mount, according to a first embodiment;

[0009] FIG. 2 is a bottom perspective view of the cable mount shown in FIG. 1;

[0010] FIG. 3 is a side view of the cable mount shown in FIGS. 1 and 2;

[0011] FIG. 4 is a top perspective view of the cable mount of FIGS 1-3 shown in a state of use with a cable secured into the cable mount;

[0012] FIG. 5 illustrates a perspective view of a representative hot melt adhesive dispenser and adhesive stick;

[0013] FIG. 6 is a close-up view of the tip of the hot melt adhesive dispenser shown in FIG. 5 when mated with the cable mount shown in FIGS. 1-4;

[0014] FIG. 7 is a top perspective view of a cable mount, according to a second embodiment;

[0015] FIG. 8 is a bottom view of the cable mount shown in FIG. 7;Attorney Docket No.: HI24-035PCT

[0016] FIG. 9 is a side view of the cable mount shown in FIGS. 7 and 8;

[0017] FIG. 10 is a top view of a cable mount, according to a third embodiment;

[0018] FIG. 11 is a bottom view of the cable mount shown in FIG. 10;

[0019] FIG. 12 is a top perspective view of the cable mount of FIGS. 10 and 11, shown in a state of use by being mounted on a mounting surface and securing a cable;

[0020] FIG. 13 is a top perspective view of a cable mount, according to a fourth embodiment;

[0021] FIG. 14 is a side view of the cable mount shown in FIG. 13;

[0022] FIG. 15 is a perspective view of a cable mount base and secondary cap components of a cable mount assembly, in accordance with aspects of the present disclosure;

[0023] FIG. 16 is a perspective view of the cable mount assembly of FIG. 15 shown assembled and in a state of use with a cable secured in the cable mount assembly; and

[0024] FIG. 17 is a perspective view of a cable mount having multiple cable pathways, in accordance with aspects of the present disclosure.DETAILED DESCRIPTION

[0025] With reference to FIGS. 1-3, a cable mount 10 is shown in accordance with aspects of the present disclosure. The cable mount 10 is a unitary construction having a body 12 with at least one cable grip 30 and at least one dispensing port 40. In the embodiment shown in FIGS. 1-4, the cable mount 10 has two opposing cable grips 30, each cable grip 30 extending from a top surface 14 of the body 12 at or near each end 16 of the body 12, with the dispensing port 40 located substantially equidistant between the two opposing cable grips 30. Each cable grip 30 generally resembles a hook extending away from the body 12 with a central opening 32 concentrically formed around a longitudinal cable pathway axis A-A and a grip opening 34 to provide for placement and securing of a cable 50 into the cable mount 10.

[0026] The cable grips 30 shown in FIGS. 1-4 are provided to face in generally opposite directions with each cable grip opening 34 falling on opposite sides of the cable pathway axis A-A to enable insertion and retention of a cable 50 (see FIG. 4). When inserted into the cable mount 10, the cable 50 may thus be held by the opposing cable grips 30 in a position substantially parallel with or aligned to the longitudinal cable pathway axis A-A ofAttorney Docket No.: HI24-035PCT the cable mount 10. FIG. 3 is a sideview of the cable mount 10 and shows the opposing cable grips 30 concentrically formed around the pathway axis A- A.

[0027] As shown in FIG. 2, a contact surface 18 of the cable mount 10 is provided to contact or sit substantially flush with a mounting surface while providing a reservoir area 20 or similar features, such as channels or troughs, for containment of a hot melt adhesive. In this manner, the contact surface 18 forms a discontinuous outer ridge that is raised above and surrounds the reservoir area 20. Although referred to herein as a contact surface, the contact surface is the surface of the cable mount that is in closest proximity to the mounting surface. It may be in actual contact with the mounting surface, or it may be separated by a thin layer of hot melt adhesive, for example, that seeps between the contact surface and the mounting surface during installation of the cable mount. Vents 22, sometimes referred to as weep holes, may be provided in the contact surface 18 to promote even distribution of a hot melt adhesive as the adhesive is injected through the dispensing port 40 into the reservoir area 20. Moreover, the vents 22 also provide a visual cue to a user that sufficient hot melt adhesive has been dispensed when excess hot melt adhesive flows out from the reservoir area 20 through the vents 22 to an exterior area of the cable mount 10.

[0028] The hot melt adhesive is introduced through the dispensing port 40 using a hot melt adhesive dispenser 60. An example of a hot melt adhesive dispenser 60 and adhesive stick 70 are shown in FIG. 5. A hot melt adhesive dispenser can be powered by several methods. Battery powered and butane fuel hot melt adhesive dispensers provide ease of use and do not require the use of a tethered power source. Plug-in models are less desirable for remote or outdoor use. As shown in FIG. 6, the dispensing port 40 is preferably fabricated to mate with a tip 62 of the hot melt adhesive dispenser 60 or vice versa so that securing the cable mounts 10 to a surface may be accomplished using only one hand.

[0029] Hot melt adhesives provide superior adhesion and offer the ability to minimize the footprint of the cable mounts 10. Specific hot melt adhesives are preferred that offer superior performance, including Amorphous Poly Alfa Olefins (APAOs) and Polyamides (PAs). Advantages of these hot melt adhesives include excellent high temperature and low temperature resistance, performing well in temperatures ranging from -20°C to greater than 70°C, as well as having the property of providing strong bonds to a wide range of substrates for mounting, including brick, brick mortar, glass, acrylic plastic, aluminum, iron, steel,Attorney Docket No.: HI24-035PCT concrete, and fiber concrete siding, to name a few. The cable mounts 10 shown in FIGS. 1-4, when attached to a substrate using an APOA hot melt adhesive, exhibit excellent load bearing characteristics. For example, cable mounts 10 adhered to either a brick or brick mortar substrate with an APOA hot melt adhesive, such as Infinity Bond SuperTAC 11 (Hot Melt, Minnetonka, MN, USA), can hold a suspended weight of at least 70 pounds for at least 30 minutes with no bond failure, and cable mounts 10 bonded to an iron substrate can hold a suspended weight of at least 96 pounds for at least two weeks with no sign of bond failure.

[0030] In accordance with yet other aspects of the present disclosure, FIGS. 7-9 illustrate a cable mount 110 having many of the same features as cable mount 10 shown in FIGS. 1-4. However, the cable grips 30 are provided in two pairs at or near both ends 16 of the cable mount 110 so that a cable 50 can be secured into the cable mount 10 by pressing the cable 50 through the cable grips 30 after the cable mount 10 is secured directly to a surface by using the dispensing port 40 to inject a hot melt adhesive. As shown in FIG. 8, the contact surface 18 may be provided with features, such as channels 24 to distribute the hot melt adhesive once the cable mount 110 (or cable mount 10) is pressed up against a mounting surface and the hot melt adhesive is injected through the dispensing port 40.

[0031] In accordance with yet other aspects of the present disclosure, and as shown in FIGS. 10-12, a cable mount 210 incorporates two potential methods for securing the cable 50 to the cable mount 210. The cable mount 210 can directly accept a cable 50 of a defined diameter by pressure fitting the cable 50 into a cable capture feature 212, such as a semicircle slot provided between the raised cable grips 30. In addition, the cable mount 210 also has a feature in which a cable tie 220 can be threaded through a slot feature 214 in the cable mount 210. The slot feature 214 extends through the cable grips 30 such that the cable tie 220 extends underneath the cable 50 when the cable tie 220 is inserted through the slot feature 214. The slot feature 214 and cable tie 220 provide an additional securement means when, for example, the cable 50 has a diameter that exceeds the cable capture feature or when the cable 50 is not round. As discussed with respect to cable mounts 10 and 110, cable mount 210 also has a central dispensing port 40 for dispensing hot melt adhesive through the cable mount 210 when the cable mount 210 is situated and / or pressed flush against a mounting surface 80 (see, e.g., FIG. 12). Once the cable mount 210 is secured to the mounting surface 80, after injection of the hot melt adhesive through the dispensing port 40 and setting of the hot melt adhesive, the cable 50 may be inserted into the cable capture feature 212 and / or secured to the cable mount 210 by way of the cable tie 220. As shown in FIG. 11, the contact surfaceAttorney Docket No.: HI24-035PCT18 of the cable mount 210 may also include channels 24 for distributing the hot melt adhesive. A secondary port 42 may also be provided so that a user has the ability to know when sufficient hot melt has been dispensed through to the underside of the cable mount 210 because hot melt will begin to exit through the secondary port 42.

[0032] In accordance with yet other aspects of the present disclosure, cable mounts may be pre-coated with a hot melt adhesive to preclude the requirement for an adhesive dispenser. FIGS. 13-14 illustrate a cable mount 310 made from a suitable metal, such as aluminum, having a pre-coated hot melt adhesive 320 provided on a contact surface 318. The cable mount 310 has cable securement features 314, shown as projecting tabs in this embodiment, which may be physically opened and folded to secure a cable 50 to the cable mount 310. The adhesive for this method of attachment can be pre-coated on the contact surface 318 of the cable mount 310 at a uniform thickness that coats parts of or the entire contact surface 318, or as one or more localized domed features that spread upon heating. When using a cable mount 310 coated with one or more localized portions of a hot melt adhesive, it may be advantageous for the contact surface 318 of the cable mount 310 to have features, such as channels, that provide efficient flow of the adhesive to maximize coverage.

[0033] For this method of attaching the cable mount 310 to a mounting surface, an alternative power source is used to heat the cable mount 310 and melt the pre-coated adhesive 320 that is placed on the contact surface 318 of the cable mount 310. Suitable heat sources include a torch, plastic stapler, or a hot iron tip. It is preferable to have the heat source couple directly with the cable mount 310 so that only one hand is required for attachment of the cable mount 310 to the mounting surface. Because the pre-coated cable mount 310 is required to effectively conduct heat, the cable mount 310 is preferably fabricated from a suitable metal. The cable mount 310 can be a unitary design that directly secures a cable or can be designed to interlock with a secondary cap having cable securement features. The secondary cap can be a durable polymer and have cable securement features that change depending on the cable size and geometry.

[0034] FIGS. 15-16 illustrate aspects of a cable mount assembly 410 having a cable mount base 420 and a secondary cap 430. As shown in FIG. 15, a hot melt adhesive 422 is pre-coated on a contact surface 424 of the cable mount base 420. A thickness of the hot melt adhesive pre-coat should be approximately 0. 1 inches or greater to provide sufficient strengthAttorney Docket No.: HI24-035PCT to the bond formed by heating the pre-coated cable base mount 420. The cable mount base 420 is preferably fabricated from a metal capable of rapidly transferring heat (e.g., aluminum). The cable mount base 420 is placed against the mounting surface and a heat source applied directly to the cable mount base 420 to melt the hot melt adhesive 422 and secure the cable mount base 420 to the mounting surface upon cooling of the hot melt adhesive 422. Interconnect features such as locking handles 426 are integrated into the cable mount base 420 to interlock with the secondary cap 430.

[0035] The secondary cap 430 also includes interconnect features such as locking tabs 432 shown in FIG. 15 that mate with the interconnect features (i.e., the locking handles 426) of the cable mount base 420. The secondary cap 430 requires a secure fit with the cable mount base 420 and may be fabricated from a durable plastic, for example, such as nylon. The secondary cap 430 has cable securement features 434 similar to the cable mounts described earlier. In this case, the cable securement features 434 are the opposed cable grips described with respect to cable mount 10. FIG 16 illustrates the cable mount assembly 410 fully assembled with the secondary cap 430 secured to the cable mount base 420 and a cable 50 held by the cable securement features 434.

[0036] Various suitable methods for heating the cable mount base 420 to melt the precoated hot melt adhesive 422. A rapid and highly effective solution is to use a butane fueled torch. Alternatively, a soldering attachment to a butane torch can be modified to work similar to a hot iron tip. Contacting the tip to the metal surface of the cable base mount 420 rapidly transfers heat and melts the pre-coated hot melt adhesive 422.

[0037] In accordance with yet other aspects of the present disclosure, a plastic stapler may be used to heat the cable base mount 420. The coil wire junction of the plastic stapler rapidly heats and can be pressed against the metal surface of the cable base mount 420 to transfer heat and melt the pre-coated hot melt adhesive 422. In one example, a plastic stapler was used to adhere a cable base mount 420 to a mounting surface comprised of a fiber cement siding material. The heating element of the plastic stapler was placed against the aluminum surface of the cable base mount 420 and heated for approximately three seconds to melt the hot melt adhesive 422 coated on the contact surface 424 of the cable base mount 420. The plastic stapler heat source was then shut off while maintaining pressure against the cable base mount 420 for an additional 7-10 seconds. A secure bond of the cable base mount 420 was observed after removal of the heating element.Attorney Docket No.: HI24-035PCT

[0038] As described above with respect to cable mounts 10, 110, 210, and 310, the cable mount assembly 410 may have channels or reservoirs provided on the contact surface 424 to allow the adhesive 422, particular when not applied across the entire contact surface 424 of the cable mount assembly, to flow in a manner that more evenly distributes the hot melt adhesive 422 over a greater area of the cable base mount 420. For example, the adhesive 422 can be pre-coated as a localized mound in the center of the cable base mount 420 and flow outward through channels upon contact of the cable base mount 420 with a heat source.

[0039] In accordance with yet additional aspects of the present disclosure, the contact surface of cable mounts 10, 110, 210, 310, and 410 may be provided with a roughened surface to provide friction when bonded to mounting surface and resist the opportunity for the cable mount to slide or move when the hot melt is in a flowable state prior to setting.

[0040] FIG. 17 illustrates a cable mount 510 is shown in accordance with aspects of the present disclosure. The cable mount 510 is a unitary construction having a body 512 with a plurality of cable grips 530 and at least one dispensing port 540. In the embodiment shown in FIG. 17, the cable mount 510 has multiple opposing cable grips 530, each cable grip 530 extending from a top surface 514 of the body 512 to form multiple longitudinal cable pathways B-B to provide for placement and securing at least one or a plurality of cables into the cable mount 510.

[0041] As shown in FIG. 17, a contact surface 518 of the cable mount 510 is provided to contact or sit substantially flush with a mounting surface while providing a reservoir area or similar features, such as channels or troughs, for containment of a hot melt adhesive, as described with respect to other embodiments. Although referred to herein as a contact surface, the contact surface is the surface of the cable mount that is in closest proximity to the mounting surface. It may be in actual contact with the mounting surface, or it may be separated by a thin layer of hot melt adhesive, for example, that seeps between the contact surface and the mounting surface during installation of the cable mount.

[0042] Many modifications and other embodiments, within the scope of the claims, will be apparent to those skilled in the art.

Claims

Attorney Docket No.: HI24-035PCTWhat is claimed is:

1. A cable mount for securing a cable to a mounting surface, the cable mount having a unitary construction and comprising: a body having two ends, a top surface, and a contact surface; at least one cable grip extending away from the top surface; and a dispensing port that provides an opening through the top surface for dispensing a hot melt adhesive through the body to the contact surface.

2. The cable mount of claim 1, where the at least one cable grip comprises two cable grips, each cable grip extending from the top surface of the body at or near each end of the body with the dispensing port 40 located substantially equidistant between the two cable grips.

3. The cable mount of claim 2, wherein each cable grip resembles a hook extending away from the body with a central opening concentrically formed around a longitudinal cable pathway axis and a grip opening that opens in an opposite direction from the grip opening of the other cable grip to provide for placement and securing of a cable into the cable mount.

4. The cable mount of claim 1, wherein the contact surface forms a discontinuous outer ridge that is raised above and surrounds a reservoir area.

5. The cable mount of claim 1, wherein vents are provided in the contact surface to promote even distribution of the hot melt adhesive as the hot melt adhesive is injected through the dispensing port into the reservoir area.

6. The cable mount of claim 1, wherein the hot melt adhesive comprises Amorphous Poly Alfa Olefins (APAOs) or Polyamides (PAs).

7. The cable mount of claim 1, wherein the dispensing port is formed to mate with a tip of a hot melt adhesive dispenser.Attorney Docket No.: HI24-035PCT8. The cable mount of claim 1, wherein the at least one cable grip comprises two pairs of cable grips, each pair of cable grips being provided at or near an end of the cable mount so that a cable can be secured into the cable mount by pressing the cable through the cable grips after the cable mount is secured directly to the mounting surface.

9. The cable mount of claim 1, wherein the contact surface comprises channels to distribute the hot melt adhesive once the cable mount is pressed up against the mounting surface and the hot melt adhesive is injected through the dispensing port.

10. The cable mount of claim 1, further comprising a slot feature that enables a cable tie to be inserted through the slot feature to provide an additional securement means for securing a cable to the cable mount.

11. The cable mount of claim 10, further comprising a secondary port through which the hot melt adhesive can exit when sufficient quantity of the hot melt adhesive has been injected through the dispensing port.

12. A cable mount for securing a cable to a mounting surface, the cable mount comprising: a metal body having a top surface and a contact surface; and a hot melt adhesive pre-coated on the contact surface such that, when a power source is used to heat the metal body while the metal body is pressed against a mounting surface, the pre-coated adhesive is melted to form a bond between the cable mount and the mounting surface.

13. The cable mount of claim 12, further comprising projecting tabs that open and fold to secure a cable to the cable mount.

14. The cable mount of claim 12, wherein the hot melt adhesive is pre-coated at a uniform thickness that coats parts of or the entire contact surface.

15. The cable mount of 12, further comprising one or more channels in the contact surface to provide efficient flow of the hot melt adhesive when melted.Attorney Docket No.: HI24-035PCT16. A cable mount assembly for mounting a cable onto a mounting surface, the cable mount assembly comprising: a cable mount base having a contact surface and a hot melt adhesive pre-coated onto the contact surface for bonding the cable mount to the mounting surface; and a secondary cap having cable securement features for securing a cable to the secondary cap; wherein the cable mount base and the secondary cap both have interconnect features to interlock the cable mount base to the secondary cap.

17. The cable mount assembly of claim 16, wherein the hot melt adhesive pre-coat is approximately 0.1 inches or greater.

18. The cable mount assembly of claim 16, wherein the cable mount base is fabricated from a metal capable of rapidly transferring heat to the hot melt adhesive.

19. The cable mount assembly of claim 16, wherein interconnect features of the cable mount base are locking handles integrated into the cable mount base to interlock with the interconnect features of the secondary cap.

20. The cable mount assembly of claim 19, wherein the interconnect features of the secondary cap are locking tabs that mate with the locking handles of the cable mount base.

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