Reel-in-box jumper cables for organized bulk packaging
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Solution Overview
Problem
Bulk packaging of flexible segments, such as communication cables, often results in tangled and unorganized cables, leading to damage and waste, as existing methods like bundling with tie-wraps do not effectively manage the organization and separation of cables.
Innovation Solution
A connecting device with a separating element, such as perforations in shrink wrap or resilient members, is used to couple and separate flexible segments, allowing for organized storage and easy dispensing, with a bulk packaging system that includes a reel and container for efficient use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible segments are bundled together with tie-wraps for bulk packaging, then the packaging is simple and easy to manufacture, but the cables become tangled and unorganized leading to damage and waste
Solution Approach 1:
The packaging system divides the bulk bundle into individual cable segments using a segmented reel structure. Each cable is separated into its own compartment or section on the reel, preventing tangling while maintaining bulk packaging efficiency. The tie-wraps are applied in a segmented manner rather than binding all cables together as a single mass.
Solution Approach 2:
The invention transitions from flat, two-dimensional bundling with tie-wraps to three-dimensional organized storage on a reel structure. Cables are arranged radially or in layered patterns on the reel, utilizing spatial dimensions to maintain organization while in bulk form.
2Volume of stationary object
If multiple cables are bundled together tightly, then the packaging volume is reduced, but the cables become difficult to separate and organize for use
Solution Approach 1:
The reel structure segments the bulk packaging into individual cable access points. Users can remove or separate individual cables from the reel without having to untangle or cut through a tight bundle, as each cable maintains its own pathway or compartment on the reel structure.
Solution Approach 2:
The reel acts as an intermediary structure between the bundled cables and the user. It provides a mechanical framework that holds cables in organized positions, allowing easy extraction and separation while maintaining compact packaging when cables are in use.
3Quantity of substance
If cables are stored in a bulk bundle, then storage efficiency is improved, but the opportunity for damage and waste increases
Solution Approach 1:
The reel structure provides protective support for cables before they are removed from packaging. Cables are pre-positioned in organized, supported configurations on the reel that prevent bending, kinking, or mechanical damage during storage and handling, rather than being loosely bundled where they can be damaged.
Solution Approach 2:
The invention uses disposable or replaceable tie-wraps and protective elements on the reel that can be easily applied and removed. These inexpensive protective components prevent cable damage during packaging and can be replaced if damaged, protecting the more valuable cable itself.
Data Source
AI summary
A connecting device for connecting runs of communication material having a predetermined length and coupling elements at both ends is provided. The connecting device includes a first end, an opposing second end, and a separating element. The first end couples to a coupling element of a first run of communication material and the second end couples to a coupling element of a second run of communication material. The first run and second run of communication material is separated in response to activation of the separating element. Also provided is a bulk cable packaging system that includes a plurality of runs of communication material, each run having a predetermined length and coupling elements at both ends and a plurality of connecting devices. The runs of communication material are coupled together with the connecting devices is operatively coupled to a reel. The reel is then operatively coupled within a container.