Flexible extruded cable molding system, methods, and tools

Abstract

A molding system includes a flexible cable carrier body that defines a sealing opening that provides access to an interior channel. A continuous length of the flexible cable carrier body is wrapped about a spool for storage and for ease of dispensing at a work site. The continuous length of the cable carrier body is cut to desired custom lengths during installation at the work site. An insertion tool having a plow and feeder channel can facilitate payoff of the fiber/cable into the cable carrier body.

1 . A method of manufacturing and storing cable molding, the method comprising the steps of:
 a) extruding a cable carrier body, the extruded cable carrier body defining an enclosed interior channel, the extruded cable carrier body being made of a flexible material;   b) cutting an opening in the cable carrier body that provides access to the enclosed interior channel;   c) applying an adhesive backing to a mounting surface of the cable carrier body; and   d) after cutting the opening and applying the adhesive backing, wrapping a continuous length of the extruded cable carrier body around a spool.   
     
     
         2 . The method of  claim 1 , wherein the step of wrapping a continuous length around the spool including wrapping a continuous length of about 500 feet around the spool. 
     
     
         3 . The method of  claim 1 , wherein the step of extruding the cable carrier body includes extruding a cable carrier body having a square cross-sectional shape. 
     
     
         4 . The method of  claim 3 , wherein the step of applying the adhesive backing includes applying the adhesive backing to a selected one of three mounting surfaces of the extruded cable carrier body. 
     
     
         5 . The method of  claim 1 , wherein the step of extruding the cable carrier body includes extruding a cable carrier body having a quarter-round cross-sectional shape. 
     
     
         6 . The method of  claim 5 , wherein the step of applying the adhesive backing includes applying the adhesive backing to a selected one of two mounting surfaces of the extruded cable carrier body. 
     
     
         7 . The method of  claim 1 , wherein the step of cutting the opening includes cutting the cable carrier body such that the opening is defined by a non-linear cut, the non-linear cut extending from an exterior surface of cable carrier body to the interior channel. 
     
     
         8 . The method of  claim 7 , wherein the step of cutting the opening further includes cutting the cable carrier body such that first and second projections are formed in first and second closing portions of the cable carrier body, the first protrusion and the second protrusion being aligned between the interior channel and the exterior surface to create a labyrinth type seal that encloses the interior channel. 
     
     
         9 . A method of installing a cable molding system, the method comprising the steps of:
 a) providing an extruded cable carrier body defining an enclosed interior channel and an opening that provides access to the enclosed interior channel, the extruded cable carrier body being made of a flexible material, a continuous length of the extruded cable carrier body being wrapped around a spool;   b) dispensing a portion of the continuous length of the extruded cable carrier from the spool;   c) securing the cable carrier body to an existing surface;   d) cutting the extruded cable carrier body to a desired length; and   e) inserting a cable within the interior channel of the cable carrier body;   f) wherein the opening of the cable carrier body recovers after insertion of the cable to enclosed the interior channel.   
     
     
         10 . The method of  claim 9 , wherein the step of securing includes securing the cable carrier body to an existing exterior surface of a building. 
     
     
         11 . The method of  claim 9 , wherein the step of securing includes securing the cable carrier body to an existing interior surface of a building. 
     
     
         12 . The method of  claim 9 , wherein the step of securing includes adhering at least a first exterior mounting surface of the cable carrier body to the existing surface. 
     
     
         13 . The method of  claim 12 , wherein the step of providing includes providing a extruded cable carrier body having a mounting surface, the mounting surface including an adhesive backing material provided thereon. 
     
     
         14 . The method of  claim 9 , wherein the step of inserting the cable includes opening the opening of the cable carrier body with a plow tool. 
     
     
         15 . The method of  claim 9 , wherein the step of securing includes bending the cable carrier body along a non-linear pathway. 
     
     
         16 . The method of  claim 15 , wherein the step of bending includes bending the cable carrier body in a first curving configuration, wherein a mounting surface of the cable carrier body is mounted to an existing curved surface. 
     
     
         17 . The method of  claim 15 , wherein the step of bending includes bending the cable carrier body in a second curving configuration, wherein a mounting surface of the cable carrier body is mounted to an existing planar surface. 
     
     
         18 . The method of  claim 9 , wherein the step of providing including providing a continuous length of about 500 feet of the extruded cable carrier body. 
     
     
         19 . The method of  claim 9 , wherein the step of providing including providing a extruded cable carrier body having a square cross-sectional shape. 
     
     
         20 . The method of  claim 19 , wherein the step of securing includes securing a selected one of three mounting surfaces of the extruded cable carrier body to the existing surface. 
     
     
         21 . The method of  claim 9 , wherein the step of providing including providing a extruded cable carrier body having a quarter-round cross-sectional shape. 
     
     
         22 . The method of  claim 21 , wherein the step of securing includes securing a selected one of two mounting surfaces of the extruded cable carrier body to the existing surface. 
     
     
         23 . A cable molding system, comprising:
 an extruded cable carrier body defining an enclosed interior channel, the cable carrier body having at least a one planar, exterior mounting surface, the cable carrier body defining a sealing opening that provides access to the enclosed interior channel, the extruded cable carrier body being made of a flexible material that permits a continuous length of the extruded cable carrier body to be wrapped around a spool.   
     
     
         24 . The cable molding system of  claim 23 , wherein the extruded cable carrier body has a continuous length of about 500 feet. 
     
     
         25 . The cable molding system of  claim 23 , wherein the extruded cable carrier body has a square cross-sectional shape. 
     
     
         26 . The cable molding system of  claim 25 , wherein the extruded cable carrier body has three planar, exterior mounting surfaces, the opening being formed in a non-mounting surface of the body. 
     
     
         27 . The cable molding system of  claim 26 , wherein the interior channel is centrally located in the extruded cable carrier body. 
     
     
         28 . The cable molding system of  claim 23 , wherein the extruded cable carrier body has a quarter-round cross-sectional shape. 
     
     
         29 . The cable molding system of  claim 28 , wherein the extruded cable carrier body has two planar, exterior mounting surfaces, the opening being formed in a non-mounting surface of the body. 
     
     
         30 . The cable molding system of  claim 29 , wherein the non-mounting surface of the body is a convexly curved surface. 
     
     
         31 . The cable molding system of  claim 23 , wherein the sealing opening includes a labyrinth structure, the labyrinth structure being defined by a non-linear cut in the cable carrier body, the non-linear cut extending from an exterior surface of cable carrier body to the interior channel. 
     
     
         32 . The cable molding system of  claim 31 , wherein in the non-linear cut defines a first protrusion formed in a first closing portion of the cable carrier body and a second protrusion formed in a second closing portion of the cable carrier body, the first protrusion and the second protrusion being aligned between the interior channel and the exterior surface to create a labyrinth type seal that encloses the interior channel. 
     
     
         33 . The cable molding system of  claim 23 , further including an adhesive backing material provided on the one planar, exterior mounting surface of the cable carrier body. 
     
     
         34 . The cable molding system of  claim 23 , wherein the flexible material of the cable carrier body permits an installer to mount the cable carrier body in a first curving configuration such that first exterior mounting surface of the cable carrier body is mounted to a curved existing surface, and mount the cable carrier body in a second curving configuration such that first exterior mounting surface of the cable carrier body is mounted to a planar existing surface. 
     
     
         35 . An insertion tool comprising:
 a support section defining a feeder channel and a plow arrangement, the plow arrangement being configured to spread apart one or more portions of a carrier body to provide access to an internal channel, the feeder channel defining a pathway leading from an exterior of the carrier body to the internal channel of the carrier body when the plow is inserted into the carrier body; and   a handle section configured to enable manipulation of the plow arrangement by a user.   
     
     
         36 . The insertion tool of  claim 35 , wherein the support section includes a first section and a second section, each section defining a portion of the feeder channel, one of the first and second sections being pivotally moveable relative to the other of the first and second sections to provide access to an interior of the feeder channel. 
     
     
         37 . The insertion tool of  claim 36 , wherein the plow arrangement is fully defined by one of the first and second sections. 
     
     
         38 . The insertion tool of  claim 36 , wherein the first section and the second section each define about half of the feeder channel. 
     
     
         39 . The insertion tool of  claim 35 , wherein the feeder channel defines a sufficient curve to maintain a minimum bend radius. 
     
     
         40 . The insertion tool of  claim 35 , wherein the plow arrangement defines a wedge shape having a rounded tip. 
     
     
         41 . The insertion tool of  claim 35 , wherein the plow arrangement includes a blade extending along at least one edge of the plow arrangement. 
     
     
         42 . The insertion tool of  claim 41 , wherein the blade can be molded from a softer material than a remainder of the plow arrangement. 
     
     
         43 . The insertion tool of  claim 35 , wherein the handle section includes opposite planar surfaces connected by a rounded edge. 
     
     
         44 . The insertion tool of  claim 43 , wherein the opposite planar surfaces are secured together via a snap-fit connection. 
     
     
         45 . The insertion tool of  claim 35 , wherein the handle section tapers outwardly as the handle section extends away from the support section.