Abstract:
A device is provided that is adapted for mounting on a vertical support, such as a stud at a construction job site, to hold a spool of wire off the floor, allowing the wire to be dispensed easily, yet providing sufficient drag on the reel to avoid excess unspooling of the wire. The device is adapted for mounting on a stud or comparable vertical support without the use of tools or fasteners so it can be moved quickly from location to location. The device is conveniently disassembled into two smaller assemblies for storage and transport to the job site.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/804,306, filed Mar. 22, 2013, the contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The disclosure relates to devices for dispensing wire, cable, flexible tubing and the like from a reel or spool. In particular, the disclosure relates to devices for holding at least one spool and dispensing wire, cable, flexible tubing and the like from a spool in a construction site. 
     2. Description of the Background 
     Typically, during construction or remodeling of a building, wire, cables, cords and hoses (referred to collectively herein as “wire”) will need to be run. The wire typically is held on a spool or reel (referred to collectively herein as “spool”). There are many known devices and methods for holding the spool and dispensing the wire. The typical method used by contractors is to mount a section of pipe horizontally across two studs, with the pipe running through the central channel of the spool as an axle, so that the spool is held up off the ground and wire can be dispensed (or “unspooled”) as the spool turns freely. However, this approach has three main drawbacks; (1) the wire often kinks, jamming the spool so that it does not spin easily, (2) a full spool of wire can develop momentum and continue to dispense excess wire after the operator has stopped pulling on the wire and (3) moving the spool to a different area of the job site is difficult because the pipe needs to be unfastened from the studs in order to be moved. 
     There are several known devices for holding reels or spools and dispensing wire, but many of these devices have drawbacks. One example of such a device is a reel holder that sits on the floor. This device not only creates a tripping hazard at the job site, but often it is difficult to make the device dispense wire freely. 
     SUMMARY OF THE INVENTION 
     A device is provided that is adapted for mounting on a vertical support, such as a stud at a construction job site, to hold a spool of wire off the floor, allowing the wire to be dispensed easily, yet providing sufficient drag on the reel to avoid excess unspooling of the wire. The device is adapted for mounting on a stud or comparable vertical support without the use of tools or fasteners so it can be moved quickly from location to location. The device is conveniently disassembled into two smaller assemblies for storage and transport to the job site. 
     In certain embodiments the device comprises a straight assembly  150  having a first end  154 , a second end  152 , a longitudinal axis  184 ; junction region  156  adjacent to the second end  152 , and adapted to be joined to an angled assembly  110  having a first end  112  and a second end  114 , a junction region  122  adjacent to the first end  112  adapted to be joined to the junction region  156  of straight assembly  150 , an angled section  118  between the first end  112  and the second end  114 , a short straight section  120  between the first end  112  and the angled section  118 , wherein the short straight section  120  has a longitudinal axis, a long straight section  116  between the angled assembly  118  and the second end  114 , the angled assembly  110  is affixed to a first curved bracket  130  having a first end  131 , a second end  132 , a short arm  135 , a long arm  136 , an outer surface  133  and an inner surface  134  and a second curved bracket  140  having a first end  141 , a second end  142 , a short arm  145 , a long arm  146 , an outer surface  143  and an inner surface  144 ; wherein the long straight section  116  has a longitudinal axis  182  and wherein the longitudinal axis  184  of the straight assembly  150  is at an angle beta  186  to the longitudinal axis  182  of the long straight section  116 . 
     In certain embodiments, when the straight assembly  150  is joined to the angled assembly  110 , the angle between the longitudinal axis  184  of the straight assembly and the longitudinal axis of the short straight section  120  is less than about 15 degrees, preferably less than 10, more preferably less than about 7 degrees. Typically, when the straight assembly  150  is joined to the angled assembly  110 , the opening defined by the first end  131  and the second end  132  of the first curved bracket  130  faces in the same direction as the first end  154  of the straight assembly. The short arm  135  of the first curved bracket  130  and the short arm  145  of the second curved bracket  140  are attached to the angled assembly  110  by a weld or a fastener. Generally, the first curved bracket  130  and the second curved bracket  140  are affixed on the same side of the long straight section  116 . Typically, the angle beta is about 95 to about 105 degrees, preferably about 97 to about 99 degrees. 
     In certain embodiments, the straight assembly  150  further comprises an end cap  190 , holes  162  and a reel retention fastener  164 . Typically, the device of claim  1  wherein the angled assembly  110  further comprises an end cap or plug  190 . 
     The junction regions  122  and  156  each have an outer surface and an inner surface and an outer diameter and an inner diameter. In certain embodiments, the inner diameter of the junction region  156  is larger than the outer diameter of junction region  122 . In certain embodiments, the junction region  156  defines a hole  160  and the junction region  122  defines a hole  126 , and further comprises a button  124 . In preferred embodiments, button  124  is spring-loaded. 
     In other embodiments, the inner surface of junction region  156  is threaded. In certain embodiments, the inner surface of junction region  122  is threaded. In embodiments in which the inner diameter of the junction region  156  is larger than the outer diameter of junction region  122 , the outer surface of junction region  122  is threaded. In other embodiments in which the inner surface of junction region  156  is threaded and the inner surface of junction region  122  is threaded, the device further comprising a hollow cylindrical connector  170  having a first end and a second end, an inner surface and an outer surface, wherein the outer surface is threaded. In certain embodiments, the threaded connector  170  is threaded only on the first end and the second end is permanently affixed to junction region  122  or  156 . In such embodiments, the mating junction region  156  or  122 , respectively, is threaded on its inner surface. In such embodiments, device  100  is assembled by screwing the angled assembly  110  to the straight assembly  150  using the threaded first end of threaded connector  170 . 
     In other embodiments, the invention provides a device for holding a spool for dispensing wire comprising a straight assembly  150  having a first end  154 , a second end  152 , a longitudinal axis  184 ; junction region  156  adjacent to the second end  152 , joined to an angled assembly  110  having a first end  112  and a second end  114 , a junction region  122  adjacent to the first end  112  adapted to be joined to the junction region  156  of straight assembly  150 , an angled section  118  between the first end  112  and the second end  114 , a short straight section  120  between the first end  112  and the angled section  118 , wherein the short straight section  120  has a longitudinal axis, a long straight section  116  between the angled assembly  118  and the second end  114 , the angled assembly  110  is affixed to a first curved bracket  130  having a first end  131 , a second end  132 , a short arm  135 , a long arm  136 , an outer surface  133  and an inner surface  134  and a second curved bracket  140  having a first end  141 , a second end  142 , a short arm  145 , a long arm  146 , an outer surface  143  and an inner surface  144 ; wherein the first curved bracket and the second curved bracket are adapted to grasp a substantially vertical wooden stud and support the device when it is in use. When the device is installed for use on a wooden stud wherein angle alpha  188  between the longitudinal axis  184  of the straight assembly and the vertical is less than about 90 degrees, preferably about 75 to about 85 degrees. 
     The above described and other features are exemplified by the following drawings and the detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and advantages will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings, in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. 
         FIG. 1  is a perspective view showing an exemplary embodiment of the device  100  in an assembled state, illustrating the angled assembly  110  joined to the straight bar assembly  150 , and an illustration of one embodiment of a junction  156  between the straight assembly  150  and the angled assembly  110 . 
         FIG. 2  is an exploded perspective view showing the exemplary embodiment of the device  100  in an unassembled state with the straight bar assembly  150  separated from the angled assembly  110 , and the first curved bracket  130  and the second curved bracket  140  separate from the rest of the angled assembly  110 . 
         FIG. 3  is a perspective view of part of an unassembled angled assembly  110 , showing the long straight section  116 , the short straight section  120  and the angled section  118 . 
         FIG. 4  is a perspective view of part of an unassembled straight bar assembly  150 . 
         FIG. 5  is a perspective view showing details of the first curved bracket  130 . 
         FIG. 6  is a perspective view showing details of the second curved bracket  140 . 
         FIG. 7  is a perspective view of an exemplary embodiment of the device installed on a supporting stud of dimensional lumber  200  at a construction site for use, showing the straight bar assembly  150 , the angled assembly  110  including the first curved bracket  130 , and the second curved bracket  140  in relation to the supporting wooden stud  200 . 
         FIG. 8A  and  FIG. 8B  are longitudinal section views of another embodiment of a junction between straight assembly  150  and angled assembly  110 , showing in  FIG. 8A  a threaded portion of the junction region  122  of the angled assembly joined to a threaded connector  170 , and in  FIG. 8B , a threaded portion of the junction region  156  of the straight assembly positioned onto the thread connector  170  to join the junction portion  156  of the straight assembly to the junction portion  122  of the angled assembly. 
         FIG. 9  is the perspective view of  FIG. 7 , schematically illustrating the relationships between a vertical line  180 , the longitudinal axis  182  of the long straight section of the angled assembly  110 , the longitudinal axis  184  of the straight assembly  150 , the angle a  188  between the vertical line  180  and the longitudinal axis  184  of the straight assembly  150 , and the angle  186  between the longitudinal axis  184  of the straight assembly  150  and the longitudinal axis  182  of the long straight section of the angled assembly  110 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIG. 1  is a perspective view showing an exemplary embodiment of the device  100  in an assembled state, illustrating the angled assembly  110  joined to the straight bar assembly  150 . In the assembled state the present invention contains various components. In the assembled state the device is configured to be affixed to stud or other vertical support by means of a first curved bracket  130  and a second curved bracket  140  positioned below the first curved bracket  130 . First curved bracket  130  and second curved bracket  140  are affixed to the angled assembly  110 . In preferred embodiments, the first curved bracket  130  and the second curved bracket  150  are welded to the long straight section  116 . See  FIGS. 2 and 3  for details. While welding is a preferred method for attaching the brackets  130  and  140  to the angled assembly  110 , other methods may also be used including, but not limited to, fasteners such as nuts and bolts, machine screws in tapped holes, self-threading screws, rivets, etc. In other preferred embodiments, brackets  130  and  140  may be affixed to the angled assembly  110  by forging or casting. 
     In the assembled state, the device  100  is adapted for positioning on a stud using the first curved bracket  130  and the second curved bracket  140  attached to an angled assembly  110 . In preferred embodiments, the device can be installed and used without using a fastener. Once installed on the stud, the straight assembly  150  will be positioned in roughly perpendicular to the stud. In preferred embodiments, the angle alpha  188  between the longitudinal axis  184  of straight assembly  150  and vertical  180  will be less than about 90 degrees, and the straight assembly  150  is angled slightly upwards. In preferred embodiments, and angle alpha  188  is about 75 to about 85 degrees. This angle helps keep a spool of wire in position on the straight assembly  150  as the cable or wire is unspooled or dispensed. In addition, the upward angle of the straight assembly  150  also allows for better control of the spinning speed of the spool by allowing the spool to rub slightly against the supporting stud to provide drag. As used herein, “drag” means that a portion of the spool of wire loaded on the device contacts the stud with sufficient friction to require that force is applied to the wire to cause unspooling of the wire. 
     The spool is installed on the device  100  by passing the straight assembly  150  through the center channel of the reel hub to serve as an axle or spindle for the rotation of the spool during the unspooling of the wire. Once the reel is installed on the device  100 , a reel retention fastener  164  is installed in holes  162 . See  FIGS. 1 ,  2 , and  4 . Suitable reel retention fasteners include, but are not limited to, lynch pins, circle cotter pins, R-pins or hair-pin cotter pins. In certain embodiments in which the device comprises tubing, end caps  190  can be used. As used herein, “end caps” includes plugs. 
     The device can be constructed of tube stock or bar stock. In preferred embodiments, the device is constructed from tube stock. The device can comprise a metal, a composite or an engineering plastic. Suitable metals include steel, steel alloys such as stainless steel, aluminum, aluminum alloys, copper, brass, magnesium and magnesium alloys. Composites include fiberglass and carbon fiber composites. Engineering plastics include acrylonitrile butadiene styrene (ABS), nylon 6, nylon 6-6, polyamides (PA), polybutylene terephthalate (PBT), polycarbonates (PC), polyetheretherketone (PEEK), polyetherketone (PEK), polyethylene terephthalate (PET), polyimides, polyoxymethylene plastic (POM/Acetal), polyphenylene sulfide (PPS), polyphenylene oxide (PPO), polysulphone (PSU), polytetrafluoroethylene (PTFE/TEFLON®), polyvinyl chloride (PVC), and ultra-high-molecular-weight polyethylene (UHMWPE/UHMW). One of ordinary skill can use any or all of metals, composites or engineering plastics as needed in construction of the device  100 . In preferred embodiments, the device comprises steel tubing. 
       FIG. 2  is an exploded perspective view showing an exemplary embodiment of the device  100  in an unassembled state with the straight bar assembly  150  separated from the angled assembly  110 , and the first curved bracket  130  and the second curved bracket  140  separate from the rest of the angled assembly  110 . The straight assembly  150  has a first end  154 , a second end  152  and a junction region  156  adjacent to the second end. The second end  152  of the straight assembly  150  is connected to the angled assembly  110  at junction region  156 . 
     The angled assembly  110  has a first end  112  and a second end  114 . The first end  112  is adjacent to the corresponding junction region  122 . Junction region  156  and junction region  122  are connected together to assemble device  100 . 
     There are several suitable methods for connecting the straight assembly  150  to the angled assembly  110 . One embodiment is illustrated in  FIG. 2 , in which the inner diameter of junction region  156  is larger than the outer diameter of junction region  122 . The outer diameter in junction region  122  can be reduced by known methods appropriate to the materials used. For example, the diameter of steel tubing can be reduced by swaging. The straight assembly  150  is joined to the angled assembly  110  by inserting junction region  122  into junction region  156  and securing the connection by aligning the hole  160  until pin  124  until it is seated in hole  160 . 
     Another embodiment is shown in  FIG. 8A  and  FIG. 8B .  FIG. 8A  and  FIG. 8B  are longitudinal section views showing in  FIG. 8A  a threaded portion of the junction region  122  of the angled assembly joined to a threaded connector  170 , and in  FIG. 8B , a threaded portion of the junction region  156  of the straight assembly positioned onto the threaded connector  170  to join the junction portion  156  of the straight assembly to the junction portion  122  of the angled assembly. 
       FIG. 5  and  FIG. 6  illustrate a perspective view showing the details of first curved bracket  130  and second curved bracket  140 , respectively. These two brackets are identical, but mounted spaced apart along the length of the long straight section  116  with the open ends directed in opposite directions so as to grasp the stud. The first curved bracket  130  has a first end  131 , a second end  132 , a short arm  135 , a long arm  136 , an outer surface  133 , an inner surface  134  and a curved section  137 . The second curved bracket  140  has a first end  141 , a second end  142 , a short arm  145 , a long arm  146 , an outer surface  143 , an inner surface  144  and a curved section  147 . In certain embodiments, short arms  135 ,  145  and long arms  136 ,  146  can be of equal length. 
     The first curved bracket  130  and the second curved bracket  140  should be positioned on the long straight section  116  of the angled assembly  110 . The first curved bracket  130  and second curved bracket  140  should be spaced apart from one another with the inner surface  134  of curved section  137  and the inner surface  144  of curved section  147  facing horizontally in opposite directions, that is viewed from the longitudinal axis  182 . 
     In an embodiment, first curved bracket  130  and second curved bracket  140  are sized to fit onto a standard two by four dimensional wooden stud. The size of the bracket may be selected to fit different size studs and vertical supports. Both first curved bracket  130  and second curved  140  comprise curved sections  137 ,  147  that are rounded and adapted to grip the stud tightly. The added weight of placing the reel on straight bar assembly  150  further wedges the stud into this curved sections  137 ,  147  to reduce the likelihood of the device slipping down the stud. 
     While the disclosure has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.