Device for unwinding coiled material from carton

An improved device which allows a carton of coiled wire, packaged in a way to allow the coil to be unwound from its center through a circular knockout in the carton, to rotate as the wire is being pulled out of the center knockout. As the wire is pulled it makes contact with a flared center column. The action of the wire against the center column and the pull of the wire on the coil causes the device and the carton of wire to rotate. This rotating action prevents twists and kinks in the wire and allows it to unwind easily. The device can be operated sitting on a surface, hanging from a support or held in the operators hand. The device has no parts that adjust or need to be removed in order to mount a carton of coiled wire and there is no need for the wire to be fed through a guide. The wire can be pulled at angles from near horizontal to approximately 45 degrees up off horizontal and in any direction.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The invention is an improved device for the unwinding of electrical wire, 
communication cable, or other coiled material from the cardboard carton in 
which it is typically packaged in a free flowing way without removing the 
main coil of material from the carton and without creating twists of kinks 
in the material. 
2. Description of Prior Art 
Similar devices can be described in two categories: devices that are 
suspended from a structure above the device, and devices that sit on a 
base requiring a somewhat level and smooth surface. There appears to be no 
prior art designed to operate in both a suspended position and a sitting 
position. A third position for operation of an unwinding device that has 
not been addressed by prior art is for the operator of the device to hold 
it in his/her hand during operation. 
The use of removable or adjustable parts in prior art is a disadvantage 
because they can become lost and require more set up time. Guides through 
which the material must be threaded also require more set up time and tend 
to create friction especially with some of the larger and stiffer wires, 
or softer plastic tubing. 
Tashiro, U.S. Pat. No. 2,985,404 (1961) describes a device that operates 
only sitting on a base and has no provision for moving it from one 
location to another. It also has removable parts. 
Eckert, U.S. Pat. No 3,041,006 (1962) describes a device that also only 
operates sitting on a base and has both removable parts and a guide 
through which the wire must be fed. The center column in this device does 
not rotate which causes friction as the wire moves around it. The wire 
guide is also the carrying handle but cannot function as both 
simultaneously. The wire guide also is designed for small diameter round 
wire. If the carton of wire is very heavy the handle would not be very 
comfortable to use. 
Shumake, U.S. Pat. No. 3,118,634 (1964) describes a device that also only 
operates sitting on a base, is designed primarly for small diameter round 
wire and uses two guides through which the wire has to be fed. It also has 
clamps to hold the carton in place which require all the cartons used to 
be of similar size. 
Collmann, U.S. Pat. No. 3,593,943 (1971) describes a device that also only 
operates sitting on a base and has parts that need to be removed and then 
replaced to mount the carbon of wire. The handle for carrying the device 
is threaded into the center column of the device and will tend to loosen 
when being carried. 
Marcell, U.S. Pat. No. 3,974,980 (1976) describes a device that operates in 
a suspended position only and has parts that require unfastening and 
refastening and adjusting. It also has a wire guide through which the wire 
is fed. It does not have a means to carry it from one location to another 
in operational mode. 
3. Objects and Advantages 
It should be noted that even though the present invention can be used to 
unwind a variety of materials, it is primarily intended for use with wire. 
Therefore it will be described as used in connection with wire coils but 
should be understood that the term "wire" is intended to designate any 
material that might be used with the device. 
It is the object of this invention to improve on prior devices and provide: 
(a) A device that can be operated either suspended or resting on a base. 
Sometimes, especially in remoldeling work, there is no place from which to 
hang a device. On the other hand in a muddy unfinished cellar or 
crawlspace there is often on place to set a device down, thus the need for 
a device that can operate in either position. 
(b) A device that can be operated while held in the operator's hand by the 
handle allowing the operator to move from one point to another reeling out 
the coiled wire. This has a great advantage when working in situations 
where pulling or dragging the uncoiled wire across rough, abrasive, muddy 
or uneven surfaces might cause damage to the wire. 
(c) A device that has no parts that need to be removed, unfastened, or 
adjusted to mount or unmount coiled wire in its carton or to operate the 
device, thus reducing loose or lost parts and reducing the time required 
to change cartons. 
(d) A device that does not require the wire to be threaded through a guide 
allowing for a wider range of materials to be used and also making 
changing cartons easier and faster. 
The device (1) has no parts that need to be removed or adusted to mount a 
carton of wire or to operate; (2) dispenses wire without the need of a 
wire guide through which the wire must be threaded: (3) can be operated 
siting on a surface, suspended, or held in the operators hand; and (4) has 
a comfortable handle to use in transporting the wire from one location to 
another. Field testing revealed no need for a braking mechanism to prevent 
overspinning. The hand-held method allows the operator to walk along as 
the coil turns, reeling out the wire as is necessary when placing it in a 
ditch, for example, without having to drag the wire along the ditch or 
along the ground causing possible damage to the wire or its protective 
cover. 
SUMMARY OF THE INVENTION 
The improved device that allows the unwinding of coiled wire from the 
cardboard carton in which it is packaged is characterized by the fact that 
it can be operated in any of three positions: (1) sitting on the floor or 
other surface, (2) held in the hand to reel out wire as the operator walks 
along, or (3) hangng from a floor joist or other overhead support. It also 
has no parts that need to be removed or adjusted in order to mount the 
carton or operate the device. Finally it does not require the wire to be 
fed through a guide thereby reducing friction, minimizing set-up time and 
allowing the wire to be pulled in any direction from the device. 
The improved device is also characterized by the shape of the center column 
and by the retractable handle and bearing. The flared shape of the center 
column keeps the wire from climbing over the top of the column as it is 
pulled. The bearing on the handle allows the device to turn when it is 
suspended or while it is being held. The fact that the handle retracts out 
of the way into the center column allows the top of the column to be used 
as the template for the holes in the carton and makes the unit more 
compact and damage resistant when not in use. 
Other objects, features, and characteristics of this invention, as well as 
the functions of other elements of the device, methods of operation, and 
the combination of parts and the economies of manufacture, will become 
apparent as the reader considers the following descriptions, accompanying 
drawings and claims.

DESCRIPTION OF FIGURES 1 TO 8 
Referring now to FIG. 2 specifically, where all major parts of the device 
can be viewed in the cross section, the device sits on a circular 
base(10). A circular carton support (12) with a center column (17), 
comprised of an upper portion (14) and a lower portion (16), fastened to 
the carton support (12) by a bolt (18) and a locknut(24), sits on a 
turntable bearing(20) which sits on circular base(10). Turntable 
bearing(20) is held in position by a shoulder(22) of base(10). Base(10) is 
held in position on bolt(18) by a locknut(24a). Locknut (24a) holds 
base(10) in position but is not tight against it to allow rotation of the 
device on turntable bearing(20). A handle grip(30) and a handle strap(38) 
are mounted on bolt(18) with a bearing(28) allowing rotation of the device 
when handle grip(30) is held in fixed position. A groove(32) in handle 
grip(30) provides a center of gravity positioning of a suspension 
hook(48), illustrated in FIG. 1, from which the entire device can be hung. 
A collar(26) holds bearing(28) up under the head of bolt(18) up under the 
head of bolt(18). A hold in handle strap(38) which is just larger than the 
outside diameter of collar (26) allows handle strap(38) to move up and 
down along collar(26). 
FIG. 3 shows handle grip(30) and handle strap(38) in retracted position. 
FIG. 4, shows an enlarged, exploded perspective view of portion of handle 
grip(30) and portion of handle strap(38). FIG. 5, a perspective view of 
the first embodiment, shows the circular shape of base(10) and carton 
support(12). FIG. 6, is a vertical section of a second embodiment of the 
device, and FIGS. 1 and 8, perspective views of the second embodiment, 
show a flat and square carton support(40) fastened to turnable bearing(20) 
which is fastened to a flat and square base(42) with small screws. FIG. 7, 
is an enlarged portion of FIG. 2 or 5 showing vertical section of bolt 
(18), collar(26), bearing(28), and part of handle strap (38), upper column 
portion (14) and lower column portion (16). 
The base (10), the coil and carton suppport (12) and the center column (17) 
may be formed of molded material with the coil and carton support (12) and 
the center column (17) being molded as a single unit. 
OPERATIONAL DESCRIPTION OF FIGURES 
A carton of wire(44), shown in FIG. 1, is prepared for mounting on the 
device by cutting a hole in the top and bottom center of carton(44). The 
size of the hole should be the same as outside diameter of the top of 
center column(17). The top of center column(17) can be traced as a 
template. Some cartons already have a circular knockout in the top of the 
carton. This can be used as is or it may have to be enlarged. Carton(44) 
is then placed on the device so that center column(17) extends up through 
the holes in carton(44). The hole in the bottom of carton(44) will fit 
tightly around the outside diameter of lower portion (16) of center column 
(17) keeping carton(44) centered on the device. The loose end of a 
wire(46) in the center of the coil is then pulled through the space 
between the edge of the top hole in carton(44) and upper portion (14) of 
center column (17). 
When the loaded device is operated in sitting position and wire(46) is 
pulled, it causes the entire coil of wire and carton(44) and the upper 
section of the device to rotate on turntable bearing(20). In the suspended 
position the entire device and carton(44) rotate on bearing(28), except 
for the handle strap(38) and handle grip(30) which is suspended from 
suspension hook(48) in groove(32). In the hand held position the device 
operates the same as in the suspended position except that it can be moved 
as it operates. 
When the carton(44) is removed from the device any wire left in the carton 
is still in a neat coil ready to be used at another time. 
The descriptions and specifications discussed above should not be construed 
as limiting the scope of the invention but as merely providing 
illustrations of some of the presently preferred embodiments of this 
invention. The scope of the invention should be determined by the claims 
rather thean by the examples given.