Abstract:
The present invention is directed toward a device and method for hanging and distributing both spooled and non spooled products. The invention provides a means to hang a series of adjacent spools from a single axle such that any single spool can be removed and replaced without disturbing any other spool on the axle. The invention also provides a means to hang a container.

Description:
PRIORITY TO PENDING U.S. APPLICATION  
       [0001]     This application claims priority to U.S. Provisional Application 60/58,676 filing date Jul. 6, 2004, for the subject matter contained therein. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to a device and method for hanging and dispensing both spooled and non spooled products. In particular, the present invention provides a device that a) rotatingly engages a spool on first and second engagement means, and provides a means for hanging the spool and distributing product therefrom, and b) engages a container on first and second engagement means and provides a means or hanging the container and distributing product therefrom.  
       BACKGROUND OF THE INVENTION  
       [0003]     Nails, screws, pins, clips and many other loose products are shipped, stored, and distributed in containers such as bags, boxes, buckets and pails. Flexible elongated products, such as wire, tubing, rope, and chain, are commonly sold on spools made of rigid material such as plastic, metal, or wood. Both loose and spooled products are used extensively in building construction, automotive, and many other industries. In the building industry alone, millions of feet of electrical wire and millions of pounds of nails and screws are dispensed each year. Problems associated with handling and dispensing these products negatively impacts both safety and productivity.  
         [0004]     Spools can be heavy and difficult for a person to handle. For example a single plastic spool of electrical wire can weigh from twenty to one hundred fifty pounds or more. Many devices currently exist to aid in dispensing such products from their spools. Presently existing dispensing tools typically suspend the spool from a shaft or axle which is inserted into a hole in the center of the spool. The spool rotates about the shaft or axle as product is pulled from the spool. However, suspending the spools from a shaft presents safety and productivity problems that prior art devices fail to overcome.  
         [0005]     Many safety problems inherent in existing spooled product dispensing designs can be demonstrated by examining U.S. Pat. No. 5,887,819 to Korn. The Korn patent shows the typical way in which spooled products are supported for distribution: a wire spool rack includes a left side member, a right side member, and a rod; the ends of the rod are disposed in a slot defined in the left side member, and a slot defined in the right side member; spools of coiled wire are rotatingly mounted on the rod; more than one rod may be mounted in the rack, and more or less than three spools may be mounted on the rod(s). When distributing electrical wire four or five spools are typically held on a single rod. To load or change spools on the rods workers must support the weight of three or four spools while loading another. This number of spools can weigh hundreds of pounds, and often exceeds the maximum amount of weight that can be safely handled by available manpower. Each time a spool runs out of wire, each time a wire size needs to be changed, each time a wire color needs to be changed, and each time the distribution location needs to be changed, multiple spools need to be unloaded and loaded on the rods.  
         [0006]     The shape of a spool creates another safety problem which prior art devices fail to overcome. While the spool shape may be ideal for dispensing coiled products, it is less than ideal for a worker to grip and carry. In order set up or change the distribution location within a worksite, a worker must pick up each individual spool of wire and carry it to the desired location. Each time a worker carries an unsupported spool of wire he risks physical injury. If a worker looses his grip on a spool and tries to regain control he can easily suffer a muscular or skeletal injury. If a spool falls on a worker&#39;s foot, a broken bone is likely to occur. The primary way the prior art addresses the problem of moving spools from one location to another is to adapt a cart to carry spools of wire. U.S. Pat. No. 5,509,671 to Campbell describes one such device wherein a cart includes racks for holding spools. Each rack is sized to typically hold three of four spools. Spools are secured to a main bracket by slipping a tube through openings formed in the center of the spools. The spools and the tube are then raised into position. The racks are releasably secured to and selectively removable from the cart to enable the spools on the racks to be carried to a site which is remote from the cart. Devices such as that described by Campbell suffer from many of the same safety disadvantages as U.S. Pat. No. 5,887,819 to Korn described above: each time a spool runs out of wire, each time a wire size needs to be changed, and each time a wire color needs to be changed, an entire rack must be handled. A loaded rack can easily exceed the amount of weight that can be safely handled with available manpower. Additionally, a fully loaded cart can weigh six hundred pounds or more, be unbalanced, unstable, and prone to overturning. These problems make cart type spool carriers an extreme safety hazard at any work site.  
         [0007]     Devices which rely on a shaft to support multiple spools are costly in terms of productivity. On devices such as U.S. Pat. No. 4,869,344 to Peterson, U.S. Pat. No. 5,887,819 to Korn, U.S. Pat. No. 5,509,671 to Campbell and U.S. Pat. No. 4,533,091 to Knight, multiple spools ride against one another on a single axle. Spools tightly adjacent to each other on a single axle can lock together making distribution difficult. The rate at which any individual spool rotates will likely be different than the rotation rate of any adjacent spool. When a heavy spool rotates faster than an adjacent lighter spool, friction between the spools causes the lighter spool to spin too fast. This can cause the product to loop and tangle. Should excess wire become tangled about the axle, the axle must be completely unloaded and reloaded to clear the problem. Even when no problems occur, loading and unloading spools on shafts is time consuming because multiple spools must be unloaded and reloaded on a shaft whenever a single spool needs to be changed.  
         [0008]     Another productivity issue is related to spool breakage. Spools are increasingly constructed of rigid plastic. When dropped or banged these plastic spools tend to break. Most existing distribution devices require the user to carry unsupported spools of product to distribution locations. Because spools of wire are heavy and difficult to handle they are frequently dropped and broken. Spools are also frequently broken during transport to and from a work site. Spools are typically transported in open bins in the back of work trucks and vans. There is no way to position a spool so that it will be stable during such transport. Existing distribution tools do nothing to protect spools during transport. Because wire can get hung up on broken spools entire spools of wire are often discarded when the spool breaks. The cost of broken spools adds significant expense to an electrician&#39;s overhead.  
         [0009]     Another productivity related shortcoming of prior art devices is that they provide no means of distributing wire in multiple directions. In the building construction trade it is often necessary to pull a long length of wire, such as romex wire, in one direction from one location, and to later pull another length of the same wire from the same location but in a different direction. In order to change the direction of wire distribution on existing devices, the spool must be unloaded, the distribution device reoriented, and the spool reloaded on the device.  
         [0010]     Workers frequently need to distribute wire, nails, screws, and other products when working on a scaffold. In this situation the worker is presented with a major safety problem. Loose products such as nails and screws are typically distributed from containers such as bags, boxes, buckets or pails which sit on the floor of the scaffolding. Such containers create obstacles which the worker might trip on, causing the products or the worker to fall from the scaffold. There is currently no known product to keep nail, screw, or other product packages secured off the scaffold floor.  
         [0011]     When distributing wire from a scaffold, wire spools typically remain on a distribution device on the ground. Wire is then pulled up through the scaffold. Wire pulled in this manner is prone to getting tangled in the scaffold, creating a danger to all workers in the vicinity of the scaffold. Additionally, every time a spool needs to be changed, the electrician must climb off the scaffold, change the spools, and climb back up the scaffold. When climbing up the scaffold, the electrician must pull the wire as he climbs, creating an additional safety hazard. U.S. Pat. No. 6,688,550 to Mullins attempts to overcome problems associated with pulling wire from remote locations by providing a portable supply rack which is stabilized by hanging it at a desired work station. The Mullins supply rack has at least one support rod having opposite ends. Each of the opposite ends of the support rod is insertable through corresponding aligned apertures in a pair of side walls. Each of the opposite ends of the support rod includes an aperture which receives a securing member such as a clip or pin therein. In order to use such a device on a scaffold, the support rod would have to be inserted through the center of a spool. The support rod would then be mounted to the side walls of the supply rack and the securing members secured to the support rod. The supply rack would then be hung from the scaffold. This process would create a safety hazard by causing the electrician to handle pieces such as the support rod, securing members, supply rack, and spool, while on the scaffold. If any one piece is dropped it becomes a danger to those working below. If the supply rack is loaded on the ground, its shape and weight would make it difficult and dangerous to carry up the scaffold.  
         [0012]     Space on any work vehicle is limited. Existing wire distribution devices take up valuable space on these vehicles in addition to the space that is used for the spools themselves. Furthermore, current distribution devices are bulky and difficult to handle and must be hauled to and from a work site.  
         [0013]     It is therefore an object of the present invention to provide a product hanger that overcomes the above mentioned problems of prior art devices.  
         [0014]     Another object of the present invention is to provide a product hanger that allows distribution of product from a spool without the use of a solid axle, shaft, or rod.  
         [0015]     Another object of the present invention is to provide a product hanger that is safe to use on scaffolding.  
         [0016]     Another object of the present invention is to provide a product hanger that provides omni-directional distribution from a spool.  
         [0017]     Another object of the present invention is to provide a product hanger that can support a container.  
         [0018]     Another object of the present invention is to provide a product hanger that allows a single spool to be removed and installed for distribution without removing and installing other spools.  
         [0019]     Another object of the present invention is to provide a product hanger that can be safely handled, loaded, and unloaded by a single person.  
         [0020]     Another object of the present invention is to provide a product hanger that provides a safe and convenient means for a person to carry spools.  
         [0021]     Another object of the present invention is to provide a product hanger that protects spools during transport.  
         [0022]     Another object of the present invention is to provide a product hanger that conserves space on transport vehicles.  
         [0023]     Another object of the present invention is to provide a product hanger that consists of a minimum number of parts.  
         [0024]     Another object of the present invention is to provide a product hanger that is inexpensive to manufacture, and simple to use.  
       SUMMARY OF THE INVENTION  
       [0025]     The present invention is directed toward a product hanger comprising at least one main support member which defines a longitudinal axis and comprises at least one hanging means for hanging the product hanger from a support. A first end of the main support member comprises a first vertical support arm extending downwardly to a terminating end, and the terminating end comprises a first engagement member. A second end of the main support member comprises a second vertical support arm extending downwardly to a terminating end, and the terminating end comprises a second engagement member.  
         [0026]     Another embodiment of the invention is a method of hanging a spool of product, and distributing product from the spool. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0027]     The accompanying drawings illustrate a complete embodiment of the invention according to the best modes so far devised for the practical application of the principles thereof, and in which:  
         [0028]      FIG. 1  depicts the product hanger of the present invention.  
         [0029]      FIG. 2  depicts a preferred embodiment of the product hanger of the present Invention in which the product hanger is constructed of a single length of rigid material.  
         [0030]      FIG. 3  depicts a preferred embodiment of the product hanger of the present invention with a spool attached thereto.  
         [0031]      FIG. 4  depicts a first product hanger of the present invention positioned adjacent to a second product hanger of the present invention.  
         [0032]      FIG. 5  depicts a preferred embodiment of the product hanger of the present Invention in which the product hanger is adapted to provide omni directional dispensing of product from a spool.  
         [0033]      FIG. 6  depicts a preferred embodiment of the product hanger of the present Invention wherein the width of the product hanger is adjustable.  
         [0034]      FIG. 7  depicts a preferred embodiment of the product hanger of the present Invention wherein the product hanger is adapted to engage a container.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]     Referring now to the drawings where similar elements are numbered the same,  FIG. 1  depicts the product hanger  10  of the present invention. The product hanger  10  comprises at least one main support member  20  defining a longitudinal axis  11 . The main support member  20  comprises at least one hanging means  30  for hanging the product hanger  10  from a support (not shown). A first end  23  of the main support member  20  comprises a first vertical support arm  40  which extends downwardly to a terminating end  43  of the first vertical support arm  40 . The terminating end  43  of the first vertical support arm  40  comprises a first engagement member  60 . A second end  25  of the main support member  20  comprises a second vertical support arm  50  which extends downwardly to a terminating end  53  of the second vertical support arm  50 . The terminating end  53  of the second vertical support arm  50  comprises a second engagement member  70 . The first and second engagement members are designed to engage and support a product to be held between the vertical support arms  40 ,  50  and may be any engagement members known to those of average skill in the art.  
         [0036]     In one embodiment of the invention, the two engagement members  60 ,  70  engage a hole that resides in the center of a spool without the need for a shaft or axle running through the center of the spool. The spools are mounted and dismounted from the product hanger  10  by flexing the vertical support arms  40 ,  50 , sliding them over the spools until the two engagement members  60 ,  70  are adjacent to two ends of the hole disposed in the center of the spool, and releasing the vertical support arms  40 ,  50  so that the two engagement means  60 ,  70  enter the hole to engage the spool. Alternatively, as seen in  FIG. 2 , a length of pipe or tubing  24  may be inserted through the hole in the center of the spool, and engaged by the two engagement members  60 ,  70 . This is useful to engage a spool that would otherwise be too narrow be engaged by the two engagement members  60 ,  70 . Because the hanger  10  hangs a single spool, individual spools may be removed and replaced from within a series of adjacent spools without removing any spools except the one being changed, something impossible to accomplish using prior art devices.  
         [0037]     The hanging means  30  is any hanging means known to those of average skill in the art, such as a closed loop section of the main support member  20 . A closed loop is used, for example, for transporting large heavy spools: a pipe or rod is inserted through the closed loop and one or more persons carry each end of the pipe or rod. In a preferred embodiment of the invention as shown in  FIG. 5 , the hanging means  30  includes a rotating joint  31  which is any rotating joint known to those of average skill in the art. The rotating joint  31  is operable to allow the main support member  20  to rotate 360 degrees in relation to a support from which the product hanger  10  is hung. A rotating hanging means is used, for example, for hanging an individual spool of wire for omni directional dispensing of the wire. The invention includes a product guide  41  to facilitate omni directional rotation of the product hanger by initiating rotation of the main support member  20 . The product guide comprises at least one guide arm  42  pivotally attached to the main support member  20 . The guide arm  42  comprises a guide opening  43  through which product being dispensed from the spool is pulled. The lateral force of the product against the guide opening initiates rotation of the main support member  20  about an axis  44 .  
         [0038]     In a most preferred embodiment of the invention as shown in  FIGS. 2 and 3 , the main support member  20  comprises a first hanging means  21  and a second hanging means  22 . The main support member  20 , the first and second hanging means  21 ,  22 , the vertical support arms  40 ,  50 , and the first and second engagement members  60 ,  70  are formed from a single length of rigid material. The first and second hanging means  21 ,  22  are arcuately formed sections of the first and second ends  23 ,  25  of the main support member  20  forming a substantially identical pair of hooks extending perpendicular to and from opposite ends of the longitudinal axis  11 . The first and second hanging means  21 ,  22  extend into the first and second vertical support arms  40 ,  50 . The first and second vertical support arms  40 ,  50 , are thus integral extensions of the first and second hanging means  21 ,  22 .  
         [0039]     The open hook hanging means as shown in  FIGS. 2-4  are particularly useful in hanging a series of spools for distribution from a single axle. In the construction trade, wire is generally distributed off of four or five spools hung on a single axle. On existing devices, a single axle runs through the center of the spools necessitating the removal of several spools to change a single spool. With the present invention, the product hanger is mounted to an individual spool, and then hung from a support. Because the hanging means can fit over a support which is too big to pass through the center of a spool, stronger supports can be used than previously possible. This prevents the support from sagging, thus keeping the spools from binding and locking together. The open hook hanging means also provides an alternative method of changing an individual spool hanging adjacent to other spools on a single axle. The product hanger is unhooked from the axle together with the individual spool, the spool is changed, and the product hanger is then hung back on the axle with the new spool in place. Changing an individual spool hanging adjacent to other spools on a single axle, without disturbing the other spools, is something impossible to accomplish using existing devices.  
         [0040]      FIG. 4  shows a most preferred embodiment of the present invention wherein a first spacing means  100  and a second spacing means  200  position the spools at an operable distance from adjacent spools. In a most preferred embodiment of the invention, the first and second spacing means  100 ,  200 , are comprised of upper ends  110 ,  210  of the first and second vertical support arms  40 ,  50 . This is preferably accomplished by forming the first and second vertical support arms  40 ,  50  to angle in towards each other. This angle will vary depending on the length of the vertical support arms  40 ,  50 , and is easily determinable by those of average skill in the art without the need of excessive experimentation. Alternatively, the first and second spacing means  100 ,  200 , may be formed into the main support member or the first and second hanging means  21 ,  22  ( FIG. 2 ).  
         [0041]     Referring back to  FIG. 1 , the first and second engagement members  60 ,  70  angle in towards each other. In one embodiment of the invention, the first and second engagement member s  60 ,  70  form an angle of between about 90 degrees and 45 degrees with respect to the first and second vertical support arms  40 ,  50 . In a preferred embodiment of the invention, the first and second engagement member s  60 ,  70  form an angle of about 70 degrees with respect to the first and second vertical support arms  40 ,  50 . The angle of the engagement member s keeps the spool in place by engaging a lip on the inside of the hole that extends through the spool. The shape and angle of the engagement member s varies depending on the shape of the spool, and will be easily discoverable by those of average skill in the art. In another preferred embodiment of the invention the first and second engagement member s  60 ,  70  are integral extensions of the first and second vertical support arms  40 ,  50 , for example, if the first and second vertical support arms  40 ,  50  are formed of bent wire, the wire at the end of each support arm  40 ,  50  is bent in towards the other to form the engagement means  60 ,  70 . For securely holding spools in place it is useful to form the engagement means  60 ,  70  into a loop  61  ( FIG. 2 ). Experimentation has shown that the loop design is best suited for keeping spools in place. The exact size and design of the loop varies depending on spool design, and is easily discoverable by those of ordinary skill in the art without undue experimentation. In yet another preferred embodiment of the invention, the first and second engagement members  60 ,  70  are rollers  71  ( FIG. 6 ) rotatingly attached to the first and second vertical support arms  40 ,  50 . The rollers  60 ,  70  are preferably angled as shown in  FIG. 6  to help keep the spools in place.  
         [0042]     The product hanger of the present invention is constructed of rigid material such as metal, pot metal, metal alloy, steel, stainless steel, spring steel, steel wire, extruded plastic, and/or pvc. The preferred material is spring steel or extruded plastic. In a preferred embodiment of the present invention as shown in  FIG. 2 , the main support member  20 , the first and second hanging means  21 ,  22 , the first and second vertical support arms  40 ,  50 , and the first and second engagement member s  60 ,  70 , are formed from a single piece of rigid material. In an alternative embodiment of the present invention, the distance between the first vertical support arm  40  and the second vertical support arm  50  is adjustable. As shown in  FIG. 6 , a sectional main support member  300  provides an adjustable distance between the first vertical support arms  40  and the second vertical support arm (not shown). The sectional main support member  300  is any sectional support member known to those of average skill in the art, and preferably is a male section  320  which slides into a female section  310  and is secured by at least one set screw  330 . Other adjustable members contemplated by this invention are track and slider type members.  
         [0043]     In yet another preferred embodiment of the invention as depicted in  FIG. 7 , the product hanger  10  is adapted to support a container  400 . The first and second engagement members  60  are adapted to engage the container  400 . The engagement members  60  engage the container by any means that would be known by a person of average skill in the art. In one embodiment the engagement members  60  point towards each other and form an angle of approximately 90 degrees in relation to their respective vertical support arms  50 . The container may be any pail or bucket known to those of average skill in the art, and preferably comprises first and second channels  410 ,  415  vertically disposed in opposing sidewalls of the container  400 . The channels  410 ,  415  are adapted to engage the vertical support arms  40 ,  50 . A bottom section  420  of the container  400  is any shape which would be consistent with the container  400  being secured in the product hanger  10 . In a preferred embodiment the bottom section  420  comprises a substantially flat surface. In a most preferred embodiment, the bottom section  420  comprises at least one channel disposed therein to engage the engagement members  60 .  
         [0044]     The above description and drawings are only illustrative of preferred embodiments which achieve the objects, features and advantages of the present invention, and it is not intended that the present invention be limited thereto. Any modification of the present invention which comes within the spirit and scope of the following claims is considered part of the present invention.