Patent Publication Number: US-2021171312-A1

Title: Mobile Reel Carrier

Description:
I. RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/946,354, filed on Dec. 10, 2019. 
    
    
     II. FIELD OF THE INVENTION 
     This application discloses claims and embodiments a mobile reel carrier for on-loading and off-loading rolled product to and from a drum or spool containing rolled product(s). 
     III. BACKGROUND OF THE INVENTION 
     Many apparatuses, systems, and methods have been and are offered to address winding and/or dispensing rolled products, such as bare and/or insulated wire and/or cable. These apparatuses, systems, and methods include a non-exhaustive recitation of varied articles, such as reels having an intermediate spool disposed between end flanges, stationary reel racks, mobile reel caddies that are manually manipulated and positioned, reel elevation mechanisms for dispensing product, manually operated wire or cable metering devices, stationary and/or portable payout stands. 
     However, each category of dispenser identified above generally suffers from at least one drawback, such as the need for manually mounting the drum(s) or spool(s) and thereafter manually manipulating the device to achieve payout of the product. Such manual payout is complicated with the concern of navigating uneven and/or soft terrain. Because of the manual manipulation of these various options, one or more individuals are exposed to a variety of injury risks because of the weight, angle of positioning, terrain, and other related hazard-inducing concerns. 
     More particularly, wood reels are usually large and extremely heavy. Manual positioning of such wood reels, especially with rolled products (e.g., cable and/or wire) placed thereon, proves very difficult for one or more individuals. Individuals have difficulty moving such large reels, which can measure between several hundred pounds to nearly 15,000 pounds in extreme instances. Utilizing more than one individual to move such reels, despite improving the likelihood and relative ease of moving the reel, the addition of other individuals instead introduces increased likelihood of injury risk, and depending upon the dimension of the reel, may prove to be inefficient and equally as difficult without any improvement in moving the reel and doing so safely. 
     Accordingly, there is a need for an apparatus, system, and/or method that provides improved safety and injury risk-mitigation for individuals tasked with on-loading and/or off-loading rolled products from such drums or spools. 
     IV. SUMMARY OF THE INVENTION 
     In one embodiment, a reel carrier for a rolled product is described, the reel carrier comprising a pallet having a platform bound by a frame, the pallet having a shaft, a first sidewall upwardly depending from the frame and a second sidewall upwardly depending from the frame, the first sidewall and the second sidewall configured in mutual opposition and supporting the shaft therebetween, the shaft rotatable in a forward and reverse direction, the first sidewall and the second sidewall collapsible, a reel supported on the shaft and rotatable about the shaft in a forward and a reverse direction, the reel configured to take-up the rolled product thereon to subsequently pay-off the rolled product from the top-side of the reel in an over-the-top delivery to optimize the structural integrity of the rolled product and minimize the structural stress of the rolled product, and a motor operably coupled to cause rotation of the shaft supporting the reel. 
     The carrier further comprises a control panel operably coupled with the motor. 
     The carrier further comprises a plurality of wheels depending from the pallet. In one such embodiment, the motor is operably coupled to at least one of the plurality of wheels, the motor configured and adapted to cause rotation to the at least one of the plurality of wheels for providing locomotion to the carrier. In another such embodiment, the motor is operably coupled to the plurality of wheels, the motor configured and adapted to deploy and/or retract each one of the plurality of wheels within the frame of the pallet, wherein the motor is configured and adapted to deploy and/or retract each one of the plurality of wheels within the platform of the frame thereby concealing the plurality of wheels. 
     The carrier further comprises a canopy having a top panel, a front panel, and a rear panel, wherein the front panel and rear panel downwardly depend from the top panel, the front panel and rear panel configured and oriented in mutual opposition to one another, wherein the canopy complements the first sidewall and the second sidewall and defines an enclosure for the reel supported on the shaft between the first sidewall and the second sidewall. 
     The carrier further comprising means for elevating the shaft between a base position and an elevated position, wherein elevation means is configured and adapted for placement within the pallet. 
     In another embodiment, a reel carrier for a rolled product is described, the reel carrier comprising a pallet having a platform bound by a frame, the pallet having a shaft, a first sidewall upwardly depending from the frame and a second sidewall upwardly depending from the frame, the first sidewall and the second sidewall configured in mutual opposition and supporting the shaft therebetween, the shaft rotatable in a forward and reverse direction, the first sidewall and the second sidewall collapsible, a reel having a round drum, the reel and round drum supported on the shaft and rotatable about the shaft in a forward and a reverse direction, the reel and round drum configured to take-up the rolled product thereon to subsequently pay-off the rolled product from the top-side of the reel in an over-the-top delivery to optimize the structural integrity of the rolled product and minimize the structural stress of the rolled product, and a motor operably coupled to cause rotation of the shaft supporting the reel. 
     The carrier further comprises a control panel operably coupled with the motor, wherein the control panel is operably coupled with the motor to control take-up of the rolled product onto the reel and round drum and control pay-off of the rolled product from the reel and round drum. The control panel is operably coupled with the motor and comprises individual control for powering-on and powering-off of the motor, forward and reverse rotation of the reel and round drum supported on the shaft, vertical elevation and de-elevation of the shaft, variable rotational speed and breaking of the reel and round drum as supported on the shaft. 
     In one variation of this embodiment, the carrier further comprises a plurality of wheels depending from the pallet, wherein the motor is operably coupled to at least one of the plurality of wheels, the motor configured and adapted to cause rotation to the at least one of the plurality of wheels for providing locomotion to the carrier. 
     In another variation of this embodiment, the carrier further comprises a plurality of wheels depending from the pallet, wherein the motor is operably coupled to the plurality of wheels, the motor configured and adapted to deploy and/or retract each one of the plurality of wheels within the frame of the pallet. The motor is configured and adapted to deploy and/or retract each one of the plurality of wheels within the platform of the frame thereby concealing the plurality of wheels. 
     The carrier further comprises a control panel operably coupled with the motor, wherein the control panel is operably coupled with the motor to control take-up of the rolled product onto the reel and round drum and control pay-off of the rolled product from the reel and round drum, wherein the control panel is operably coupled with the motor and comprises individual control for powering-on and powering-off of the motor, forward and reverse rotation of the reel and round drum supported on the shaft, vertical elevation and de-elevation of the shaft, variable rotational speed and breaking of the reel and round drum as supported on the shaft, and the control panel operably coupled with the motor to deploy and retract each one of the plurality of wheels within the platform of the frame. 
     The carrier further comprises a canopy having a top panel, a front panel, and a rear panel, wherein the front panel and rear panel downwardly depend from the top panel, the front panel and rear panel configured and oriented in mutual opposition to one another, wherein the canopy complements the first sidewall and the second sidewall and defines an enclosure for the reel supported on the shaft between the first sidewall and the second sidewall. 
     The carrier further comprises means for elevating the shaft between a base position and an elevated position, wherein elevation means is configured and adapted for placement within the pallet. 
     In another aspect, a system for storing and transporting a rolled product is described, the system comprises a reel carrier for a rolled product. Consistent with the previous embodiment, the reel carrier at least comprises a pallet with a first sidewall and a second sidewall, a reel having a round drum supported on a shaft supported between the sidewalls and rotatable, and a motor operably coupled to cause rotation of the shaft supporting the reel. 
     More particularly, the reel carrier comprising the system described above comprises a pallet having a platform bound by a frame, the pallet having a shaft, a first sidewall upwardly depending from the frame and a second sidewall upwardly depending from the frame, the first sidewall and the second sidewall configured in mutual opposition and supporting the shaft therebetween, the shaft rotatable in a forward and reverse direction, the first sidewall and the second sidewall collapsible. The reel carrier comprises a reel having a round drum, the reel and round drum supported on the shaft and rotatable about the shaft in a forward and a reverse direction, the reel and round drum configured to take-up the rolled product thereon to subsequently pay-off the rolled product from the top-side of the reel in an over-the-top delivery to optimize the structural integrity of the rolled product and minimize the structural stress of the rolled product. The reel carrier also includes a motor operably coupled to cause rotation of the shaft supporting the reel. The reel carrier additionally includes a canopy having a top panel, a front panel, and a rear panel, wherein the front panel and rear panel downwardly depend from the top panel, the front panel and rear panel configured and oriented in mutual opposition to one another, wherein the canopy complements the first sidewall and the second sidewall and defines an enclosure for the reel supported on the shaft between the first sidewall and the second sidewall. 
     The system protects the rolled product on the reel and round drum via the canopy that is placed in complementary orientation to the first sidewall and the second sidewall, forming a complete protective shell enclosure over the rolled product, the canopy in combination with the first sidewall and the second sidewall forming the complete protective shell enclosure to minimize physical and/or structural damage that might otherwise happen to the rolled product during on-loading, transport, off-loading, and/or installation of the rolled product. 
     The system is controlled through automated command via the control panel to achieve locomotion of the reel carrier device and minimize physical damage to human laborers, and once the canopy is removed for take-up or pay-off of the rolled product, the control panel allows control of the location, proximity, and speed by which take-up and/or pay-off is achieved. 
    
    
     
       V. BRIEF DESCRIPTION OF THE DRAWING(S) 
       The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
         FIG. 1  is a perspective view of a reel carrier apparatus; 
         FIG. 2  is a front view of  FIG. 1  with the wheels retracted; 
         FIG. 3  is an exploded sectional view of a sidewall with elevation means; 
         FIG. 4 a    is a front view of the pallet with the sidewalls deployed (Dep); and 
         FIG. 4 b    is a front view of the pallet with the sidewalls collapsed (Col). 
     
    
    
     VI. DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments, as represented in the attached figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. 
     The features, structures, or characteristics of the invention described throughout this specification may be combined in any suitable manner in one or more embodiments. For example, the usage of the phrases “example embodiments”, “some embodiments”, or other similar language, throughout this specification refers to the fact that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present invention. Thus, appearances of the phrases “example embodiments”, “in some embodiments”, “in other embodiments”, or other similar language, throughout this specification do not necessarily all refer to the same group of embodiments, and the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     In accordance with the drawings illustrating at least one embodiment, as generally depicted in  FIG. 1  through  FIG. 4 a    and  FIG. 4   b,  a reel carrier apparatus  10  comprises a pallet  11  having a platform  12  bound by a frame  14 . The pallet  11  has a shaft  16  that supports a reel  18 . The reel  18  has a round drum  20  rotatable about the shaft  16  in a forward and a backward direction. The carrier  10  also includes a motor  22  operably coupled to independently control forward or backward rotation of the shaft  16  or the drum  20 , with the motor  22  capable of separate engagement of the shaft  16  and the drum  20  to effectuate take-up and/or pay-off, and with the motor  22  capable of concurrent, but separate engagement of the shaft  16  and drum  20 . It is envisioned that the pallet  11  may further comprise a plurality of wheels  24  depending therefrom and providing the appropriate elevation of the pallet  11  relative to the surface(s) upon which the carrier  10  may travel. In one embodiment, the plurality of wheels  24  is retractable relative to a frame  14  of the pallet  11 . In another embodiment, the plurality of wheels  24  is retractable within the frame  14  of the pallet  11 . In another embodiment, the plurality of wheels  24  is retractable without the frame  14  of the pallet  11 . In another embodiment, the plurality of wheels  24  is retractable as a combination within and without the frame  14  of the pallet  11 . 
     The pallet  11  has a platform  12  that has an exterior surface and an interior surface, with a thickness defining the separation between the exterior surface and the interior surface. The pallet  11  includes a frame  14  bounding the perimeter of the exterior and interior surfaces defining the platform  12 . In general, the pallet  11  has an orthogonal configuration, whether as a square or rectangular shape. However, it is further envisioned that the pallet  11  (and its constituent elements described herewith) may also have a disk, ovoid, or other polygonal shape. Regardless of pallet  11  shape, the pallet  11  and its constituent parts may be manufactured from a durable material, such as metal, alloys, plastic, or similarly durable materials, and combinations of these materials, and thereby avoiding utilization or over-reliance on resources difficult to renew (such as wood or wood-like products often used for both pallets and reels that are then-used for shipping and/or storage purposes). 
     It is envisioned that the reel  18  and/or drum  20 , and in additional embodiments both the reel  18  and drum  20 , may be configured so that the orientation of the reel  18  and/or drum  20  prevents take-up and pay-off from occurring in a manner that places distress on the rolled product. For example, it is envisioned that the reel  18  and/or drum  20  may be configured and oriented to inhibit the rolled product from paying-off via the underside of the reel  18  and/or drum  20 , or from a counterclockwise rotation of the reel  18  and/or drum  20  when viewed from the right-side of the carrier  10  (with the sidewall  26  immediately adjacent this perspective) or from a clockwise rotation of the reel  18  and/or drum  20  when viewed from the left-side of the carrier  10  (with the sidewall  28  immediately adjacent this perspective). Paying-off rolled products from the underside of the reel, drum, or spool places tremendous physical strain and stress on the product and damages the product causing short-term inefficiencies and shortened life-span of the product, increasing costs for the end-user. By comparison, paying-off rolled products from the topside (over-the-top) of the reel, drum, or spool optimizes the structural integrity of the rolled product and minimizes the stress and strain placed on the rolled-product during delivery and installation. 
     The motor  22  may comprise a variety of configurations, including combinations of known components. For example, the motor  22  may be supplied energy via a standard fossil-fuel utilizing source (e.g., gasoline, diesel, and/or propane powered motors). In another example, the motor  22  may be supplied energy via electrical energy stored in some sufficient manner, whether by battery, capacitor, and/or utilization of electrical sources (including high-voltage electrical outlets). 
     The motor  22  is envisioned to control the forward and reverse rotational direction of the shaft  16 , reel  16 , and/or drum  20 . This control may be achieved through a number of possible means, including motorized, automated rotation of the shaft  16 , the reel  16 , and/or the drum  20 . Moreover, it is envisioned that the motor  22  controls the locomotion of the carrier  10  via one or more wheels  24 , whereby the motor  22  automates and controls the direction of at least one wheel  24 . It is further envisioned that the motor  22  may control at least two wheels  24 , at least three wheels  24 , at least four wheels  24 , and includes the possibility of control all wheels  24  provided. Moreover, it is further envisioned that the motor  22  additional controls the direction of each wheel  24  during locomotion to move the carrier  10 . 
     Various means may be utilized for deploying and retracting the plurality of wheels  24 . For example, each wheel  24  may be configured to include a pivot with a locking mechanism to secure the wheel  24  in a deployed or retracted manner. Similarly, each wheel  24  may be configured to include a reciprocating post for deploying or retracting the wheel  24  between retracted and deployed positions. The wheels  24  may be deployed and retracted using manual or automated means, including manual manipulation of pivots and posts or automated manipulation utilizing hydraulic, pneumatic, mechanical, or other similar means, and/or combinations thereof. It is further envisioned that the motor  22  also controls the locomotion of the carrier  10  apparatus, wherein the motor  22  controls the deployment of one or more wheels  24  and the locomotion of the wheels  24  and the carrier  10  supported thereby. 
     It is envisioned that the pallet  11  may further comprise a first sidewall  26  and a second sidewall  28 , each one of the sidewalls  26 ,  28  upwardly depending from the frame  14  of the pallet  11 . In one embodiment, the first sidewall  26  and the second sidewall  28  are oriented in parallel to the general rotational direction of rotation of the drum  20  and are thereby oriented in parallel to one another ( 26  and  28 ). In such an orientation, therefore, the first sidewall  26  and the second sidewall  28  are mutually opposed to one another in substantially similar orientations. In another embodiment, the first sidewall  26  and the second sidewall  28  are oriented in a non-parallel orientation to one another ( 26  and  28 ), such that the sidewalls  26 ,  28  may be independently angled relative to shaft  16 , reel  18 , and drum  20 , as well as the pallet  11  and platform  12  thereon. In such orientations it is desirable that the support of and insertion with and/or through of the shaft  16  is such that alignment and balance of the shaft  16  traverses the sidewalls  26 ,  28  at tangential points along each that are substantially in mutual opposition with one another ( 26 ,  28 ). 
     Consistent with  FIG. 4 a    and  FIG. 4   b,  it is further envisioned that the sidewalls  26 ,  28  of pallet  11  are separately capable of positioning between a collapsed and deployed or retracted position, as indicated by directional arrows (Col to Dep) relative to the platform  12 . Securing each sidewall  26 ,  28  in a collapsed and/or retracted or deployed position may be achieved by a number of means, including removable pins, snap-fit impingement, one or more hinges, channels, and the like. The flexible, multiple positioning of the sidewalls  26 ,  28  imparts additional capability by allowing the user/operator to conveniently store and/or stack one or more carriers  10  in a manner that optimizes transports of one or more carriers  10  to minimize movement and damage to the carrier  10 , dead or under-utilized space within a transport, and other similar considerations. 
     The sidewalls  26 ,  28  include the shaft  16  that is intermediately disposed between the sidewalls  26 ,  28 , with the shaft  16  so disposed to support the reel  18  (and drum  20 ) for rotation thereabout. The orientation of the sidewalls  26 ,  28  provides access via the front, top, and rear of the carrier  10 . This access also accommodates a canopy  30  of complementary shape so that when the canopy  30  is placed into position, the canopy  30  and the sidewalls  26 ,  28  form an enclosure about the reel  18  and the components related thereto. Thus, the carrier  10  further comprises a canopy  30  having a top panel  32 , a front panel  34 , and a rear panel  36 , wherein the front panel  34  and the rear panel  36  downwardly depend from the top panel  32 , the canopy  30  complementing the first sidewall  26  and the second sidewall  28  and defining an enclosure for the reel  18  and related components. It is envisioned that the canopy  30  may be hinged or otherwise attached to the pallet  11  via platform  12 . Moreover, it is also envisioned that the canopy  30  may be controlled by the control panel  38  via motor  22  (consistent with the disclosures herewith) to fully automate the opening and closing of the canopy  30  in cooperation with the remainder of the carrier  10  apparatus described herein. 
     Likewise, the other constituent parts or components of the carrier  10 , including first sidewall  26  and second sidewall  28 , the canopy  30  (and its components, top panel  32 , front panel  34 , and rear panel  36 ) may be manufactured from similarly durable materials, such as metal, alloys, plastic, and the like, and combinations of these materials. 
     The carrier  10  may also include a control panel  38 . It is envisioned that the control panel  38  may include a variety of controls, including power (on/off); forward and backward rotation, including variable speed rotation; elevation and return; braking; and other associated controls for controlling the carrier  10  apparatus. It is envisioned that the control panel  38  is operably coupled with the motor  22  for specifically controlling on-loading (e.g., take-up) and off-loading (e.g., pay-off) of rolled product onto and/or from a reel  18  and/or drum  20  housed within the carrier  10 , as well as controlling the locomotion and/or direction of one or more wheels  24  consistent with the disclosure provided above. It is further envisioned that the control panel  28  may also control the collapsible and/or deployable positioning of the sidewalls  26 ,  28  relative to the pallet  11  for storage and/or deployment as necessitated. 
     More particularly, as related to elevation and return controls, it is envisioned that the carrier  10  may include elevation means  40  disposed within the pallet  11 . Elevation means  40  supports the shaft  16  and is adjustable between a base position Bp and an elevated position Ep. As depicted in  FIG. 3 , it is envisioned that elevation means  40  may comprise a variety of components and/or elements, including as shown a piston or linkage  40   a  for advancing and urging the shaft post  16   a  from a base or starting position (Bp) to an elevated position (Ep) and then returned to the base or starting position (Bp) when the piston or linkage advance is removed and/or returned to a non-advanced/retracted position. By urging the shaft post  16   a,  the shaft arm  16   b  is also urged from a base or starting position (Bp) to an elevated position (Ep) and returned when removed or reversed. 
     The features described herewith provide several advantages not previously disclosed or known with rolled product take-up, transport, and pay-off apparatus(es) and/or system(s). For example, a carrier consistent with the description herewith is not known to have an automated take-up and pay-off mechanism in conjunction with an automated locomotion control mechanism, especially controlled by a motor that responds to a control or control panel input. Moreover, an apparatus or system is not known that includes a protective canopy to minimize and/or inhibit damage to the rolled product during on-loading, transport, off-loading, and installation preparation. Furthermore, an apparatus or system is not known that includes a multi-position sidewall and/or sidewalls that may be deployed and/or collapsed for storage. 
     It is to be understood that the embodiments and claims are not limited in its application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned, but the claims are limited to the specific embodiments. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims. 
     Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the embodiments and claims presented in this application. It is important, therefore, that the claims be regarded as including such equivalent constructions. 
     Furthermore, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially including the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the claims of the application, nor is it intended to be limiting to the scope of the claims in any way. It is intended that the application is defined by the claims appended hereto.