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.

What is claimed is: 
     
         1 . An apparatus for routing a communication line along a building structure, the apparatus comprising:
 an elongated extrusion defining an interior passage for receiving the communication line, the elongated extrusion having a flexible construction and being wrapped around a spool, the elongated extrusion being paid off the spool to deploy the elongated extrusion;   the elongated extrusion having a quarter-round transverse cross sectional shape, the quarter-round transverse cross-sectional shape including:
 first and second mounting surfaces oriented perpendicular relative to each other; and 
 a non-mounting structure that extends across a space between the first and second mounting surfaces to enclose the interior passage of the extrusion, the non-mounting structure including a first extension that extends from the first mounting surface toward the second mounting surface, the first extension having a base end integral with the first mounting surface, the non-mounting structure including a second extension that extends from the second mounting surface toward the first mounting surface, the second extension having a base end integral with the second mounting surface, the first and second extensions being sized such that neither the first nor the second extension extends completely across the space between the first and second mounting surfaces, the first extension being longer than the second extension, the first and second extensions meeting at an overlap region, the overlap region extending over a length that coincides with a minority of a total length of the space between the first and second mounting surfaces, the first and second extensions being configured to flex relative to one another to allow the communication line to be inserted into the interior passage of the elongated extrusion. 
   
     
     
         2 . The apparatus of  claim 1 , wherein the first extension is more than twice as long as the second extension. 
     
     
         3 . The apparatus of  claim 1 , wherein the overlap region defines a labyrinth seal. 
     
     
         4 . An apparatus for routing a communication line along a building structure, the apparatus comprising:
 an elongated extrusion defining an interior passage for receiving the communication line, the elongated extrusion having a flexible construction and being wrapped around a spool, the elongated extrusion being paid off the spool to deploy the elongated extrusion;   the elongated extrusion having a quarter-round transverse cross sectional shape, the quarter-round transverse cross-sectional shape including:
 first and second mounting surfaces oriented perpendicular relative to each other; and 
 a non-mounting structure that extends across a space between the first and second mounting surfaces to enclose the interior passage of the extrusion, the non-mounting structure including a first extension that extends from the first mounting surface toward the second mounting surface, the first extension having a base end integral with the first mounting surface, the non-mounting structure including a second extension that extends from the second mounting surface toward the first mounting surface, the second extension having a base end integral with the second mounting surface, the first and second extensions being sized such that neither the first nor the second extension extends completely across the space between the first and second mounting surfaces, the first extension being longer than the second extension, the first and second extensions meeting at an overlap region, the first extension extending across a majority of a total length of the space between the first and second mounting surfaces, the second extension extending across a minority if the total length of the space between the first and second mounting surfaces, the first and second extensions being configured to flex relative to one another to allow the communication line to be inserted into the interior passage of the elongated extrusion. 
   
     
     
         5 . The apparatus of  claim 4 , wherein the first extension is more than twice as long as the second extension. 
     
     
         6 . The apparatus of  claim 4 , wherein the overlap region defines a labyrinth seal. 
     
     
         7 . A method of routing a communication line along a building structure, the method comprising:
 providing the apparatus according to  claim 1 ;   unspooling the elongated extrusion from the spool;   securing the unspooled elongated extrusion at a predetermined location of the building structure; and   inserting the communication line into the interior passage of the elongated extrusion through the space between the first and second mounting surfaces.   
     
     
         8 . A method of routing a communication line along a building structure, the method comprising:
 providing the apparatus according to  claim 4 ;   unspooling the elongated extrusion from the spool;   securing the unspooled elongated extrusion at a predetermined location of the building structure; and   inserting the communication line into the interior passage of the elongated extrusion through the space between the first and second mounting surfaces.   
     
     
         9 . An apparatus for routing a communication line along a building structure, the apparatus comprising:
 a spool;   an elongated extrusion defining a passage for receiving the communication line, the elongated extrusion having a flexible construction and being wrapped around the spool, the elongated extrusion being paid off the spool to deploy the elongated extrusion;   the elongated extrusion including:
 at least one mounting surface configured to attach the elongated extrusion to the building structure; and 
 a non-mounting structure extending at least partially over the passage of the elongated extrusion, the non-mounting structure including first and second extensions configured to flex relative to one another to allow the communication line to be inserted into the passage of the elongated extrusion; and 
   the at least one mounting surface positioned such that the non-mounting structure is accessible when the elongated extrusion is attached to the building structure.   
     
     
         10 . A method of routing a communication line along a building structure, the method comprising:
 providing the apparatus according to  claim 9 ;   unspooling the elongated extrusion from the spool;   securing the unspooled elongated extrusion at a predetermined location of the building structure; and   inserting the communication line into the passage through the non-mounting structure of the elongated extrusion.   
     
     
         11 . An apparatus for routing a communication line along a building structure, the apparatus comprising:
 a spool;   an elongated extrusion having a flexible construction and being wrapped around the spool, the elongated extrusion being paid off the spool to deploy the elongated extrusion;   the elongated extrusion including a body, the body having first and second body portions and defining a passage for receiving the communication line, the body having a transverse cross sectional shape including:
 at least one mounting surface configured to attach the elongated extrusion to the building structure; and 
 a non-mounting structure extending at least partially across a space between the first and second body portions to at least partially cover the passage of the extrusion, the non-mounting structure including:
 a first extension that extends from the first body portion toward the second body portion; and 
 a second extension that extends from the second body portion toward the first body portion, 
 
   the first and second extensions being sized such that neither the first extension nor the second extension extends completely across the space between the first and second body portions;   the first and second extensions being configured to flex relative to one another to allow the communication line to be inserted into the passage of the elongated extrusion; and   the at least one mounting surface positioned to make the non-mounting structure accessible when the elongated extrusion is attached to the building structure.   
     
     
         12 . The apparatus of  claim 11 , wherein the first and second extensions extend across a same length of the space between the first and second body portions. 
     
     
         13 . A method of routing a communication line along a building structure, the method comprising:
 providing the apparatus according to  claim 11 ;   unspooling the elongated extrusion from the spool;   securing the unspooled elongated extrusion at a predetermined location of the building structure; and   inserting the communication line into the passage of the elongated extrusion through the space between the first and second body portions.