Abstract:
A spool includes a plurality of plates having a body and a pair of legs defining a winding area for receiving rope, wire or similar material. Each plate further includes a slot in the body and a tab extending from the body. The tab of one plate is inserted through the slot of another plate to join the various plates. The plates can pivot about their tab and slot joints such that the spool may be collapsed by disengaging one of the tab and slot joints and pivoting the plates to a generally flat position. The tabs may be provided with features such as ears or tongues to prevent undesired separation of the plates.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The present invention relates to spools for holding wire, rope and similar materials and, in particular, to a collapsible spool. 
     Numerous spools are known in the prior art. Such spools typically include a hub around which rope, wire or similar material is wound. The hub is typically bordered by flanges, walls or similar structures for containing the material in a defined area about the hub. 
     Typically, the spools are manufactured by one party and shipped to another party for use, where the desired material is wound on the spool. As with shipping other products, it is often desirable to minimize the space utilized during shipping, thereby lowering shipping costs. 
     Accordingly, it is an object of the present invention to provide a spool for winding wire, rope or similar materials. 
     Another object of the present invention is to provide a spool that reduces the amount of space needed for shipping the spool. 
     These and other objects of the present invention are attained by the provision of a spool having a plurality of plates, a slot formed in each of the plates and a tab extending from each of the plates through the slot of another one of the plates. The slots may include a plurality of segments. 
     According to one embodiment of the present invention, each of the tabs includes at least one ear formed thereon. The ears are in a first position which allows them to pass through the slots with the tabs, and are moved to a second position after the tabs are inserted through the slots. In the second position, the ears cannot be pulled back through the slots. 
     According to another embodiment of the present invention, a pair of legs extends from each of the plates. The legs include tie-off holes for securing the end of the wire or other material to the spool after it is wound thereon. 
     According to another embodiment of the present invention, each of the tabs includes a tongue thereon. Each of the tongues flexes toward the tab it is on as that tab is inserted through one of the slots. The tongues flex away from the tabs after the tabs are inserted through the slots. 
     According to another embodiment of the present invention, a lip is located adjacent each of the slots. The lips are located so as to press the tongues toward the tabs on which they are located as the tabs are inserted in the slots. The lips bend the tongues away from the tabs when the tabs are pulled back through the slots without first compressing the tongues toward the tabs. 
     According to another embodiment of the present invention, a spool comprises a first plate, a second plate and a plurality of plates pivotally joined between the first and second plates such that said spool may be pivoted between a collapsed position and an assembled position. The first and second plates include means for joining said first and second plates when the spool is in the assembled position. The means may include a tab and slot arrangement. Each plate may also include a recessed area for nesting with a corresponding area on an adjacent plate when the spool is in the collapsed position. 
     Other objects, advantages and novel features of the present invention will now be apparent to those skilled in the art from the following detailed description of the preferred embodiments and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a plate that is a component of a spool according to the present invention. 
     FIG. 2 is a perspective view of a spool according to the present invention in its collapsed state. 
     FIG. 3 is a perspective view of a spool according to the present invention in its assembled state. 
     FIG. 4 is a side plan view of the spool shown in FIG. 3. 
     FIG. 5 is an enlarged partial cross-sectional view showing the interlocking relationship among the plates that form components of a spool according to the present invention. 
     FIG. 6 is a perspective view of an alternative embodiment of a plate that forms a spool according to the present invention. 
     FIG. 7 is an enlarged partial cross-sectional view showing the interlocking relationship among the plates shown in FIG. 6 when assembled to form a spool. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 is a perspective view of a plate 1 that is a component of a spool according to the present invention. Plate 1 is preferably made from a relatively rigid, sturdy material, such as steel, and generally comprises a body 1a with a pair of legs 1b extending therefrom. Legs 1b and edge 1c of body 1a define a winding area 1d within which wire, for example, may be wound. Legs 1b are generally V-shaped to provide added strength. The V shape also allows legs 1b to nest when the spool is in the collapsed position, as described below. Legs 1b are offset from body 1a so as to form a notch 1e on each side thereof. Each leg 1b further includes a tie-off hole 1f therein. Holes 1f are used to tie off the wire or other material after it is wound on the spool, as described below. 
     Body 1a further includes a slot 1g formed therein. Slot 1g, in the embodiment shown, includes three segments: 1h, 1i and 1j. A recessed area 1k is formed between edge 1c and slot 1g. Recessed area 1k allows the various plates to nest when the spool is in its collapsed position, as described below. A lip 1l is formed adjacent slot 1g and angles away from body 1a. Lip 1l assists in holding the various plates of one embodiment of the spool together, as described below. 
     A tab 1m extends from body 1a and has a pair of ears 1n disposed on each side thereof. Tab 1m and ears 1n engage a slot corresponding to slot 1g on another plate, as described below. Body 1a further includes a pair of tie-off holes 1o therein. Holes 1o provide a means for attaching rope, wire or similar material to the spool before winding begins. Plate 1 can be manufactured by a number of methods. For example, the plates could be stamped from a sheet of steel. The offset arrangement of legs 1b of the particular embodiment of plate 1 shown in FIG. 1 allows the plates to be blanked out in a nested pattern. Body 1a, including tab 1m and ears 1n, of one plate are formed from the metal between legs 1b of the preceding plate. Legs 1b of the preceding plate terminate at notch 1e of the following plate. This reduces the amount of scrap metal generated during manufacture. 
     Turning to FIG. 2, a spool according to the present invention is shown in its collapsed state. In the particular embodiment shown, the spool consists of eight plates like those shown in FIG. 1. Corresponding letters have been used to indicate corresponding features of the differently numbered plates. 
     The spool in its collapsed state is assembled by inserting tab 1m and ears 1n through slot 2g (not shown) on plate 2. Ears 1n must be bent at such an angle as to pass through segments 2i and 2j of slot 2g. Ears 1m are then bent back to the flat position so that tab 1m and ears in cannot pull back through slot 2g, thereby disengaging plates 1 and 2. The same process is repeated for the remaining plates such that tab 2m and ears 2n extend through slot 3g, tab 3m and ears 3n extend through slot 4g, tab 4m and ears 4n extend through slot 5g, tab 5m and ears 5n extend through slot 6g, tab 6m and ears 6n extend through slot 7g, and tab 7m and ears 7n extend through slot 8g. In this collapsed position, the various plates nest with one another. For example, the opposite side of recessed area lk, which is a raised area, rests in recessed area 2k of plate 2. Similarly, legs 2b nest in legs lb. 
     To assemble a spool according to the present invention, the plates are pivoted about the tab/slot joints until tab 8m and ears 8n are adjacent slot 1g. Ears 8n are bent so that tab 8m and ears 8n generally correspond to the configuration of slot 1g. Tab 8m and ears 8n are then inserted through slot lg. Ears 8n are then bent such that tab 8m and ears 8n cannot pull back through slot lg. The assembled spool is shown in FIG. 3. A side plan view of the assembled spool is shown in FIG. 4. FIG. 5 shows a close-up, cross-sectional view of the joints between several of the plates. 
     Wire, rope or similar material may be wound on the spool by first tying one end to the spool through a tie-off hole 1o-8o. The material is then wound about edges 1c-8c between legs 1b-8b. When winding is complete, the material is tied off through one of the tie-off holes 1f-8f. 
     As shown in the figures, the spool occupies less space in its collapsed position than in its assembled position. Thus, it is advantageous to ship the empty spools to the party that will wind the wire, for example, in the collapsed position. This reduces the amount of space needed for shipping. Conversely, more spools can be shipped in a given cargo area. The user can easily assemble the spools for winding. 
     FIG. 6 shows an alternative embodiment of a plate that forms a component of a spool according to the present invention. For purposes of comparison with the prior embodiment, this plate is also identified as plate 1 and the same letter designations are used for corresponding parts. The plates in this embodiment of the invention differ form those of the prior embodiment in that ears 1n have been replaced by a tongue 1p on tab 1m. Tongue 1p is flexible and extends away from tab 1m in the opposite direction of lip 1l. 
     When assembling the spool, tab 1m is inserted through slot 2g. As this occurs, lip 2l presses against tongue 1p and causes it to flex toward tab 1m as it is inserted through slot 2g. When tongue 1p is through slot 2g, it flexes back to its original position. To disengage plates 1 and 2, tongue 1p must be pressed toward tab 1m so that it can be pulled back through slot 2g. If this is not done, tongue 1p will engage the back side of lip 2l as plates 1 and 2 are pulled apart. This causes tongue 1p to bend farther away from tab 1m and press against body 2a, thereby preventing plates 1 and 2 from being separated. A plurality of such plates would be joined, as in the prior embodiment, to form a spool. The tab and slot joint arrangement for this embodiment is shown in FIG. 7. 
     Although the invention has been illustrated and described in detail, it is to be clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation. Numerous variations may be made to the disclosed embodiments without departing from the scope of the invention. For example, in the embodiment shown in FIGS. 6 and 7, it is not necessary to include segments 1h and 1i of the slots, as no ears are present to pass through them. The tab and slot arrangements may also be varied in the number of manners. Accordingly, the spirit and scope of the invention are to be limited only by the terms of the appended claims.