Patent Publication Number: US-2018037435-A1

Title: Wire caddy

Description:
This disclosure relates to portable coiled wire support for manual transportation and deployment of spooled wire. This application claims the benefit of provisional application 62/370,713 filed on Aug. 4, 2016, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD 
     Background 
     Cords, threads, wire, fishing line, and similar flexible linear materials have been stored on, and deployed from, spools for millennia. For example there are over ten thousand U.S. patents related to fishing reels alone. Nonetheless, improvements in spools and related to using spools remain a fertile technology area due to the many materials spooled and the many uses of spooled material. 
     While there are many devices for supporting spooled wire for manual deployment by electricians, persistent difficulties with tangling, jamming, over-run, and other issues remain. 
     SUMMARY 
     A toolbox-size device contains wire spools that are supported by both a cradle and a removable axial spindle. This dual support contributes to solving several problems involved with manual wire deployment devices. Particular object spatial and size relationships can include of the cradle, spindle, spool diameter, spool hub, arbor opening diameter, enclosure size, and exit aperture location; provide a solution to reliably and smoothly deploy electrical wire manually from a hand-carried device. The cradle holds spools generally in place when the axial spindle is removed to add or remove spools. The dual support system allows the use of spools with damaged flanges normally not possible with a cradle-based system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic drawing of a wire spool. 
         FIG. 2  is a table showing industry standard sizes for the spools of  FIG. 1 . 
         FIG. 3  shows an exploded view of an embodiment wire caddy. 
         FIG. 4  shows three spools loaded into the embodiment of  FIG. 3 . 
         FIG. 5  shows a schematic cut away view of a spool accommodated in the embodiment of  FIG. 1 . 
         FIG. 6A  shows the position of a spooled wire after a recoil. 
         FIG. 6B  shows a wire caddy with cradle spacing that is too large 
         FIG. 6C  shows a wire caddy with the problem of a loop of wire caught in a corner. 
         FIG. 7A  shows an example broken spool. 
         FIG. 7B  shows a broken spool operational in the wire caddy of  FIG. 3 . 
         FIG. 8  is a photo of a prototype wire caddy, its components are shown to a consistent scale. 
     
    
    
     DETAILED DESCRIPTION 
     Structure 
     While these teachings apply to a wide range of spools of various dimensions, the example and discussion is based on spools of a type widely used in the wire and cable industries for AWG wire gauges of 14, 12 and 10 gauge.  FIG. 1  shows a schematic drawing of a wire and cable industry standard wire spool. The various structures and distances usually specified include flange diameter  101 , traverse  102 , barrel outer diameter  103 , and arbor hole size  104 .  FIG. 2  shows a table of nominal standard sizes. 
     An example embodiment wire caddy is shown in an exploded state in  FIG. 3 . Although not drawn to a specific scale the relative sizes of components are accurate. The depicted version is sized to hold up to three 6½″ diameter spools. An enclosure  200  of a similar size and shape as a toolbox holds a spool support  201 . The spool support has two opposing flat end plates  202  joined by rods  203  that make up a cradle  204 . In addition, the end plates have openings to accept a spindle that extends axially through the spool or spools  205 . The spindle  207  radiuses in this example are about 80%-90% of that of the arbor opening. In this example, the cradle rods are rollers. 
     The spool support fits loosely the enclosure as seen in  FIG. 4  and is readily removable from the enclosure. The portrayed example shows handhold cutouts  206  for this purpose. The end of the wire  212  of each spool is shown threaded through respective exit apertures  211 .  FIG. 5  shows a schematic form of a cutaway view with the lid closed and wire exiting through an aperture located on an angled portion of the lid, near one edge. 
     Many existing spool caddies have axial spindles; one example is seen in FIG. 6 of U.S. Pat. No. 6,375,115 showing a device providing axial support. Some others have arcuate cradles (see FIG. 1 in patent application US 2007/0120003.) The current teaching is that using both types of support in a specific geometric and spacing relationship to each other and in relationship to the location of the exit provides unique advantageous properties. 
     Some of the geometric relations that provide the device with its favorable properties are—a cradle of a radius of about the radius of the flange and a spindle between 80%-90% the radius of the arbor opening; the spindle&#39;s axis is located by the end plates such that the spools are resting on the cradle even when the spindle is inserted. When the lid is closed, the distance to the spindle from the lid is about 1.5 times the radius of the spool; and the angled portion of the lid is about 16-degrees. This angled portion of the lid can be thought of as an exit support surface. In some embodiments, the exit support surface may not be comprised in a lid but might be a portion of the nearest sidewall or otherwise supported. 
     The existing exit aperture radius is between 0.5″ and 1″. The cradle covers an arc of about 140-degrees centered on the bottom of the spools. 
     The cradle also acts as a fence or guard to prevent un-tensioned wire from dropping too far below the extent of the flange. In other devices, if a wire falls below a flange, there is a large possibility of the wire interfering with a neighboring spool or wire or otherwise causing other than smooth operations. An alternate cradle (not shown) comprised of a continuous mesh material, for example, may also be a very functional guard. In a rod-based cradle design with small diameter rods, the largest of the angular spacing between rods can be what determines a reliable guard and a “leaky” guard.  FIGS. 3, 4 and 5  are based on an example design supporting spools of 12 gauge stranded wire. The angular spacing between adjacent rods is about 45 degrees. One of the operational events that can cause snagged wire in other designs is the release of the wire after being pulled. The wire&#39;s stiffness can cause it to pull back and result in the slack case seen in  FIG. 6A . With a proper cradle seen in this figure as in the current embodiment, this is not a problem. 
       FIG. 6B  shows a case of supporting rods  303  being too far apart and allowing the snagged wire to be uncontrolled and result in a stray loop  300 . 
     The requirements of the cradle as guard are determined by the stiffness and “springiness” of the wire. The less stiff the wire, the more closely the rods would need to be. In the present example the wire is 12 gauge stranded. 
     Exit Corner Configuration 
     In many of the present figures, the exit opening is shown as a hole in an angled surface near one upper corner of the enclosure. A benefit of this “barn” shape of the corner with the direction of the exit at about 16-degrees is to reduce the chance of a stiff wire getting caught in the corner, as seen in  FIG. 6C . If the exit were at the top of the sidewall, a stiff wire that was pulled and then released could easily get caught with a loop in the corner of the enclosure. If the opening is in a non-angled orientation, attempting to redirect the wire at near a 90-degree angle will generate significant friction and make pulling the wire difficult. 
     Broken Spools 
     The flanges of plastic spools are easily broken. Even though there may be significant wire on the spool, these are generally discarded because of the difficulty in using a broken spool as seen in  FIG. 7A . 
     As seen in  FIG. 7B , the described and pictured wire caddy embodiment can operate normally even with a broken spool  301 .