WO2005081846A2

WO2005081846A2 - Devices for dispensing wire

Info

Publication number: WO2005081846A2
Application number: PCT/US2005/005003
Authority: WO
Inventors: Steven J. King; Scott A. King
Original assignee: King Electrical Contractors, Llc
Priority date: 2004-02-20
Filing date: 2005-02-17
Publication date: 2005-09-09
Also published as: WO2005081846A3; US20050184190A1

Abstract

A dispenser for retaining electrical wire by standing on a floor or mounting on a wall stud, the dispenser has a support assembly for providing a base for use on a floor, a bracket assembly for coupling to a wall stud and a central mast assembly for holding the electrical wire. The central mast assembly selectively mount upright upon the support assembly and the bracket assembly.

Description

DEVICES FOR DISPENSING WIRE

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority to U.S. Provisional Patent Application No. 60/546,478, filed February 20, 2004 which is incorporated herein by reference. BACKGROUND OF THE INVENTION

1. Field of the Invention [0002] The subject disclosure relates to improved devices for storing and dispensing wire and cable, and more particularly to systems for efficiently storing, displaying, transporting and using the improved devices.

2. Background of the Related Art [0003] Use of dispensers having spindles for holding wire or cable has been widely used and well understood in the art. The prior art dispenser is purchased as a rigid, fully assembled product. The connections and joints between the components are often welded or otherwise not removably attached so that packaging for shipment and display is cumbersome. As a result, freight costs become prohibitive. Further, the number of packages that fit on a shipping palette or shelf is so undesirably limited that sales and distribution are significantly hampered. The same bulkiness prevents retailers from stocking the dispensers in any quantity at the distribution centers and retail outlets. As a result, delay in delivering ordered products often occurs. Such assemblies are difficult to promote, market and merchandise. Moreover, after purchase, contractors cannot easily store and transport the wire cart. [0004] Thus, there is a need for an improved wire and/or cable dispenser that can be easily transported and assembled while assuring adequate structural integrity when assembled.

SUMMARY OF THE INVENTION [0005] It is an object of the subject disclosure to provide a wire dispenser that can be easily mounted on a wall or floor as desired. [0006] It is an object of the subject disclosure to provide a wire dispensers herein as a kit in a box or bag that can be efficiently displayed, transported and assembled. [0007] It is another object of the subject disclosure to provide a device that can dispense wire from spools but be disassembled for storage, transport and display. [0008] One embodiment of the subject disclosure is directed to a dispenser for retaining electrical wire by standing on a floor or mounting on a wall stud, the dispenser has a support assembly for providing a base for use on a floor, a bracket assembly for coupling to a wall stud and a central mast assembly for holding the electrical wire. The central mast assembly selectively mount upright upon the support assembly and the bracket assembly. [0009] Another embodiment of the subject disclosure is directed to a caddy for spools of electrical wire having an elongated base portion defining a longitudinal axis and first and second upstanding frame portions extending from the elongated base, respectively. A handle portion extends between and releasably secured to the first and second upstanding frame portions. First and second reel shaft members, substantially along the longitudinal axis, mount on the first and second upstanding frame portions, respectively, such that a plurality of spools can be retained thereon. [0010] Still another embodiment of the subject disclosure is directed to a cart for storing and dispensing wire including a pair of opposing support frame portions, each support frame having a distal end and a proximal end. A first frame connector portion extends between and releasably secures to the distal ends of the pair of support frame portions. A second frame connector portion extends between and releasably secures to the proximal ends of the pair of support frame portions. An axle extends between and releasably secures to the proximal ends of the pair of support frame portions. First and second wheels disposed on each end of the axle allow rolling the cart and two reel shaft members extend from the first frame connector portion to the second frame connector portion such that a plurality of coiled cables can be retained thereon, wherein the reels can be removed for storage and loading coiled cables thereon. [0011] It should be appreciated that the present invention can be implemented and utilized in numerous ways. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0012] So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings. [0013] Figure 1 illustrates a perspective view of a dispenser of electrical wire mounted on a wall stud in accordance with the subject disclosure. [0014] Figure 2 illustrates a perspective view of the dispenser of Figure 1 mounted on a floor. [0015] Figure 3A illustrates a side view of a frame plug of the dispenser of Figure 1. [0016] Figure 3B illustrates a cross-sectional view of the frame plug of Figure 3A. [0017] Figure 3C illustrates a top, partial cross-section view of the frame plug of Figure 3 A. [0018] Figure 4 illustrates a perspective view of a loaded caddy for electrical wire that can be easily hand carried and efficiently packaged in accordance with the subject disclosure. [0019] Figure 5A illustrates a side view of the caddy of Figure 4 without any spools loaded thereon, [0020] Figure 5B illustrates a top view of the caddy of Figure 5A. [0021] Figure 5C illustrates an end view of the caddy of Figure 5A. [0022] Figure 6 illustrates a perspective view of a wire handling cart for transporting and dispensing electrical wire that can be easily packaged, transported and stored in accordance with the subject disclosure. [0023] Figure 7 illustrates the components of the cart of Figure 6. [0024] Figure 8 illustrates a perspective view of another wire handling cart for transporting and dispensing electrical wire that can be easily paclcaged, transported and stored in accordance with the subject disclosure. [0025] Figure 9 illustrates the components of the cart of Figure 8. [0026] Figure 10 illustrates a perspective view of another dolly type wire handling cart for transporting and dispensing electrical wire that can be easily packaged, transported and stored in accordance with the subject disclosure. [0027] Figure 11 illustrates the components of the cart of Figure 10. [0028] Figure 12 illustrates a perspective view of another wire handling cart for transporting and dispensing electrical wire that can be easily packaged, transported and Stored in accordance with the subject disclosure. [0029] Figure 13 illustrates a side view of the wire handling cart of Figure 12. [0030] Figure 14 illustrates the components of the cart of Figure 12.

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RECTIFIED SHEET (RULE 91* DETATLED DESCRD7TION OF PREFERRED EMBODIMENTS [0031] The present invention overcomes many of the prior art problems associated with wire and cable dispensers. The advantages, and other features of the system disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements whenever possible. [0032] Referring now to Figures 1 and 2, a dispenser 100 capable of mounting on a wall stud 110 (Figure 1) or being converted to stand upright on a floor (Figure 2) is shown. The dispenser has a central mast assembly 102 for supporting a plurality of arms 104. The arms 104 cradle a coil of wire. In other words, a wire is simply wrapped into a circular shape and placed over the central mast assembly 102. The central mast assembly 102 includes a central post 106 with a sleeve 108 rotatably mounted thereon. Preferably, the central post 106 is circular in cross-section while the sleeve 108 is square. When mounted on a wall stud 110, the central post 106 threadably engages a bracket assembly 120. When standing on the floor, the central post 106 threadably engages a support assembly 140. In each case, a hitch clip 112 may retain the sleeve 108 on the central post 106 such that the axial mast can freely rotate about the central axis. When loaded with coiled wire, an end of the wire is fed through a wire guide 116 attached to the central mast assembly 102. The wire guide 116 may be fixed in place but is preferably allowed to rotate about the central post 106. In another embodiment, one or more collars allow stacking one or more additional central mast assemblies upon the first central mast assembly 102 so that multiple coils of different wire may be placed thereon. [0033] Referring to Figure 1, the bracket assembly 120 has a branch 122 that defines a hole on a distal end 124 for threadably engaging the central post 106. A proximal end 126 of the branch 122 has opposing hooks 128 for selectively mounting on the wall stud 110. Preferably, the relationship between the hooks 128 is fixed to attach to a 2" x 4" or 2" x 6" wall stud. Alternatively, the hooks 128 can be adjustable to accept variable size wall studs. A brace 132 extends from one of the hooks 128 toward the distal end 124 to further support the dispenser 100. The hooks 128 allow easy coupling to the wall stud 110 without fasteners. As a result, the dispenser 100 can be quickly moved from location to location as desired by the user. Similarly, the central mast assembly 102 can be removed from the bracket assembly 120 and attached to the support assembly 140 for placement on the floor. [0034] Referring to Figure 2, the support assembly 140 is a main tube 142 that defines a hole to threadably receive the central post 106. The main tube 142 is supported by three additional tubes 144 so that a stable base is provide to the dispenser 100. Preferably, the support assembly 140 has a plurality of non-marking feet (not shown) attached at various locations. It is envisioned that both the bracket assembly 120 and support assembly 140 could be varied considerably while still performing the desired function to accomplish the goals of the preferred embodiment. [0035] Still referring to Figures 1 and 2, the plurality of arms 104 for retaining coiled cables extend from and are releasably secured to the sleeve 108. The arms 104 form buttons on the proximal ends that insert into slotted holes formed in the sleeve 108. As shown in Figures 3A-3C, a sleeve plug 160 preferably retains the arms 104 within the sleeve 108. In a preferred embodiment, a frame plug 160 is inserted in both ends of the sleeve 108. The frame plug 160 has deflectable ears 162 that protrude in the slotted key holes formed in the sleeve 108. A protruding circular portion 164 fills most of the slotted key holes. To insert or remove the arms 104, the proximal ends of the arms 104 are forced pass the deflectable ears 162 that deflect to temporarily provide clearance for the proximal ends of the arms 104. [0036] The sleeve plug 160 also forms a central opening 166. The central openings 166 of each sleeve plug 160 pass over the central post 106. Thus, the sleeve 108 remains centered about the central post 106 while being allowed to freely rotate. Preferably, the frame plug is nylon, h a preferred embodiment, a wire is coiled directly on to the rotating arms 104. In another embodiment, the arms may be fixed in place such that spools of wire may be placed thereon. It is envisioned that the axial mast may be selectively fixed in place or rotate depending on configuration of the surroundings. [0037] Referring to Figure 4, an exemplary portable caddy for eight spools 250 or coiled cables of wire is shown and referred to generally by the reference numeral 200. It is envisioned that the caddy 200 may be configured to support more or less spools 250 as would be appreciated by those of ordinary skill in the art. Preferably, the caddy 200 is sized and configured to be easily carried by a person. [0038] Referring to Figure 5A-5C, the portable caddy 200 has an elongated base portion 202 for stabilizing the caddy 200 on the floor and a handle 204 for easy carrying. The elongated base 202 consists of two rails 206 having plastic end caps (not shown). An upstanding frame portion 210 is welded to each of the rails 206. In another embodiment, the upstanding frame portions 210 are releasably coupled to the rails by a friction fit, bolt, clip, spring-loaded button with corresponding hole or other means lαiown to those of ordinary skill in the art. A reel shaft 212 mounted substantially along the longitudinal axis on each of the upstanding frame portions 210. Preferably, the reel shafts 212 are welded to the respective upstanding frame portion 210. In another embodiment, the reel shaft 212 is selevtively fixed to the upstanding frame portion 210. For example, the reel shaft 212 may define a hole for receiving a set screw or other mechanism. The reel shafts 212 retain a plurality of spools 250 or coiled cables. Pin clips 214 are selectively disposed in holes on the reel shafts 212 to prevent the spools 250 from falling off or moving undesirably during use. Preferably, the pin clips 214 mount so as to substantially maintain spacing between adjacent spools 250. [0039] A handle portion 204 extends between the upstanding frame portions 210. The handle 204 preferably forms a notch 220 for receiving the upstanding frame portions 210. Fastening means such as a nut and bolt or other mechanism releasably connect the handle 210 to the upstanding frame portions. As a result, the caddy 200 can be easily broken down into subparts with hardware for storage, transport and display. In a preferred embodiment, the sub parts are the handle 204 and two sub assemblies, each sub assembly consisting of an upstanding frame portion 210 with a rail 206 and reel shaft 212 coupled thereto. Of course, in alternative embodiments, the caddy 200 could be further disasssembled as desired. In still another embodiment, one or more portions, such as the rails 206 and reel shafts 212, telescope or are differently sized such that a further reduction in size may be accomplished. [0040] Referring now to Figure 6, a cart 300 for storing and dispensing wire is illustrated. Preferably, the cart 300 is fabricated susbtantially from steel that is powder coated. Zinc plating can also be utilized to further improve the wear characteristics of the cart 300. In one embodiment, the cart 300 is sized and configured to hold twelve spools (not shown) of 7" diameter by 5" width or six spools of 7" diameter by 10" width. [0041] Referring now to Figures 6 and 7, the cart 300 includes a pair of opposing support frame portions 302. For simplicity, only one component is shown in Figure 7 when the components are the same. Each support frame portion 302 has a distal end 304 and a proximal end 306. A first frame connector portion 308 extends between and releasably secures to the distal ends 304 of the support frame portions 302. A second frame connector portion 310 extends between and releasably secures to the proximal ends 306 of the support frame portions 302. Preferably, the frame portions 308 and the connector portions 310 are interchangeably with each other. In one embodiment, spring-loaded push buttons on the frame connector portions 308, 310 engage holes formed in the support frame portions 302 to accomplish the releasable securement. As a result, a solid frame can be formed for use but can be easily broken down for storage, display and transport. [0042] An axle 312 extends between and releasably secures to the support frame portions 302. A pair of wheels 314 mount on the axle 312 for rolling the cart 300. Preferably, cotter pins (not shown) retain the wheels 314 and, thereby, the axle 312 in place. An elongated handle 320 releasably connects to the frame connector portions 308, 310. Each end of the handle 320 has rubber grips 322. In a preferred embodiment, threaded bolts engage holes formed in the connector portions 308, 310, respectively, and provide posts to receive holes formed in the handle 320. The posts 334 define throughbores so that cotter pins (not shown) can effectively secure the handle 320 thereon. As a result, the cart 300 can rest on the floor or be lifted from the distal end to roll on the wheels 314. [0043] To support the spools, two reel shafts 330 extend from the first frame connector portion 308 to the second frame connector portion 310 such that a plurality of spools can be retained thereon. The reel shafts 330 are held in place by hitch pins (not shown) such that the reel shafts 332 can be removed for storage and loading coiled cables or spools thereon. As would be appreciated by those of ordinary skill in the pertinent art, the cart 300 can be disassembled into a very small box or bag for shipment, display, storage and transport. It is envisioned that the reel shafts 330 may be removed and one or more larger spools may be mounted directly onto the handle 320. [0044] Referring to Figure 8, a cart 400 for storing and dispensing wire is illustrated. In one embodiment, the cart 400 is sized and configured to hold six spools (not shown) up to 18" in diameter. Referring now to Figure 9 as well, the cart 400 includes a support frame 402 for attaching various components thereto. In an alternative embodiment, the support frame 402 consists of two or more pieces that frictionally engage so that the support frame 402 can be reduced in size when desired. The support frame 402 has a fixture 404 that receives a wheel axle 406. Bolts or like fastening means (not shown) pass through holes 408 in the wheel axle 406 to secure the wheel axle 406 to the support frame 402. A pair of wheels 412 mount on the axle 406 to facilitate rolling the cart 400. Preferably, cotter pins (not shown) retain the wheels 412 in place. The support frame 402 also has a protuberance 414 that receives a swivel locking caster 416. The protuberance 414 defines a hole 418 that aligns with a hole 420 formed in the caster 416. The aligned holes 418, 420 receive a clevis pin 422 that can be held in place by a cotter pin (not shown). As a result, the cart 400 can rest on the floor in a locked or unlocked position, or rolled to a desired location. [0045] To support the spools, three reel axle pair assemblies 450 are mounted to the support frame 402. Each axle pair assembly 450 includes two complimentary arms 452. Each arm 452 has a shoulder 454 that couples to a semi-circular shell 456. The semicircular shells 456 couple onto opposing sides of the support frame 402 by fasteners (not shown) in holes 436 of the support frame 402. In another embodiment, the semi-circular shells 456 have locating pins to help position and facilate assembly. Upon placing spools on the arms 452, the wires can be passed through one of two wire guides 460 formed on the support frame 402. In operation, the cart 400 is loaded with spools and rolled to the desired location. For storage, display and transport, the cart 400 is easily disassembled and packed in a relatively reduced size package. [0046] Refering now to Figure 10, a cart 500 for storing and dispensing wire is illustrated. In one embodiment, the cart 500 is sized and configured to hold six spools (not shown) up to 16" in diameter or fifteen spools of about 7" in diameter. Referring now to Figure 11 as well, the cart 500 has a pair of opposing support frame portions 502. For simplicity, only one component is shown in Figure 11 when the components are the same. Each support frame portion 502 has a distal end 504 and a proximal end 506. A top frame connector 508 extends between and releasably secures to the proximal ends 506 of the support frame portions 502. A bottom frame connector 510 extends between and releasably secures to the distal ends 506 of the support frame portions 502. Preferably, two straight frame connectors 515 extend between the opposing frame portions 502 to add further structural support to the cart 500. In one embodiment, spring-loaded push buttons (now shown) on the top frame connector 508, bottom frame connector 510 and straight frame connectors 515 engage holes formed in the support frame portions 502 to accomplish the releasable securement. As a result, a solid frame can be formed for use but can be easily broken down for storage, display and transport. As would be appreciated by those of ordinary skill in the pertinent art, the cart 500 can be disassembled into a very small box or bag. [0047] An axle 512 extends between and releasably secures to the near the distal ends 504 of the support frame portions 502. A pair of wheels 514 mount on the axle 512 for rolling the cart 500. A user can lift the top frame connector 508 to roll the cart 500 on the wheels 514. When at rest, the cart 500 is stable on the floor in either of two positions by resting on the bottom frame connector 510, the upright position, or by resting on the wheels 514 and the support frame portions 502, the prone position. [0048] To support the spools, five reel shafts 530 extend between the support frames 502 such that a plurality of spools can be retained thereon. The reel shafts 530 are held in place by hitch pins (not shown) such that the reel shafts 530 can be removed for storage and loading coiled cables or spools thereon. In a preferred embodiment, the reel shafts 530 have a plurality of holes formed therein for receiving hitch pins such that spacing between reels can be varied and maintained as desired. In use, the wire is fed through a wire guide 550 formed on the top frame connector 508. [0049] Referring to Figures 12 and 13, a cart 600 for storing and dispensing wire is illustrated. In one embodiment, the cart 600 is sized and configured to hold ten spools (not shown) up to 18" in diameter and still fit through a 36" doorway. Referring now to Figure 14 as well, the cart 600 includes a base 602 for attaching various components thereto. In an alternative embodiment, the base 602 consists of two or more pieces that frictionally engage so that the support frame 602 can be reduced in size when desired. [0050] The base 602 defines a central opening 604 that receives an axial mast 606 in an upstanding manner. A cotter pin (not shown) or like fastening means secures the axial mast 606 to the base 602 so that the axial mast 606 may rotate about its axis. In another embodiment, the axial mast 606 threads into the base 602. The axial mast 606 has a plurality of locations 608 for receiving spindle assemblies 610. The spindle assemblies 610 can attach to the locations 608 by bolts, threads and like fastening means. In another embodiment, a plurality of holes in the axial mast 606 allow varying the configuration of where the spindle assemblies 610 are mounted. Preferably, the attachment leaves the spindle assemblies 610 upwardly angled so that the wire spools are normally urged in place. Wheels 630 mount on the base 602 to facilitate rolling the cart 600. Preferably, at least one of the wheels 630 has a locking feature 632. As a result, the cart 600 can rest on the floor in a locked or unlocked position, or rolled to a desired location. [0051] A wire guide 612 extends from one of the spindle assemblies 610 and is secured in place by an adjustable bracket 614. By adjusting the mounting of the adjustable bracket 614, the angle at which the wire passes through the wire guide 612 can be varied. For example, when passing wire directly through a drop ceiling, an upward angle helps reduce friction. When the axial mast 606 rotates, the relationship between the spindle assemblies 610 and the wire guide 612 is maintained. The wire guide 612 also includes a collar 618 for selectively coupling to a handle 616. The handle 616 is rotatably connected to a collar 620 on the base 602 at one end 622, and able to couple to the handle 616 at the other end 624. As a result, the axial mast 606 may be fixed in place by capturing the top end 624 of the handle 616 in the collar 618 of the wire guide 612. When not captured, the axial mast 606 is free to rotate. By rotating, the axial mast 606 self-adjusts to facilitate wire removal. In one embodiment, a captive pin (not shown) is used to selectively couple the handle 616 to the wire guide 612. For storage, display and transport, the cart 600 is easily disassembled and packed in a relatively reduced size package. [0052] In alternative embodiments, the devices herein are fabricated from lightweight plastic such as, for example, polyvinyl chloride (PVC) and acrylic, wood, aluminum, like materials now known and later developed, and combinations thereof. Further, alternative structures may be employed to form the base and other components. For example, tripod arrangements, telescoping components and solid panels would all form acceptable bases and supports. Although each device was described as having particular application to hold certain sizes and quantities of spools, those skilled in the art will readily appreciate that any number of spools may be advantageously stored and utilized. [0053] While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention as defined by the claims.

Claims

WHAT IS CLAIMED IS:

1. A dispenser for retaining electrical wire by standing on a floor or mounting on a wall stud, the dispenser comprising: a support assembly for providing a base for use on a floor; a bracket assembly for coupling to a wall stud; and a central mast assembly for holding the electrical wire, the central mast assembly capable of being selectively mounted upright upon the support assembly and the bracket assembly.

2. A dispenser as recited in Claim 1, further comprising at least one arm releasably secured to the central mast assembly.

3. A dispenser as recited in Claim 2, further comprising a frame plug inserted in the central mast assembly for retaining the at least one arm within a slotted hole formed by the central mast assembly

4. A dispenser as recited in Claim 3, the frame plug being nylon and having deflectable ears that extend at least parially into the slotted hole.

5. A dispenser as recited in Claim 3, wherein the at least one arm forms a button head on an end inserted within the slotted hole.

6. A dispenser as recited in Claim 1, further comprising a wire guide connected to the central mast assembly.

7. A caddy for spools of electrical wire comprising: a) an elongated base portion defining a longitudinal axis; b) first and second upstanding frame portions extending from the elongated base, respectively; c) a handle portion extending between and releasably secured to the first and second upstanding frame portions; and d) first and second reel shaft members, substantially along the longitudinal axis, mounted on the first and second upstanding frame portions, respectively, such that a plurality of spools can be retained thereon.

8. A caddy as recited in Claim 7, further comprising a plurality of pin clips disposed on the first and second reel shaft members for retaining the plurality of spools.

9. A caddy as recited in Claim 7, wherein the elongated base further includes first and second rails selectively mounted to the first and second upstanding portions, respectively.

10. A caddy as recited in Claim 7, wherein the first and second reel shaft members releasably mount to the first and second upstanding frame portions.

11. A cart for storing and dispensing wire comprising: a) a pair of opposing support frame portions, each support frame having a distal end and a proximal end; b) a first frame connector portion extending between and releasably secured to the distal ends of the pair of support frame portions; c) a second frame connector portion extending between and releasably secured to the proximal ends of the pair of support frame portions; d) an axle extending between and releasably secured to the proximal ends of the pair of support frame portions; e) first and second wheels disposed on each end of the axle for rolling the cart; and f) two reel shaft members extending from the first frame connector portion to the second frame connector portion such that a plurality of coiled cables can be retained thereon, wherein the reels can be removed for storage and loading coiled cables thereon.

12. A cart as recited in Claim 11, further comprising a handle releasably connected to at least one of the frame connector portions.

13. ■ A cart as recited in Claim 11, further comprising push buttons on the frame connector portions for engaging holes formed in the opposing support frame portions.