Abstract:
A knockdown spool comprising a one piece barrel and having a pair of end flanges releasably attached through rotational motion to opposite ends of the barrel by locking means capable of being released in order to separate end flanges from barrel. The barrel contains aligning and locking channels which cooperate with a protrusion on outside walls of flange hub. The aligning and locking channels contain a curve and cusp serving as locking mechanism. Integrally designed within the hub is a recessed passage way leading to a recessed multi-faceted drive connection. Said drive connection of the spool provides a user the opportunity to thereby create a powered mechanical device for quickly and conveniently winding, re-winding, dispensing and storing of or re-using materials of long continuous lengths by attaching the spool to a powered driver via a multi-faceted bit.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of prior filed co-pending provisional application No. 61/209,278 entitled “Knockdown Spool with Integrally Recessed Hexagonal Drive Connection” filed on Mar. 5, 2009 in the name of Cory Arthur Strong, said provisional application being hereby incorporated by reference as if fully set forth herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention pertains to so called knockdown reels of the type which, at present, comprise cylindrical or tubular barrels of predetermined length having flanges on opposite ends thereof containing a hub with engage-able connection points formed in various ways which are connected to opposite ends of the barrel at the time the reels are to be used. Reels of this type are shipped to manufactures, and distributors in knocked down condition for purposes of compactness during the shipping process. They are consumed in large quantities by manufactures and users of strand material such as electric wiring, string, rope, chain, and other materials and objects in long continuous lengths from light weight to heavy weight. Reels of this type quite commonly are formed at present from certain synthetic resin compounds or plastics while others are formed from sheet metal, cardboard, or wood, in various ways. In general, the present invention pertains to reels of a less heavy construction. These heretofore mentioned aspects of the current spool art are of benefit and interest to the spool manufacturers and distributors. However, they lack appeal and functionality for end consumers in trades, households, and light industrial applications. 
         [0003]    The manufacturer or distributor who purchases the spool from the spool manufacturer, most often an industrial or commercial manufacturer or distributor, winds or wraps goods on the spool by way of mechanical means. The most often used method is a permanently mounted, industrial bench winding device. The manufacturer or distributor then dispenses the material as needed or sells the spool with the material on it as a consumer good to distributors or retailers. The end consumer who purchases either the entire spool of goods or a portion of the goods dispensed from the spool receives no benefit nor has interest in the spool and, as a result, either discards the spool, or in the case of heavy industrial type spools, return ships it. If the end user or consumer has the need or desire to re-wind or store the dispensed material for re-use, the current spool art offers no way to accomplish this quickly and conveniently without the use of an industrial bench winder. An exception is a reel design specific to the flying of kites, not of the knock down type, discussed later. Consumers or end users, specifically households and light industry, have long sought a means to quickly and conveniently re-wind, dispense, re-use and/or store light weight goods on spools in the interest of conservation and cost saving. Without having access to a permanently mounted, expensive, and cumbersome industrial type bench winding device, and the ability to operate it, the heretofore mentioned tasks are impractical, if not impossible, as well as time consuming. 
         [0004]    Prior patented art found in the United States Patent Office includes, U.S. Pat. No. 6,045,087, Vislocky, et al. Apr. 4, 2000, and U.S. Pat. No. 5,575,437, Campbell, Nov. 19, 1996 that pertain to knockdown spool assembly and disassembly, specifically the ease thereof. The art in both cases consists of improvements to overall strength and alignment of the barrel to fit into the flange for rapid assembly by the user, and in the case of Campbell, rapid disassembly. U.S. patents McCaffrey, U.S. Pat. No. 4,903,913, February 1990, and Crellin, U.S. Pat. No. 3,785,584, January 1974 both address knockdown spools, however, in a different way. The art from these patents attempts to address the problems of loose fit, lack of positive interlocking means to attach the barrel to the flanges, and overall strength of an assembled spool. Additionally, these four mentioned sources of prior art focus on a form of snap together parts as an improvement or alternative to spin welding, glue, or solvents as the attachment method in the interest of conserving space for shipping purposes. This art provides adequate solutions to the aforementioned issues but is different from this invention in several ways. None of this prior art mentions, depicts, or includes as integral to the design, an invention that permits a user to mechanically re-wind or dispense for future use, material or objects in long continuous lengths quickly and conveniently, without the use of an industrial bench winding device. This invention makes these tasks possible with the attachment of a common, hand-held, powered driver. 
         [0005]    Current spool manufacturing methods provide viable products for the spool manufacturers, manufacturers of goods that need to be placed on spools, and finally distributors. They address the need to ship large quantities of spools in relatively small packages in addition to quick assembly and in some cases disassembly. They are also designed to be used in conjunction with the heretofore bench winding method. The bench winder is a widely accepted and commonly used method of winding material onto a spool in an industrial setting. However, these spool manufacturing methods do not provide a quick and convenient way to re-wind or dispense for future use material or objects in long continuous lengths for the end consumer in a household, trade, or light industrial environment or application. Many objects or materials in long continuous lengths can and do have more than one use or can be re-used many times. Instead, they are often discarded or thrown away due to lack of the ability to quickly and conveniently re-wind or dispense material. 
         [0006]    Fagan, in U.S. Pat. No. 5,190,237 shows a reel or spool driven by a powered driver to wind kite string. As indicated in the title of the art, this reel includes a clutch mechanism, which inherently comprises several moving and stationary parts to accomplish the job. Additionally, this design requires a specific order of assembly. The clutch assembly and it&#39;s many parts of the Fagan design are eliminated with this invention, which includes an integrally designed hexagonal drive connection not requiring assembly. Thornbury, U.S. Pat. No. 5,277,350, teaches of a design incorporating a powered driver using an adapter(s) to connect to one of the kite reel handles. Like Fagan, Thornbury provides a method for rapidly winding kite string on a reel or spool using additional parts or adapters. Finally, Peterpaul, U.S. Pat. No. 6,550,712, adapts a spool to a powered driver using hub and sleeve adapters thereby creating a way to wind material onto a spool. These examples are for a single, specific, recreational activity use and employ several pieces, parts and/or adapters requiring assembly before a powered driver can be attached. The recessed integral hexagonal drive connection in this design effectively eliminates the additional pieces and creates the opportunity for a portable, hand-held, powered, winding and storage spool device. The methods mentioned above, although valid winding devices, are cumbersome when compared to the compact recessed integral design provided with this invention. Additionally, those patents are not of the knockdown spool category. This invention reveals a knockdown spool providing the opportunity for use as a portable winding or storage device when attached to a common hand held powered driver. 
         [0007]    It is determined that in a review of the prior art that there is no knockdown spool design incorporating a recessed integral hexagonal drive connection design which permits a user to quickly and conveniently attach a powered driver to a spool thereby creating a portable winding and storage spool device for re-winding, dispensing, or storing objects or materials in long continuous lengths in a household, trade, or industrial environment or application. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    The invention, an improved knockdown spool, has a recessed integral hexagonal drive connection. The drive connection is integrally designed into the flange hub, reinforced for strength and recessed for ease of use. It is an object of this invention to create a device which allows a user to rapidly connect a common, hand-held, powered driver to the spool for quick, convenient re-winding, dispensing, re-using and or storing objects or materials of long continuous lengths. 
         [0009]    Additionally, another object of this invention is to create a device for the said purposes which is easier on the user to hold and manipulate. The aforementioned recessed design of the hexagonal drive connection provides the benefit of reducing the moment arm and top heavy feel by allowing the user to operate with a hand as close to the spool as possible after the driver is attached. 
         [0010]    It is a further object of this invention to create a device which is used for the retrieval and storage of continuous lengths of materials or objects. The storage of the devices are aided by a unique design to facilitate stacking of the devices. 
         [0011]    It is also an object of this invention is to create a device that is economically positioned in the marketplace, where people will buy multiple sets of the device and use as a permanent storage device, yet enable the user to “knock-down” the device easily when not in use. 
         [0012]    It is a further object of this invention to have a multi-stage drive mechanism acceptance portal, whereby a plurality of power driven mechanisms can be adapted to function within this one device. 
         [0013]    It is a further object of this invention to create an economically viable product that one uses to store wound materials for long period of time, rather than having expensive collapsible spools that are too expensive to store material on them. 
         [0014]    Accordingly, the invention provides an improved knockdown spool for household, trade, or industrial use, to provide an economical, convenient device to re-wind, dispense and re-use objects or materials of long continuous lengths, and to encourage conservation of these materials by providing the heretofore mentioned benefits. Still further objects and advantages will become apparent from a study of the following description. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0015]    In  FIG. 1  is a side elevation of a single flange 
           [0016]    In  FIG. 2  is a frontal elevation of the exterior face of the flange 
           [0017]    In  FIG. 3  is a cross-sectional view along cutting line A-A of  FIG. 2 , detailing the interior face and hub of the flange. 
           [0018]    In  FIG. 4  is a detail of the exterior end of the hub detailing the winding means interface. 
           [0019]    In  FIG. 5 , a detail view of the exterior of flange in  FIG. 2  detailing the ingress portal to the winding means interface. 
           [0020]    In  FIG. 6 , the interior side of the flange is shown in an oblique view detailing the exterior of the hub along with the securement means and sear catch. 
           [0021]    In  FIG. 7 , the barrel is view from a frontal elevation. 
           [0022]    In  FIG. 8 , a chord section, shown as C-C on  FIG. 7 , is taken from the frontal elevation in  FIG. 7  detailing the interior of the barrel. 
           [0023]    In  FIG. 9 , an oblique elevation of the exterior of the barrel enabling the viewing both ends of the barrel. 
           [0024]    In  FIG. 10 , a completed assembled unit is shown in an oblique elevation. 
           [0025]    In  FIG. 11 , the completed assembled unit is shown through a longitudinal cross-section. 
           [0026]    In  FIG. 12 , an assembled unit is shown from a top elevation detailing the engagement of the securement means. 
           [0027]    In  FIG. 13 , as assembled unit is shown from a side elevation detailing the sear catches and their relation to the securement means. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    The present invention will be detailed in relation to the aforementioned drawings. All disclosure is representative of the best mode of practicing this invention but that it is assumed that those skilled in the art will be able to practice this invention in other fields of application, nor does this disclosure limit the construction of this invention to the parts herein disclosed. Applicant recognizes that development of future inventions may lead to better parts than those disclosed, but the intent of this application is to show the best available parts currently available by their fit, form and function to their exclusive use by this application. 
         [0029]    The device consists of two primary parts, one of which flange  36  is used in a pair, which are able to be used on either end of barrel  2 . The uniqueness of this design is that the user need not determine a left or a right flange of the spool as both flanges are the exact same, allowing for an easier user interface with the device. 
         [0030]      FIGS. 7-9  detail the barrel  2  of the device. Barrel  2  is a basically circular core having a consistent bore, having both open ends to configured to accept the securement means. Barrel  2  has an external surface  14  which is, in this disclosure of the best mode to practice this invention, circular in nature. This disclosure is not limited to only circular outer surfaces as other surfaces, such as hexagonal or decagonal, may be used to facilitate a better gripping means or would better facilitate the storage of the wound lengths stored on the spool. Barrel  2  has an interior bore  12  which interfaces with flange hub  52  through a close fit tolerance, and has barrel end face  24  which terminates barrel  2 . The distance between each barrel face  24  is determined by the capacity required and the material to be wound upon the barrel. 
         [0031]    Barrel  2  also contains securement means  3 , ingress to which is located along a common axis along barrel  2 , said ingress being through securement means ingress  16 . Ingress  16  is an opening through which securement post  70  passes. Post  70 , as seen in  FIG. 3  and  FIG. 6 , passes into ingress  16  through taper  15 , said taper serves to direct the post into the ingress aiding the user in finding ingress  16 . Slot  19  leads from ingress  16  towards channel  28 . The user supplying lateral motion directs post  70  through slot  19  until the travel terminates upon contact the channel wall  28 W. Where the width of slot  19  allowed for some locating play between post  70  and the walls  17  of slot  19 , channel  28  has a distance between the walls that contacts post  70  with a close sliding fit as defined by ANSI B4.1 where there is interference between the post and channel walls. A natural radius or curve  28 C facilitates the transition into the more confining space of channel  28 . The user will rotate barrel  2  in the direction that moves post  70  through channel  28  until post  70  rotates through expansion zone  20 , whereby the distance between the slot walls in channel  28  increases slightly to become a transition fit where is little contact or interference. Post  70  then rotates and comes in contact with cusp  22 , whereby the post is firmly captured. User repeats the assembly action on the other flanges onto the barrel to complete the assembly. The assembled device is seen in  FIG. 11 . 
         [0032]      FIG. 6  is an oblique perspective of the rear one of the two flange  36  required for the invention showing centrally located hub  52 .  FIG. 3  is a cross-sectional view detail the interior side of flange  36  along with a crossection of hub  52  where the recessed integral hexagonal drive connection passage way access opening  32  is shown along with the recessed integral hexagonal drive connection  54 . 
         [0033]    Hub  52  protrudes from the rear of flange  36  and contains not only the drive interfaces, but the securement post  70  and stiffening ribs  58 . The front or external side of flange  36  has a raised panel pattern  38 , which emanates from the center of the flange to the circumference of flange  36 . There are multiple spoke projections, where there are an equal number of pattern panels  38  as there are spaces between them. The purpose of pattern panel  38  is four-fold. Firstly, it is noted that flange  36  is not a solid piece, but rather has the pattern as spokes. The use of patterns  38  decrease the weight of the flange, reducing the torque or moment required to rotate the device, and provides for visual identification of the wound material or product should the devices be stacked. Secondly, the use of pattern panel  38  increase the strength and rigidity of the flange in comparison to a solid disk of the same thickness and dimension. Thirdly, pattern panel  38  is substantially triangularly shaped and it&#39;s surface is contoured so that they create an interlocking weave as one pattern will intermesh with an open space of another flange, enabling a more stable stacking configuration should multiple devices be stacked upon one another. Lastly, flange pattern  38  has an aesthetic consumer product appeal and contains contours that can facilitate labeling. Beveled edge  62  is internally located along the circumference of flange  36 . Edge  62  acts as a guide for the level winding of material onto barrel  2 . 
         [0034]    Located on the exterior surface  53  of hub  52  is beginning sear catch  60  and securement post  70 , which are located directly opposite of one another along the diameter of hub  52 . Securement post  70  is shown in  FIG. 6  to be circular or oval in shape, but can also be square in square as seen in the cross-sectional view in  FIG. 3 . Cusp  22  will have a matching contour to the shape of post  70  in order to accommodate a contact fit between said cusp and said post. The location of post  70  is such as that when the post is secured located into cusp  22 , barrel end face  24  is in contact with hub stop  55  as the distal end of sear catch  60  and in contact with the distal ends of stiffening members  58 . A plurality of stiffening members  58  are radially located along horizontal axis of hub  52 , on the exterior surface  53 , said members having an proximal end, which is in contact with the interior side flange  36 , and a distal end which terminates into a vertical face. 
         [0035]    Sear catch  60 , shown in FIGS.  1 , 3  and  6  has the purpose of providing a place to fasten down the end of the material sought to be rewound upon the barrel of the device. In this application, catch  60  has a vertical and a horizontal component with a radiused intersection between the two components. Space is provided between catch  60  and the interior of flange  36  to assist the user in placing the material onto the catch. The style of catch  60  is not determinative upon this application and various styles can be adapted for particular materials that are to be rewound onto the device, such as creases for holding wire or loops to hold to beads. Directly opposite of the horizontal component of catch  60 , along the surface of flange  36 , is sear catch opening  40  which aids the user in the attached or removal of the end of the material to be wound onto catch  60   
         [0036]    Hub  52  has a proximal end with a recessed integral drive connection passage way  32  accessed from the exterior of flange  36  and a distal end that is at the farthest point away from the interior side of flange  36 . A hexagonal socket drive portion  54  is located interiorally from passage  32 , said passageway  32  being larger in diameter than drive portion  54 , as seen in  FIG. 5 .  FIG. 4  is a cross-sectional view of hub  52  showing the passage way  32  and drive portion  54  in axial communication with one another. Hub  52  is strengthen and stabilized by a plurality of radial ribs  56  extending radially from the exterior  59  of drive portion  54  connecting to the interior wall of hub  53 . In this disclosure, the passage way opening  32  is circular in shape with a predetermined diameter made to accept a powered driver collet with hexagonal bit allowing the powered driver placement near flush to the exterior of flange  36  decreasing the moment arm and reducing the potential top heavy feel during use. In adapting to newer technologies, multi-sided collets are replacing knurled collects, and this device can be adapted to accept this new style of collets. It also allows for a hexagonal bit to be attached without a powered driver. There are a variety of type of combinations of collets and hex-shaped tools that will function within this device. The use of the wording hex or hexagonal is merely descriptive of the style of bits or shape of bits that can be adapted into this device. Other common styles of multi-faceted bits including Torx® and spline drive can be accommodated by simply configuring the drive portion  54  to accept other bit styles. As noted in the drawing Figures, the drive portion  54  is without any terminating stops, thus the length of the bit is not critical and can extend to or past the opposite hub for any purpose. 
         [0037]    In operation a user takes the 2 flanges and the barrel of the knockdown spool and assembles them. Holding one flange in one hand and taking the barrel in the other hand, the user slides an open end face of the barrel over the hub wall, aligning the post on the hub wall with ingress in the barrel. Push the barrel over the hub until the post contacts the curve in the channel, then turn the barrel in the direction of the channel until it locks in place. Repeat these steps with the second flange. Accomplish steps in reverse to disassemble. 
         [0038]    Once the knockdown spool is assembled it is now ready for use to wind, re-wind, dispense or store materials or objects of long continuous lengths quickly and conveniently. Hold the assembled spool in one hand. With the free hand, take a powered driver with a hexagonal bit of predetermined length and width and insert it into the recessed integral hexagonal drive connection opening until it stops or the driver contacts the flange disc. Now support the spool, as it is connected to the driver, by holding the driver with one hand. With the free hand, take the beginning of the material desired to be wound and attach it to the beginning sear catch by using a wide end or wrapping or bending the material. While operating the spool and driver combination in one hand, use the free hand as a guide for evenly winding the desired material on the spool. To dispense material operate same way using free hand to guide dispensed material. Material can be easily and neatly stored once on the spool or quickly and conveniently dispensed for re-use. This manner of use can be accomplished while sitting, standing or walking to dispense or wind material. 
         [0039]    This device has succeeded in achieving the objectives of this invention, and though only current technology exists, future technologies may produce materials and components that would accomplish these objective in different or similar manners. These advances would be considered to be within the spirit, scope and intent of this patent and the claims herein disclosed