Abstract:
An apparatus for storing, transporting, and dispensing elongate material, such as wire. The elongate dispensing system includes a reusable, stackable, storage container for having a substantially circular inner channel to contain a coil of elongate material and a dispensing guide having a plurality of interior guide mechanisms through which elongate material is dispensed without tangles or over-spooling. The storage container further includes a fastening system through which the dispensing guide removably engages said container during operation, ergonomic handles, and wire containment recesses which contain the ends of elongate material when the apparatus is not in operation.

Description:
[0001]    This is a continuation in part of U.S. patent application Ser. No. 09/588,845, now U.S. Pat. No. 6,296,118. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the invention  
           [0003]    The present invention relates to storage containers for elongate materials, such as wire or cable, and methods of use thereof. More particularly, the present invention relates to a stackable, reusable storage container and interconnecting dispensing guide.  
           [0004]    2. Description of the Background Art  
           [0005]    Storage containers for elongate material are widely used in industrial settings. In particular, storage containers are used not only for storing elongate material such as wire, but are also used as a means by which the elongate material is fed into a machine, commonly referred to as “pay out.” Both pay out and loading the elongate material into the elongate storage material containers is generally performed using the Nehoff Payout System (NPS).  
           [0006]    With reference to storage of elongate material, existing storage containers for elongate material consist of either small reels which contain approximately 6,000 lineal feet or large reel/barrel containers which contain approximately 15,000-30,000 lineal feet of elongate material. As a result of the two distinct classifications, industrial use is confined to either a mobile small capacity container capable of being moved by hand for use in projects requiring limited amounts of elongate material or a large capacity container capable of being moved only by machine for use in projects requiring large amounts of elongate material, some of which would be discarded, leaving barrels containing amounts of elongate material otherwise unusable for another project. Additionally, most small capacity storage containers are designed for only a one-time use, while most large capacity containers provide for only limited reuse as most contain left-over elongate material.  
           [0007]    With reference to the pay out of elongate material storage containers, either capacity elongate material container serves a the source from which the elongate material is loosely dispensed. Generally, while machines receiving the elongate material are capable of much higher rates of production, the storage containers of the elongate material require the machines to run at a substantially lower rate due to tangling and over-spooling problems associated with dispensing elongate material at higher rates of production.  
           [0008]    Several variants of elongate material storage containers are illustrated in U.S. Pat. Nos. 5,078,269; 4,967,978; 4,140,289; and, 4,032,078.  
           [0009]    U.S. Pat. No. 5,078,269, issued to Dekko et al, entitled, “Wire Shipping and Dispensing Container,” discloses a storage container which provides for improved dispensing of elongate materials through a specialized coiling and storage method. The Dekko et al. container requires a special apparatus to be used in the winding process by which a small quantity of elongate material is strategically coiled inside the container. The container also requires another special apparatus for the shipping and dispensing of elongated material.  
           [0010]    U.S. Pat. No. 4,967,978, issued to Roberts, entitled, “Wire Storage Reel,” discloses a wire storage reel wherein a large quantity of elongate material is wound onto the storage reel while tension is placed on the outer wall of the reel. Upon completion of the material being placed on the reel, the wire may be removed as desired by rotating the storage reel in accordance with the at the rate of the desired wire dispersion.  
           [0011]    U.S. Pat. No. 4,140,289, issued to Kovaleski, entitled, “Disposable Wire Storage and Pay-Out Spool,” discloses a cylindrical threaded spool having symmetrical conical end flanges capable of being disassembled for storage purposes. The spool is threaded to provide uniform installation and removal of large amounts of elongate material from along the body of the spool.  
           [0012]    U.S. Pat. No. 4,032,078, issued to Van de Loock, entitled, “Reel For The Storage Of Wire Or The Like,” discloses a circular reel including an array of bent wire forming the containment segments of the reel. The Van de Loock invention receives and stores large quantities of elongate material along the containment segments of the reel between two circular end pieces.  
           [0013]    In response to the problems associated with storage capacity, mobility, reuse, and high rates of dispensing material, the above-referenced patents offer various devices to resolve the a fore stated problems; however, these known devices have limitations and disadvantages associated therewith. For example, certain elongate material storage and pay out devices require the use of specialized material installation devices, while other elongate material storage containers are not reusable given the method of material installation. Further by way of example, other storage containers requires relocation via a machine due to their weight with little or no possibility of reusing the container and still require a slow rate of production to avoid tangles and over spooling.  
           [0014]    As a result, a need still exists in the art of elongate material dispensing and storage for an apparatus that properly and cost effectively dispenses elongate material. In particular, there is a need for a easily mobile, stackable, reusable storage container and dispensing guide to avoid tangles and over-spooling and increase production.  
         SUMMARY OF THE INVENTION  
         [0015]    The present invention has been developed to overcome the foregoing limitations and disadvantages of known elongate material dispensing from storage containers, and to generally fulfill a need in the art for an elongate material storage and dispensing apparatus which provides for movable, reusable and stackable containers using a standard method of loading and pay out as well as minimizing tangles and over-spooling associated with high rates of dispensing.  
           [0016]    An elongate material dispensing system, in accordance with the present invention includes a stackable, reusable storage container including outer and inner walls so as to define a substantially circular channel therebetween for storing elongate material and a dispensing guide supported by the container to prevent tangles and over-spooling as the elongate material is dispensed from the container.  
           [0017]    Accordingly it is an object of the present invention to provide a fastening mechanism which removably secures the dispensing guide to the container. The fastening mechanism is situated at the lower portion of the dispensing guide and is removably received by at least one aperture within a wall of the container so as to enable one dispensing guide to accommodate multiple containers consecutively.  
           [0018]    Another object of the present invention is to provide a dispensing guide including a main body, the lower portion of which includes the fastening mechanism and a cover which when fully assembled, creates a channel between the conically shaped interior of the cover and the main body, also conical in shape, through which the elongate material travels as it is dispensed from the substantially circular channel of the container.  
           [0019]    Yet another object of the invention is to provide a dispensing system including multiple flexible projections extending from either the main body or the cover, located between the main body and cover which further guide the elongate material from the container through the dispensing channel during operation.  
           [0020]    Still another object of the invention is to provide a dispensing system wherein at least one of the inner and outer walls of said container include a means by which a plurality of containers may be stacked in a nesting configuration. The nesting configuration varies depending on whether the container contain elongate material, as at least one of the inner and outer walls include a means for nesting containers when full or empty.  
           [0021]    Still another object of the present invention is to provide a container for storing, transporting, and dispensing elongate materials including an outer wall portion, an inner wall portion concentrically located within said outer wall portion connected together by a bottom wall portion such that a substantially circular channel is created for storing a coil of elongate material. At least one of the inner and outer walls containing a means of supporting an identical container thereon in a nesting configuration and at least one recess to secure the end of the elongate material when not being dispensed.  
           [0022]    Still another object of the present invention is to provide a container with a means for receiving the engaging a fastening mechanism of a dispensing guide within at least one of said inner and outer wall portions. The means may operatively comprise of an aperture or hole for releasably engaging a protrusion within said fastening mechanism.  
           [0023]    Still another object of the present invention is to provide a dispensing guide for directing elongate material from a container to a machine to prevent tangles and over-spooling. A dispensing guide according to the present invention includes a main body having upper and lower portions with tapered outer surfaces, each tapering away from the center of said main body, a cover having a substantially conical shaped inner surface and an aperture at the upper most section of said cover, and a fastening mechanism including at least one projection along the bottom portion of said main body. Said fastening mechanism cooperatively engages an aperture of an elongate storage container.  
           [0024]    Still anther object of the present invention is to provide a dispensing channel between the interior surface of said cover and the outer surface of said main body when said cover is operatively placed over said main body. Extending outward from at least one of said man body and said cover are a plurality of flexible projections which further direct elongate material from the container and through the dispensing channel.  
           [0025]    Still another object of the present invention is to provide an engagement means between said cover and a container whereby said cover is prevented from rotating during the dispensing of elongate material. 
       
    
    
       [0026]    For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0027]    [0027]FIG. 1 is a top perspective view of a the stackable, reusable, elongate material storage container in accordance with the preferred embodiment of the invention.  
         [0028]    [0028]FIG. 2 is a top perspective view two elongate storage containers in a stacked configuration in accordance with the preferred embodiment of the invention.  
         [0029]    [0029]FIG. 3 is a bottom perspective view of the pay out guide cap in accordance with the preferred embodiment of the invention.  
         [0030]    [0030]FIG. 4 is a bottom perspective view of the pay out guide in accordance with the preferred embodiment of the invention.  
         [0031]    [0031]FIG. 4 a  is an exploded view of the pay out guide in accordance with the preferred embodiment of the invention.  
         [0032]    [0032]FIG. 5 is illustrative of the assembly procedure for the pay out guide and cover.  
         [0033]    [0033]FIG. 6 is a perspective view of the pay out guide as interlocked with the elongate storage container in accordance with the preferred embodiment of the invention.  
         [0034]    [0034]FIG. 7 is a perspective view of the apparatus, fully assembled in accordance with the preferred embodiment of the invention.  
         [0035]    [0035]FIG. 8 is a cut-away view of the fully assembled apparatus. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0036]    Referring to FIGS.  1 - 8 , a first embodiment of the present embodiment of the elongate material storage container and pay out guide apparatus is shown generally at  100 . Specifically referring to FIGS. 1 and 2, the apparatus includes a storage container section  200  constructed from an injection molded plastic; however, alternative methods of construction and material may be used which possess characteristics and properties similar to that of the method and materials of the preferred embodiment; such methods and materials may include cast molding and various polymers.  
         [0037]    The storage channel  216 , located between the interior section  215  of the sidewall  213  and outer section  214  of the pay out base guide  220  houses the elongate material during loading, storing, and dispensing. The storage container  200  further includes a floor  217  equipped with drainage holes  240  for removal of debris or liquid which may fall into the internal storage channel  216 . Alternatively, the floor  217  may be constructed either completely void of drainage holes  240  or entirely in a grate-like manner.  
         [0038]    The exterior wall  212  of the storage container  200  which surrounds the storage channel  216  tapers inwardly toward the bottom so as to be easily stacked in variable nesting configurations. Specifically referencing FIGS. 1 and 2, the exterior wall  212  includes one multistacking system for occasion when the storage channel  216  contains elongate material and another when the storage channel  216  is empty. When the storage channel  216  contains elongate material the containers are stacked on top of one another so as to prevent damage to the elongate material (See FIG. 2). Specifically, the protrusions  231  and  239  molded with in the exterior wall  212  interconnect with the tabs  230  and indentations  244 , respectively, within the lip  236  of the exterior wall  212 . As shown in FIGS. 1 and 2 the lip  236  of the exterior wall  212  is polygonal in shape; however, as an alternative, the shape of the lip  236  may be molded into any shape (octagonal, square, oval, etc.) so long as portions of the lip  236  accommodate the securement tabs  303  of the guide cover  300  (See FIG. 3). When the storage channel  216  is empty, the storage container  200  may be stacked in a more compact configuration through the protrusions  231  and  239  engaging the depressions  232  and  233 , respectively, within the interior portion  215  of the exterior side wall  212 . Use of either stacking system is advantageous as the stacked, compact nature not only reduces shipping costs but also maintains that the stored elongate material remains in the containers during shipping. While the elongate material storage container  200  utilizes a dual system of stacking, a single system may alternatively employed, as well as a alternative system entirely, such as a hook and eye system.  
         [0039]    Additionally, the exterior wall  212  of the storage container  200  further includes various features designed to assist the user. As referenced by number  211 , the upper section of the exterior wall  212  includes slots  211  wherein the ends of the elongate material may be placed to assist the user in locating the end of the material. Further, the upper section of the exterior wall  212  includes handles  242  for ease in shipping and moving the container  200 . As shown in various figures, specifically referencing FIG. 1, the handles  242  are illustrated with contoured finger grips; however, the handles may alternatively not include individual finger grips or may be constructed in an alternate manner such as handle extending outwardly from the exterior wall  212 .  
         [0040]    Additionally referring to FIGS. 1 and 2, the elongate material storage container  200  includes a pay out base guide  220 , centrally located within the interior of the elongate material storage container  200 . The base guide  220  includes a sidewall  214  which also serves to contain elongate material within the storage channel  216 , support stands  225 , and receiving apertures  226 . The base guide  220  supports and interlocks the elongate storage container  200  to the pay out stand (See FIGS.  3 - 8 ).  
         [0041]    Specifically referring to FIGS.  3 - 8 , the pay out section of the apparatus  100  encompasses four main components: the cover  300 ; the connecting assembly  410 , the upper guide  420  and lower guide/locking assembly  430 . The main body  310  of the cover  300 , according to the preferred embodiment of is constructed from an injection molded plastic; however, the main body  310  may alternatively be constructed from any other plastic or polymer or by some means other than injection molding which would provide properties and characteristics similar to that of the preferred embodiment. Further, although the main body  310  is shown substantially conical in shape, the exterior surface of the main body  310  may alternatively be square or cylindrical in shape, so long as the interior surface  311  of the main body  310  remain conical as required to guide elongate material.  
         [0042]    Located along the lower edge of the cover  300  are depressions  302  within the main body  310  and which are located on either side of the placement tabs  303  which secure the cover to the elongate storage container  200  (See FIG. 7). Positioned on the top of the main body  310  is a rotatable collar  305  through which the elongate material is removed. The rotatable collar  305  is constructed of Teflon® and alternatively may be constructed of hardened plastic or other material similar to the properties and characteristics of the preferred embodiment.  
         [0043]    Further referring to FIGS.  3 - 8  the pay out guide  400  (shown assembled in FIG. 4) may be divided into its three remaining components  410 ,  420 , and  430 . The connecting assembly  410  includes a handle  402 , stopper  404 , elongate member  406 , partially threaded at the end  407  opposing the handle  402 , and standard threaded nuts  408  and  409 . The connecting assembly  410  removably affixes the upper guide  420  to the lower guide/locking assembly  430  through placing the elongate bar  406  through the upper guide  420  and lower guide/locking assembly  430  and securing the standard nut  409  to the threaded section  407  of the elongate member  406 . The upper guide is conical, similar shape and construction to the cap  300 ; although slightly smaller in scale.  
         [0044]    The lower guide/locking assembly  430  includes a main body  435 , recessed platform  431 , flexible extensions  433 , internal channel  432 , base  436  and interlocking devices  438 . The main body  435  of the lower guide/locking assembly  430  is conically shaped and constructed from material similar to that of the upper guide  420 . As depicted in FIGS.  4 - 6 , the lower guide/locking assembly  430  is slightly larger in diameter than the upper guide  420  and the larger end of the upper guide  420  engages the recessed platform  431  of the lower guide/locking assembly  430 . The flexible extensions  433  extend upward and outward from the large end of the lower guide/locking assembly  430 . The flexible extensions  433  are constructed from flexible nylon; however, alternative materials with properties similar to that of flexible nylon, such as rubber or the like may also be implemented. The base  436  and interlocking devices  438  are constructed from Teflon® or other similar material which may alternatively be constructed from a hardened material such as a plastic or polymer. The interlocking devices  438  are positioned slightly inward from the outer diameter of the smaller end of the lower guide/locking assembly  435  which is completely covered by the base  436 , while the interlocking devices  438  are secured to the base  436  by standard screws  437 .  
         [0045]    The pay out stand  400  is ultimately assembled securing the standard threaded nut  409  to the threaded section  407  of the elongate member  406  after passing through the internal channel  432  and through the base  436 . As the pay out stand  400  is secured to the elongate storage container  200  the base  436  rests along the top of the sidewall  214  and engaging devices  438  are positioned between the support stands  225  and engage the receiving portals  226  by rotating the pay out stand  400  clockwise.  
         [0046]    Specifically referencing FIGS. 7 and 8, the apparatus  100  is fully assembled when the cover  300  is placed over the pay out stand  400  and is resting on the top  236  of the exterior wall  212  between the molded grips  242  the protrusions  231  of the exterior wall  212 . Referring to FIG. 8, the apparatus  100  is shown in cut-away view so as to clearly illustrate the function of the apparatus  100 . The elongate material is stored in the storage channel  216  as it is dispensed during payout the elongate material extends upward as directed by the lower guide  435 . The flexible extensions  433  engage the interior surface  311  of the main body  310 , causing the extensions  433  to flex. The elongate material engages the flexible extensions  433  and is thereby directed into the dispensing channel  450  and is then routed out of the apparatus  100  through the rotatable collar  305 .  
         [0047]    Although the present invention has been described herein with respect to a preferred embodiment thereof, the foregoing description is intended to be illustrative, and not restrictive. Those skilled in the art will realize that many modifications of the preferred embodiment could be made which would be operable. All such modifications which are within the scope of the claims are intended to be within the scope and spirit of the present invention.