Abstract:
This specification discloses simplified wire payout apparatus for paying out wire directly from a box in which the wire is shipped, thus eliminating the necessity of providing mechanical payout equipment such as has been required on utility service trucks. For light-weight and low cost, a corrugated paperboard carton is used as a shipping container; and provision is made for paying out the wire without removing a spool, on which the wire is wound, from the box. The spool is preferably also made of corrugated paperboard.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     Utility service trucks, particularly those used for telephones, carry quantities of wire which are coiled on spools and payed out in the lengths required by mechanical payoff equipment. The spools generally carry a large quantity of wire and are heavy; and the payoff equipment is also heavy. 
     In order to reduce the size and operating cost of service trucks, this invention provides means for supplying the necessary wire from smaller and inexpensive spools from which the wire can be payed out without removing the spool from its shipping carton and without having any payout equipment, such as has to be used with heavy spools. 
     This invention provides a spool which can be constructed from corrugated paperboard by a novel arrangement of parts; and the spool is shipped in a special carton, which can also be made of corrugated paperboard, and which has provision for convenient payout of the wire without removing the spool from the carton. 
     Features of the invention include the special construction of the spool and carton; provision for holding the end of the wire for convenient handling and, at the same time, adequate sealing against tampering before the carton is opened for use; low friction of the spool as it rotates in the carton during payout of wire; convenient rewinding of wire on the spool of any excess wire payed out from the carton; and inspection openings through which the amount of wire remaining on the spool as the spool rotates while the wire is paying out, can be determined. 
     Other objects, features and advantages of the invention will be pointed out as the description proceeds. 
    
    
     BRIEF DESCRIPTION OF DRAWING 
     In the drawing, forming a part hereof, in which like reference characters indicate corresponding parts in all the views: 
     FIG. 1 is a side view, partly broken away and in section, of a carton and wire spool made in accordance with this invention; 
     FIG. 2 is a fragmentary sectional view taken on the line 2--2 of FIG. 1; 
     FIG. 3 is a greatly reduced scale view showing the blank from which the carton of FIG. 1 is made by folding the various panels along predetermined fold lines; 
     FIG. 4 is a reduced scale view showing one of the flanges of the spool of FIGS. 1 and 2 before the spool is assembled; 
     FIG. 5 is a fragmentary plan view of the top of the carton shown in FIG. 1 and illustrating the openings through which wire is withdrawn from the carton; 
     FIG. 6 is a sectional view on the line 6--6 of FIG. 5 but showing the top opening closed by a knockout; 
     FIG. 7 is a fragmentary, reduced scale view of the core of the spool before the spool is assembled; and 
     FIG. 8 is a view similar to FIG. 7 but showing a modified construction for the core. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
     A container or box 10 includes a front wall 12 and a back wall 14 connected to one another by side panels 15 and 16. The box is preferably made from a single blank, as shown in FIG. 3. 
     The left-hand edge of the side panel 15 is secured to the right-hand edge of the front wall 12 by a flap 17 and suitable adhesive. There are end panels 21, 22, 23 and 24 attached to the walls 12 and 14 and panels 15 and 16, respectively, along fold lines designated by the dotted line 26 in FIG. 3. There are similar end panels at the other end of the box indicated by the same reference characters but with a prime appended. These panels at the bottom of the box are similar to those at the top, except that certain openings are provided in the top panels for removal of wire from the box. 
     The flap 17 is secured to the panel 15, and the box is folded flat along fold lines 30 and 32. When the box is to be set up, preparatory to receiving a spool of wire, the folded blank is opened up so that the front and back walls 12 and 14 extend at right angles to the panels 15 and 16; and the end panels are then folded inward with the panels at the top and bottom of the box overlapping others at the same end of the box to produce the container shown in FIG. 1. 
     The bottom panels 21&#39;, 22&#39;, 23&#39; and 24&#39; are secured together with adhesive over areas sufficient to provide a strong and permanent bottom for the box; this bottom being indicated by the reference character 34 in FIG. 1. 
     The upper panels 21, 22, 23, and 24 are not secured together until after the box is filled. A spool 36, having flanges 38 and a core 40 connecting the flanges is inserted into the box 10 with the upper panels 21-24 extending upward. The spool 36 is of a size which fits loosely within the box 10 so that the spool is free to rotate in the box with no substantial pressure against the sides of the box, except such pressure as is exerted by the weight of the spool and its contents against an underlying side of the box; the particular side depending upon which way the box is oriented when being used to supply wire. 
     A coil of wire 44 is wound on the core 40 between the flanges 38 in the conventional manner. The outer end portion of the wire 44, which is designated in the drawing by the reference character 46, is led out through an opening 48 before the panel 24 is folded down into the position which it will occupy when the box is closed. The end portion 46 is then led through an opening 50 as the panel 26 is folded down into closed position. The portion 46 of the wire is then bent horizontally and the end of the wire inserted back into the box 10 through an opening 52 in the panel 22 and through an opening 54 in the panel 24, as shown in FIG. 6. 
     The upper panel 21 is then folded down to complete the closing of the box, and the various panels forming the top of the box are secured together with adhesive, or otherwise, with sufficient strength to provide a top structure which is an integral unit of the box. 
     The upper panel 22 is cut away between the openings 50 and 52 to provide a clearance 56 for the end portion of the wire, as also shown in FIG. 6. This clearance 56 is made with a wider part between the openings 50 and 52 so that a workman can insert his thumb and forefinger into the clearance 56, on opposite sides of the wire, to pull the wire upward and bring the end of the wire out of the openings 52 and 54 when more wire is to be pulled out of the box. 
     The upper panel 21 has a knockout 60 where the panel is cut part way through or cut enough to weaken it so that the knockout 60 can be removed to expose the openings 50 and 52 and the other openings in alignment with these openings 50 and 52. The knockout 60 seals the box during shipment and as long as the knockout is in place, anyone receiving the box in shipment is assured that the wire has not been tampered with or any of it withdrawn from the carton prior to delivery of the carton at its ultimate destination. 
     The spool has two flanges; the nearer flange in FIG. 1 being designated by the reference character 38 and the distant flange by the reference character 38&#39;. Both of the flanges are of similar construction, and each one has a center opening 64 which is large enough to enable a workman to insert his hand into the interior of the spool and grip the circumferential edge of the opening 64 so as to rotate the flange manually, as necessary, and the spool must be rotated in order to wind the wire back into the box. In order to provide access to the edge of the opening 64, there is a knockout 66 in each of the front and back walls 12 and 14. Removal of a knockout 66 leaves an opening 66a, as shown for the front wall 12 in FIG. 1. The opening 66a is substantially larger in diameter than the opening 64 of the flange so as to provide exposure of an outside surface of the flange which can be gripped by a workman to rotate the spool when winding wire back on the spool. 
     There is another knockout 70 in the front wall 12, and when this knockout 70 is removed it leaves an inspection opening 70a which has a radial extent equal to the radial thickness of the wire 44 on the spool 36 when the spool is full of wire. There are openings 72 at angularly spaced locations around the flange 38. These openings 72 are preferably of the same size as the opening 70a, and they are located in positions that are in alignment with the opening 70a whenever one of the openings 72 passes under the opening 70a as the spool 36 rotates in the box. The openings 72 extend completely through the flange 38 and thus expose the wire 44 to view, so that anyone using the wire from the spool 36 can see how much wire is left on the spool as each of the successive openings 72 passes under the inspection opening 70a. 
     The spool 36, which fits loosely in the box 10, rotates in the box and has relative movement with respect to any inside surface of the box in which it contacts from time to time. In order to reduce friction and to make it easier to withdraw wire from the spool, means are preferably provided for reducing the friction between the spool and the surfaces of the box. This is done economically by lining the box with wax paper 76 or by coating the blank from which the box is made with wax applied to the surfaces which will constitute the inside of the box when the blank is folded to complete the box. 
     Each of the flanges 38 is made with angularly located slots 80. The core 40 is formed with a continuous panel 82 which is long enough to form the circumference of the core. There are projections 84 extending from opposite edges of the panel 82, and these projections 84 are of a size to insert into the slots 80. The projections 84 are then bent inwardly toward the axis of the spool 36, and end portions 86 of the projections 84 are tucked into other slots 90, which are radially spaced from the slots 80. This construction is best shown in FIG. 2. To facilitate the neat bending and tucking in of the projections 84, there are weakened lines 92 formed in each projection at the time that the core blank is manufactured by die-cutting it from a panel of corrugated paperboard when the spool is made of such material. 
     FIG. 8 shows a construction of a core blank which is similar to FIG. 7 but made with projections 84&#39; which are spaced further apart, so that there is a projection 84&#39; for every other slot 84. The projections 84&#39; on one side of a panel 82&#39; are in staggered relation with similar projections 84&#39; on the other end of the core. This reduces the labor involved in connecting the flanges to the core when assembling a spool, but at some sacrifice in the strength of the spool. 
     The spool and its shipping container can be made of other material than that described above for the preferrred embodiment, and other changes and modifications can be made, and some features can be used in different combinations without departing from the invention as defined in the claims.