A method and apparatus for dispensing lengths of a flexible element

Abstract

Apparatus for dispensing lengths of a flexible element such as copper cable, fibre-optic cable or rope comprises: a length of flexible substrate 1 such as cardboard, wound with a flexible element (3 figure 5) such that the flexible substrate 1 forms a structural inner wall of a cable reel, and a dispenser 2 configured to accept the cable reel and allow rotation about an axis to distribute the flexible element. Dispenser 2 may be formed from a first section (2b figure 7) with a central hub and two fixed flanges to receive a length of pulling rope and a second section (2c figure 7) with a central hub and two fixed flanges to receive the cable reel. The two sections (2b, 2c figure 7) may be releasably fixed together magnetically for rotation about axis 2a to allow the pulling rope and flexible element (3 figure 5) to be distributed together from a dispenser frame 4.

Description

The invention relates to the winding and dispending of flexible, rope-like elements. Across many industries, there is a requirement for flexible elements, (such as copper electrical or data-carrying cable, fibre-optic cable, rope etc.) to be distributed in a variety of manners such as aerially, underground, horizontally / vertically through building structures and in temporary applications. The preferred method of storing and transporting flexible elements is in a coiled fashion, such as on reels or drums or in loose bales. Coiling flexible elements in this manner enables the easy payoff and distribution of the element, and the use of rigid drums and reels allows safe transportation and storage. The invention relates to the winding and dispensing of these flexible elements, and improvements relating to the storage, winding and dispensing of the same. Prior Art Known winding and dispensing apparatus have the ability to pay-off flexible elements from solid centred drums and reels, rotating around a central axis mounted either vertically or horizontally. The current state of the art requires flexible elements to be supplied pre-wound to a drum consisting of a solid core and fixed external flanges for transportation and subsequent distribution, meaning that post-distribution the user is left with large empty drums for storage, disposal or shipping back to the manufacturer. Alternatively, flexible elements are supplied in loose bundles, that then require winding to a drum or reel for dispensing, increasing cost and time investment for those distributing the flexible element, and introducing risk of damage in the transport, storage and winding stages. Summary of the Invention The described invention overcomes the issue of storage of large empty drums and reels by removing the requirement for a solid drum core, reducing transport and storage costs both pre-winding and post-installation of the flexible elements. The invention comprises a method and apparatus for dispensing lengths of a flexible element. According to a first aspect of the invention there is provided an apparatus for dispensing a flexible element, comprising: a length of flexible substrate, wound with a flexible element such that the flexible substrate forms a structural inner wall of a cable reel, and a dispenser configured to accept the same cable reel and allow rotation about an axis to distribute the flexible element. In some implementations, the dispenser is formed of two discrete sections wherein a first section is comprised of a central hub with two fixed flanges, configured to receive a length of pulling rope, and a second section is comprised of a central hub with one fixed flange, configured to receive the cable reel. In some implementations, the first and second sections of the dispenser are configured to be releasably rotationally fixated to each other to allow a pulling rope wound around the central hub of the first section to be distributed jointly with the flexible element. In some implementations, the first and second sections of the dispenser, when releasably rotationally fixated to each other, are rotatable around said axis and the central hub of the second section is located between the fixed flange of the second section and the second section along the axis. The flexible substrate is shaped like a sheet which is wound to a general loop shape. Thus, when the flexible element has been unwound from the flexible substrate the flexible substrate can easily be folded back to substantially flat sheet allowing it to be stored in a space efficient manner prior to disposal or reuse. Additionally, during preinstallation the storage and transportation of the flexible element according to the first aspect is lighter and / or requires less space compared to traditional cable drums enabling more space efficient storage and more efficient transportation. Also, since the flexible substrate can be realised as a thin sheet material, the cable reel does not necessitate flanges (flanges could be provided on the dispenser) the overall material use is reduced. According to a second aspect of the invention there is provided a method for dispensing lengths of a flexible element, comprising providing the flexible substrate in flat condition; and winding the flexible element around a drum wherein the flexible substrate is placed between the flexible element and the drum such that the flexible substrate is forms the structural inner wall of the cable reel. In some implementations, wherein the dispenser comprises two discrete sections, a first section comprised of a central hub with two fixed flanges, configured to receive a length of pulling rope, and a second section comprised of a central hub with one fixed flange, configured to receive the cable reel, the method further comprises mounting the cable reel onto the second section. In some implementations, the method further comprises jointly unwinding pulling rope and the flexible element from the dispenser. The invention according to the second aspect features the same or equivalent benefits as the invention according to the first aspect. Additionally, any functions described in relation to the method may have the corresponding features in an apparatus or vice versa. Descriptions of Drawings Figure 1: An example flexible substrate 1 in flat condition Figure 2: An example flexible substrate 1 in folded condition Figure 3: An example embodiment showing flexible substrate 1, in preparation for winding onto example dispenser 2, in a pre-wound flat state. Figure 4: An example embodiment showing flexible substrate 1, and example dispenser 2, in a post-wound folded state, no flexible element is shown. Figure 5: An example embodiment showing a sectional view of flexible substrate 1, and example dispenser 2 and flexible element 3, in a post-wound state, where flexible element 1 is restrained by flexible element 3. Figure 6: An example embodiment of a dispenser 2 with formed flexible substrate 1, sitting in a prior art dispenser frame 4, where dispenser 2 is axially mounted through central axle 2a to allow rotation, no flexible element is shown. Figure 7: An example embodiment of a dispenser 2, showing releasably attachable sections 2b and 2c. Specific Description of the Preferred Embodiment The present invention provides a method of winding and dispensing lengths of a flexible element (for example, but not limited to, fibre-optic cable, electrical cable, hose, rope etc.). The present invention comprises a length of a flexible substrate material [1] (for example, but not limited to, cardboard, fabric, composite etc) which, in a flat initial sheet state, is wound onto a central hub by means of a rotary motor, or hand driven wheel, or other means, to form the inner core of a cable reel (for the purposes of this description, the word ‘drum’ may be used interchangeably with similar terms, for example but not limited to Teel’, ‘pan’ etc). By winding the flat sheet flexible substrate with the flexible element, the winding process can be undertaken without requirement for adhesives or fixings. This flexible substrate material, now formed around a rotating mandrel or hub is secured by the wound flexible element as it is rotated onto the drum under tension. Once fully wound, the coiled flexible element can be fully attached to the now formed central drum core [1 ] by means of a temporary fixing (for example, but not limited to, cable ties, metal twist ties etc.) to form a transportable, deployable reel of flexible element. This reel, as defined above, is distributed by a dispenser [2] formed of two discrete sections, where the first section [2b] contains a pre-wound length of pulling rope (or similar sufficiently strong pulling material) mounted on a drum core between two fixed external flanges, and the second section [2c], being flanged on one exterior surface and flangeless on the other, is configured to receive the previously described baled flexible element wound around a flexible substrate and fixed with temporary fixings. These two discrete sections of dispenser can be configured together in a semipermanent, releasable manner (for example, but not limited to, magnetically), such that an external flange of the first section becomes a central flange of the whole by fixing to the flangeless surface of the second section. With the above described reel of flexible element secured between the flanges of the first and second section, the previously mentioned temporary tie fixings are removed, and the flexible element to be dispensed is secured to the pre-wound pulling rope in the first section by means of, for example, a joining member. Using the pulling rope, and with the assembled dispenser mounted by use of a central axle [2a] in such a way to allow rotation of the dispenser drum, for example in a prior art dispenser frame or similar [4], first the pulling rope and then the attached flexible element is distributed in a controlled manner from the rotating drum. Once the length of the flexible element has been fully dispensed, and is no longer retaining the internal flexible substrate, the substrate material is returned to its flat original sheet state and is removed from the dispenser hub, to be disposed of or reused.

Claims

What is claimed is:

1. An apparatus for dispensing lengths of a flexible element, comprising:- a length of flexible substrate, wound with a flexible element such that the flexible substrate forms a structural inner wall of a cable reel, and- a dispenser configured to accept the same cable reel and allow rotation about an axis to distribute the flexible element.

2. The apparatus for dispensing lengths of a flexible element according to claim 1, where the dispenser is formed of two discrete sections whereby:- a first section is comprised of a central hub with two fixed flanges, configured to receive a length of pulling rope, and- a second section is comprised of a central hub with one fixed flange, configured to receive the cable reel.

3. The apparatus for dispensing lengths of a flexible element according to any of the preceding claims, where the first and second sections of the dispenser are configured to be releasably rotationally fixated to each other to allow a pulling rope wound around the central hub of the first section to be distributed jointly with the flexible element.

4. The apparatus for dispensing lengths of a flexible element according to any of the preceding claims, where the first and second sections of the dispenser, when releasably rotationally fixated to each other, are rotatable around said axis and the central hub of the second section is located between the fixed flange of the second section and the second section along the axis.

5. A method for dispensing lengths of a flexible element, comprising:- providing a length of flexible substrate wound with a flexible element such that the flexible substrate forms a structural inner wall of a cable reel;- mounting said cable reel on a dispenser configured to accept the same cable reel and allow rotation about an axis; and- dispensing the flexible element by unwinding the flexible element from the cable reel.

6. The method according to claim 5 wherein providing a flexible substrate wound with a flexible element comprises:- providing the flexible substrate in flat condition; and- winding the flexible element around a drum wherein the flexible element is placed between the flexible element and the drum such that the flexible substrate is forms the structural inner wall of the cable reel.

7. The method according to claim 5 or claim 6, wherein the dispenser comprises two discrete sections, a first section comprised of a centralhub with two fixed flanges, configured to receive a length of pulling rope, and a second section comprised of a central hub with one fixed flange, configured to receive the cable reel, wherein the method further comprises:- mounting the cable reel onto the second section.

8. The method according to claim 7, further comprising:- jointly unwinding pulling rope and the flexible element from the dispenser.

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