Abstract:
Wire used for beading is coiled on a rotably mounted reel in a dispenser having a reel brake bearing against the reel with the wire passing through a channel as extended to the exterior of the dispenser with the wire frictionally engaging both the walls of the channel and a resilient element pressing against the wire to modulate the force required to withdraw the wire from the dispenser to a value which is high enough to prevent spontaneous unwinding of the wire from around the reel but still allowing easy removal from the dispenser when desired.

Description:
CLAIM FOR PRIORITY 
       [0001]    This non-provisional application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/629,995, of the same title, filed Dec. 2, 2011. The priority of U.S. Provisional Patent Application Ser. No. 61/629,995 is hereby claimed and the disclosure thereof is incorporated into this application by reference. 
     
    
       [0002]    Many hobbyists have taken up beading as a past time, making decorative jewelry and ornamental objects for their families and friends as well as themselves. Many beaded items are formed by placing beads on a wire or other filament to make necklaces, bracelets, key rings, bangles and other decorative items. Because many beaders like to practice their hobby in odd moments of spare time as they go about their daily life, transportability and convenience are important in the accessories that they use. One issue involves beading wire which is often sold on a spool which, due to its inherent stiffness, allows the wire to spontaneously unspool when carried about in a purse or beading, often putting crimps in the wire making it either unattractive for many of the beaded projects or difficult to use or too often spoiling it completely for beading applications. Beading wire is of a rather specialized construction, normally comprising a multiplicity of strands, most often, 7, 19, 21 or 49, so that it will drape properly once the beads are strung upon it. Because this drapability makes it quite easy for beading wire to come spontaneously off of a reel or unspool, a rather specialized dispenser is required. 
         [0003]    This invention relates to a dispenser for beading wire or other beading filaments which may be transported easily and conveniently which does not allow the wire to unspool spontaneously but makes it easy for the beader to withdraw the desired amount while ensuring that the beading wire even though protected does not retract into the dispenser overly easily as well as ensuring that, if by happenstance it is urged inwardly into the dispenser, the beader will have little difficulty restarting it as the dispenser is easily openable. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The invention is described in detail below with reference to the various Figures, wherein: 
           [0005]      FIGS. 1-7  illustrate one embodiment of the present invention in which a resilient gripping pad restrains the wire as it exits the dispenser; 
           [0006]      FIGS. 8 ,  8 A and  9 - 11  illustrate an alternative embodiment in which the structure of the dispenser housing serves to restrain the wire; 
           [0007]      FIG. 12  illustrates details of the clasp retaining the dispenser in a closed configuration; 
           [0008]      FIGS. 13-15  relate to material saving embodiments of the present invention providing much of the functionality of the embodiment of  FIGS. 1-12 ; 
           [0009]      FIGS. 16  A-C illustrate the details of the construction of the throat of the dispenser of a preferred embodiment of the invention; and 
           [0010]      FIGS. 17 and 18  schematically illustrate a simple experiment to estimate the force required to withdraw wire from the dispenser. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0011]    The invention is described in detail below with reference to several embodiments. Such discussion is for purposes of illustration only. Modifications to examples within the spirit and scope of the present invention, set forth in the appended claims, will be readily apparent to one of skill in the art. Terminology used throughout the specification and claims herein is given its ordinary meaning. 
         [0012]    In the embodiment shown in  FIGS. 1-7 , wire dispenser  20  comprises integrally formed housing halves  22  and  24  adjoining each other along first living hinge  26  formed adjacent triangular snout portions  28  and  30  of each housing half  22  and  24  respectively. Housing halves  22  and  24  comprise generally circular planar central portions  32  and  34  adjoining triangular snout portions  28  and  30 , with peripheral wall  36  and  38  formed thereabout, respectively. Preferably peripheral walls  36  and  38  are mateable with each other in overlapping engagement between lip  39  and ledge  41  thereby defining generally cylindrical containment cavity  40  with reel  42  disposed therein with reel  42  having hub  43  and flanges  44  and  46  formed thereupon. Axles  48  and  50  are defined by interior wall portions  52  and  54  arising from generally circular planar central portion  32  and  34  respectively. Hub  43  of reel  42  encompasses axles  48  and  50  and maintains reel  42  in position within generally cylindrical containment cavity  40 . In the closed conformation, outwardly projecting resilient gripper pads  56  and  57  on peripheral walls  36  and  38  are formed integrally with housing halves  22  and  24  respectively and serve to controllably restrain wire W and prevent it from withdrawing into dispenser  20  while flexible restraining membrane  64  adds a modulated restraining force to wire W. 
         [0013]    Retention flap  66  having retention slot  68  formed therein adjoins housing half  22  along second living hinge  70 . Retention lug  72  projecting from housing half  24  has prismatic base  74  adjoining housing half  24  while bulbous end portion  76  is spaced distally therefrom. Reel brakes  78  are defined by U-shaped slots  79  formed into generally circular planar portions  32  and  34  forming a tongue shaped flap  80  bearing against inwardly projecting retarding projections  82  which frictionally engage flanges  44  and  46 . Retarding projections  82  of reel brakes  78  project upwardly from generally circular planar portion  32  of housing half  22  and bear against flanges  44  and  46  of reel  42  to prevent free-wheeling thereof but are free to retract slightly as each of retarding ridges  84  engage retarding projections  82  seriatim as reel  42  rotates with dispenser  20  while wire W is withdrawn therefrom. When housing halves  22  and  24  are urged against each other and peripheral walls  36  and  38  are overlappingly engaged as described above, dispenser  20  may be locked into the closed configuration with retention lug  72  passing through retention slot  68  in retention flap  66  as shown in  FIG. 12 . In the closed conformation, resilient gripping pads  56  and  57  engage wire W preventing it from withdrawing into dispenser  20  while contributing to the force required to withdraw wire W from the dispenser. 
         [0014]    The embodiment of  FIGS. 8-11  illustrates an alternative gripping mechanism in which walls  58  and  60  are formed integrally with housing half  24  and define longitudinal channel or slot  62  through which wire W passes. Longitudinal channel or slot  62  is sized such that it takes advantage of the natural curvature in wire W resulting from its previous condition of being wound around hub  43  of reel  42 , as this curvature urges wire W against transverse walls  58  and  60  in housing half  24  and serves to frictionally retard its motion in or out of dispenser  20 . After wire W passes through longitudinal channel or slot  62  and thence between recessed pressing pad  57  formed integrally with housing half  22  and projecting pressing pads  56  and  57  in formed integrally with housing halves  22  and  24 , wire W exits dispenser  20  and may be snipped off at any convenient length by the user. 
         [0015]    In the alternative embodiment of  FIGS. 8 ,  9 ,  10 ,  10 A and  11 , pressing pad  57  bears against wire W from below while projecting pressing pad  56  bears against wire W from above but pressing pad  57  and pressing pad  64  serve to restrain wire W frictionally as wire W is trapped between them but must also pass through restraining membrane  64  which both yields flexibly in the direction perpendicular to wire W&#39;s travel and may deform more permanently to form a groove (not shown) accommodating wire W, while wire W is both laterally restrained between transverse walls  58  and  60  as well as being frictionally restrained as discussed above. In view of the slight but finite stiffness of wire W, and the slight curvature therein resulting from wire W being unreeled from reel  42 , both outward and inward movements of wire W are restrained by this arrangement in which wire passes between two transverse wall  58  and  60  which are spaced apart by a distance which is greater than the diameter of wire W but less than the curvature resulting in wire W over the length of transverse walls  58  and  64  resulting from its stay on reel  42  while pressing pads  57  and  56  frictionally engage wire W so that when wire W is snipped outwardly of projecting pressing pad  64  by external means (not shown) such as a wire cutter, wire W neither retreats into cylindrical containment cavity  40  nor does it spontaneously unspool outwardly without being urged in that direction by an appreciable external force. Even if pushed inwardly, the slight spacing between pressing pads  57  and  56  will often makes it possible to retrieve a free end with a finger nail or tweezers without separating the housing halves  22  and  24  from each other. In the closed configuration, gripping pads  57  and  56  are urged against wire W passing from the interior of wire dispenser  20  through slot  62  and between gripping pads  57  and  56  to the exterior of dispenser  20  thereby forestalling undesired retraction of wire W into the interior of wire dispenser  20  in use. In use, grooves (not shown) may be worn into either or both of pads  57  and  56  as well as into flexible restraining membrane  64  as wire W is withdrawn. Alternatively, such a groove may be intentionally formed but preferably is not of sufficient size that wire W passes freely therethrough. In  FIG. 10A , flexible restraining membrane  64  is depicted as having a thickness of at least about 2 mils, preferably at least about 3 mils and more usually between about to 100 mils, preferably between about 8 and 75 mils, more preferably between about 9 and 50 mils, and most preferably between about 10 and 35 mils, allowing membrane  64  to deform easily and flexibly to accommodate wires W of various thicknesses easily, making dispenser  20  well suited to accommodate wires of any of the diameters commonly used for beading. In contrast, in  FIG. 10 , restraining membrane  64  is depicted as considerably thicker so the degree of flexible deformation will be decreased and the degree of permanent deformation such as would result from wearing of a groove therein is greater. 
         [0016]    In the embodiment shown in  FIGS. 13-15 , much of the structure is the same and functions similarly as in the previous embodiments in  FIGS. 1-12  and thus need not be described in detail. In  FIGS. 13 and 14 , wire dispenser  120  comprises integrally formed housing halves  122  and  124  adjoining each other along first living hinge  126  formed adjacent triangular snout portions  128  and  130  of each housing half  122  and  124  respectively. Housing halves  122  and  124  comprise triangular snout portions  128  and  130 . In  FIG. 15 , wire dispenser  220  comprises integrally formed housing halves  222  and  224  adjoining each other along first living hinge  226  formed adjacent triangular snout portions  228  and  230  of each housing half  222  and  224  respectively. Housing halves  222  and  224  comprise triangular snout portions  228  and  230 . The embodiments of  FIGS. 13-15  are best conceptualized as functioning in the same fashion as the embodiments of  FIGS. 1-12  with those parts of the housing which are not essential to functioning of the dispenser being cut away to save material and allow for use of smaller molds resulting in improved manufacturing efficiency. 
         [0017]    The present invention also relates to a method of dispensing beading wires, comprising the steps of: providing a reel, manually graspable by a user and adapted to be retained in the user&#39;s palm, having: a hub having an axis of rotation and a pair of spaced apart flanges defining an annular wire storage region between said flanges and exterior to said hub, said reel being rotable around the axis of rotation of said hub; and having a length of beading wire wrapped around said hub and disposed between said flanges; grasping said beading wire and exerting a beading wire restraining force on said wire to prevent unreeling from around said reel without rotation of said reel around said axis; and exerting a reel braking force acting upon at least one of said flanges to hinder free rotation of said reel. 
         [0018]    Preferably, a polymeric beading wire guide is provided having an axis about which the reel is rotable and an integrally formed polymeric arm extending from the axis of said hub to a location exterior to said flanges, wherein the reel braking force and the beading wire restraining force are exerted by the arm. 
         [0019]    In a preferred embodiment of the method of manually dispensing beading wire by a user, the method comprises the steps of: providing a reel, manually graspable by a user and adapted to be held in the user&#39;s palm, having: a hub having an axis of rotation and a pair of spaced apart flanges defining an annular wire storage region between said flanges and exterior to said hub, said reel being rotable around the axis of rotation of said hub; a length of beading wire wrapped around said hub, and disposed between said flanges; wherein when the reel is held in the user&#39;s palm, the beading wire is being manually withdrawn by said user and a grip is provided for grasping the beading wire and exerting a beading wire restraining force on the wire to prevent unreeling from around said reel without rotation of said reel around said axis; and a brake is provided for exerting a reel braking force acting upon at least one of the flanges to hinder free rotation of said reel. 
         [0020]    Preferably, the reel braking force and the beading wire restraining force are exerted by a polymeric arm extending from the axis of said hub to a location exterior to said flanges. In preferred embodiments, the mass of polymer included in said arm is less than 10 grams and the arm is integrally formed from polymeric material. 
         [0021]    In a more preferred embodiment, the method comprises the steps of: providing a reel having: a hub having an axis of rotation and a pair of spaced apart flanges defining an annular wire storage region between said flanges and exterior to said hub, said reel being rotable around the axis of rotation of said hub; wherein the reel has a length of beading wire wrapped around the hub and disposed between the flanges; and a dispensing arm integrally formed from polymeric material, extends from the hub of said reel to a location exterior to the flanges, the mass of polymer included in the arm being less than 10 grams and the dispensing arm has: a gripper formed therein for grasping the beading wire and exerting a beading wire restraining force on the beading wire to prevent unreeling from around said reel without rotation of the reel around said axis; and a pressing foot for pressing against at least one of the flanges and exerting a reel braking force acting thereupon to hinder free rotation of said reel, and the reel is held, and the beading wire being manually pulled, by said user. Wires usable with the method include beading wire having a plurality of at least 7 strands up to 49 strands and ranging in diameter from between 0.007″ and 0.024″ wherein the number of strands in the beading wire is either 19 or an integral multiple of 7 with the strands being embedded in a cylindrical polymeric matrix, preferably comprising a polyamide such as nylon. More preferably, the beading wire comprises 7, 19, 21 strands. In the case where the beading wire comprises 21 or 49 strands, the strands are arrayed in circular groups of 7 strands combined to form the finished beading wire. 
         [0022]    A particularly desirable feature of the present invention lies in the controlled force required for dispensing wire. Preferably, the force required to withdraw wire from the dispenser varies with the wire diameter in accordance with the following Table 1. 
         [0000]    
       
         
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Withdrawal Force 
               
             
          
           
               
                   
                   
                   
                 More 
                 Most 
                   
               
               
                 Wire 
                 Minimum 
                 Preferred 
                 Preferred 
                 Preferred 
                 Maximum 
               
               
                 diameter 
                 Extend 
                 Extend 
                 Extend 
                 Extend 
                 Extend 
               
               
                 (in.) 
                 force (g) 
                 force (g) 
                 Force (g) 
                 Force (g) 
                 force (g) 
               
               
                   
               
             
          
           
               
                 0.024 
                 20 
                  25-1000 
                 25-500 
                 40-400 
                 1500 
               
               
                 0.018 
                 15 
                 15-750 
                 25-400 
                 40-350 
                 1200 
               
               
                 0.015 
                 10 
                 15-500 
                 25-300 
                 30-300 
                 1000 
               
               
                 0.012 
                 5 
                 10-500 
                 15-250 
                 20-200 
                 1000 
               
               
                   
               
             
          
         
       
     
         [0023]    In preferred embodiments, the dispenser will be formed from polypropylene and the transverse distance between the walls of said longitudinal channel is between about 1/32″ and 3/32″ preferably about 1/16″, with the length of the longitudinal channel being between about ½″ to about 1″. Experiments were conducted using a polypropylene dispenser hung from a support with a small tray attached to the end of the wire. Weight were successively added to the tray to determine the weight that the wire was capable of sustaining (retain force) and the weight required to withdraw wire from the dispenser (extend force) as illustrated in  FIGS. 17 and 18 . In the case of a polypropylene dispenser having a channel with a length of about ½″ and a transverse distance of about 1/16″ between said walls it was found that, for each diameter of beading wire investigated, the force required to extend the wire from within the dispenser was generally between the retain force and the extend force indicated below in Table 2. 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                 Wire diameter (″) 
                 Retain force (g) 
                 Extend force (g) 
               
               
                   
               
             
             
               
                 0.024 
                 85 
                 91 
               
               
                 0.018 
                 68 
                 74 
               
               
                 0.015 
                 51 
                 57 
               
               
                 0.012 
                 40 
                 45 
               
               
                   
               
             
          
         
       
     
         [0024]    Accordingly, it can be appreciated that, in a dispenser configured as suggested, only a moderate but easily sustainable force is required to withdraw wire from the dispenser but the wire will not unwind unless some force is applied to the free end. Thus the wire remains neatly in place in the dispenser unless the user wishes to withdraw wire but only a moderate force is required to withdraw as much wire is required. 
         [0025]    In a still more preferred embodiment, the method of manually dispensing beading wire by a user, comprises the steps of: providing a reel having: a hub having an axis of rotation and a pair of spaced apart flanges defining an annular wire storage region between said flanges and exterior to said hub, said reel being rotable around the axis of rotation of said hub; a length of beading wire wrapped around said hub and disposed between said flanges, said beading wire having a diameter between 0.007″ and 0.024″ and comprising a multiplicity of at least 19 strands or 7 strands or an integral multiple of seven strands embedded in a polyamide matrix; providing a dispensing arm integrally formed from polymeric material, extending from the hub of said reel to a location exterior to said flanges, the mass of polymer included in said arm being less than 10 grams, said dispensing arm having: a gripper formed therein for grasping said beading wire and exerting a beading wire restraining force on said beading wire to prevent unreeling from around said reel without rotation of said reel around said axis; and a pressing foot for pressing against at least one of said flanges and exerting a reel braking force acting thereupon to hinder free rotation of said reel, said reel being held, and said beading wire being manually pulled, by said user. 
         [0026]    In manufacture, dispenser  20  can be formed from any convenient polymer or even metal if it is acceptable to substitute a true hinge for the living hinge; but dispenser  20  will normally be formed from a polymer capable of forming a living hinge of rather extended duration, typically polypropylene or polyethylene although engineering resins like nylons or acetals can be substituted if shorter life span is acceptable. The mechanical dimensions suitable for living hinges are well known. 
         [0027]    While the invention has been described in detail, modifications within the spirit and scope of the invention will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references discussed above in connection with the Background and Detailed Description, the disclosures of which are all incorporated herein by reference, further description is deemed unnecessary. In addition, it should be understood that aspects of the invention and portions of various embodiments may be combined or interchanged either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention.