Patent Description:
Chalk reels are known that consist of a spool on which a line or string is wound. The spool, line and the drive transmission for the spool are supported in a housing. The drive transmission may comprise gears, springs and other components that connect the spool to an external handle for rewinding the line on the spool after use. A chalk chamber is filled or partially filled with a colored chalk such that as the line that is wound on the spool it is coated in chalk. The line can be unwound from the housing through an aperture in the housing such that it can be "snapped" on a surface to form a line of chalk on the surface. The resulting line of chalk can be used as a reference line in construction or other applications. Features of conventional chalk reels include those found in <CIT>. Another example of a chalk line device can be found in <CIT>, which discloses a chalk reel having a housing, spool and chalk line wrapped onto the spool. A chalk material is also positioned in the housing to coat the chalk line.

According to an embodiment, a chalk reel includes a housing defining a chalk chamber and an opening from the chalk chamber; a spool positioned within the chalk chamber; and a line wound on the spool and extending through the opening, the line having a width of dimension X. The spool comprises an axial hub and a sidewall. The sidewall comprises a plurality of apertures extending through the sidewall from a first face distal from the axial hub to a second face proximal to the axial hub. Each of the plurality of apertures having a maximum width of dimension Y. The dimension Y is less than or equal to twice the dimension X.

In one embodiment of the invention, the structural components illustrated herein are drawn to scale. In addition, it should be appreciated that structural features shown or described in any one embodiment herein can be used in other embodiments as well. As used in the specification and in the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

Features of chalk reels in accordance with one or more embodiments are shown in the drawings, in which like reference numerals designate like elements. The drawings form part of this original disclosure in which:.

Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" or "top" or "bottom" may be used herein to describe a relationship of one element, component or region to another element, component or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

As shown in <FIG>, a chalk reel <NUM> includes a housing <NUM> that forms a chalk chamber. In an embodiment, the housing <NUM> includes a front housing section 110a and a rear housing section 110b, which may be connected together by fasteners (not shown) such as threaded screws or other releasable connection mechanisms such that the housing sections may be separated or formed separately and assembled together. Selectively extendable from the housing <NUM> is a hook <NUM> that is coupled to a line (e.g., in the illustrated embodiment, line <NUM> in <FIG>). As discussed in greater detail below, the line <NUM> is wound around a spool (e.g., in the illustrated embodiment, spool <NUM> in <FIG>) within the chalk chamber, such that chalk in the chalk chamber may contact and adhere to the line <NUM>. The line <NUM> may be formed of any appropriate material, including but not limited to nylon, polyester, or cotton, which in some embodiments may be twisted or braided. It may be appreciated that when a user pulls on the hook <NUM> may cause the spool <NUM> to rotate and release the line <NUM> with the chalk adhered thereto. Accordingly, once the line <NUM> is extended from the housing <NUM>, and the hook <NUM> has engaged or bit into a distant surface, snapping the line relative to the hook <NUM> and the housing <NUM> will displace chalk to form a reference chalk mark on a substrate between the hook <NUM> and the housing <NUM>.

In the illustrated embodiment, the chalk reel <NUM> has a winding handle <NUM> that facilitates rotating the spool <NUM> to retract the line <NUM> and hook <NUM> into the housing <NUM>. As shown, the winding handle <NUM> may be pivotable, and as such may move from a compactified storage position to an extended winding position. In some embodiments, the chalk reel <NUM> may have a gearing system that provides a mechanical advantage for more rapidly retracting the line <NUM> and hook <NUM> into the housing <NUM>. In some such embodiments, the chalk reel <NUM> may include a clutch that may disengage the winding handle <NUM> from the spool <NUM>, so that the winding handle <NUM> does not rotate when the hook <NUM> or line <NUM> is being pulled directly. As shown, a line release actuator <NUM> may be included in the chalk reel <NUM> to actuate such a clutch, and in the illustrated embodiment may be operatively positioned between the winding handle <NUM> and the spool <NUM> (or more specifically between the winding handle <NUM> and the gearing system, not shown) to disengage the spool <NUM> from the gearing system and/or the winding handle <NUM>.

Before turning to the salient internal features of the chalk reel <NUM>, it may further be appreciated from <FIG> that the chalk reel <NUM> may include one or more doors to open the chalk chamber to permit filling the chalk chamber with chalk. As shown, in an embodiment the chalk reel <NUM> may include a nose door <NUM>, which may selectively receive the hook <NUM>, and through which the line <NUM> may extend. In an embodiment, by rotating the nose door <NUM> (e.g., by unscrewing it where it includes a threaded fastener, or through known quarter turn or half turn unlatching with a seal member), the nose door <NUM> may be separated from the housing <NUM>, and an opening to the chalk chamber may be exposed for insertion of the nose of a chalk refill bottle. In the illustrated embodiment a hinged door <NUM> is also included, and configured such that once the nose door <NUM> is separated from the housing <NUM>, the hinged door <NUM> may be further opened to provide a wider opening into the chalk chamber to facilitate easier refilling of chalk into the chalk chamber.

Turning to <FIG>, the line <NUM> and spool <NUM> may be more fully appreciated, as well as their interaction with the inside of the housing <NUM> defining the chalk chamber. It may be appreciated that the spool <NUM> may have a spool axis feature <NUM> configured to engage with a winder axis feature (not shown) that would be fixed to the gearing system and/or the winding handle <NUM> and contact therebetween would be through an opening 110c in the housing <NUM>. In the illustrated embodiment, the spool axis feature <NUM> is a receiver that would receive the winder axis feature extending through the opening 110c. As the line <NUM> is wrapped around the spool <NUM> when the line <NUM> and hook <NUM> are retracted into the chalk chamber, pulling the hook <NUM> from the housing <NUM> would pull the line <NUM> and rotate the spool <NUM>. Thus, it may be appreciated that unless the clutch is disengaged through actuation of the line release actuator <NUM>, rotation of the spool <NUM> may result in rotation of the winding handle <NUM> and/or the gearing system, which may slow or prevent free rotation of the spool <NUM> to release the line <NUM> for extension.

It is known in the art of chalk reels to include apertures in the spools, which permit permeation of chalk to interior windings of the line. For such reasons, these apertures, where included, are commonly large openings configured to maximize movement of chalk into the windings of the line carried by the spool, and move and aerate through the apertures into the spool as the spool is rotated. It is an aspect of the present disclosure to improve upon such spools.

In the illustrated embodiment, the spool <NUM> includes a first sidewall 140a and a second sidewall 140b, connected therebetween by an axial hub 140c. As shown, in the spool <NUM>, the axial hub 140c defines the spool axis feature <NUM> configured to engage with the winder axis feature. A plurality of apertures <NUM> are formed in one or more of the first sidewall 140a and the second sidewall 140b, so as to extend from an exterior of the spool <NUM> to the interior of the spool <NUM> between the sidewalls 140a and 140b. The apertures extend from an exterior face of each sidewall 140a and 140b distal from the axial hub 140c, to an interior face proximal to the axial hub 140c. Accordingly, as the line <NUM> is wound around the axial hub 140c, chalk that is at the exterior of the spool <NUM> may enter the apertures <NUM> to contact windings of the line <NUM> closer to the axial hub 140c, and not be blocked by windings of the line <NUM> radially outward from the axial hub 140c. As further shown in <FIG>, one or more of the front housing section 110a and a rear housing section 110b, at interiors thereof defining the chalk chamber and adjacent to the sidewalls 140a and/or 140b that contain the apertures <NUM>, may include chalk aeration features <NUM>, such as protruding grooves extending inwardly into the chalk chamber. It may be appreciated that such chalk aeration features <NUM> may scrape and push chalk in the chalk chamber as the spool <NUM> rotates, such that the chalk may be pushed into the apertures <NUM>.

It may be appreciated that in conventional chalk reels, having large sized apertures, or even a generally skeletal or widely webbed configuration of spool, retracting the line and hook into the housing by winding the spool may result in the line getting tangled by the chalk in the chalk chamber thereof, such that the line protrudes through the apertures and becomes tangled in the spool, the gearing mechanism, or other movable portions of the chalk reel. Some such conventional chalk reels have incorporated features such as easy-open configurations so that the spool may be removed, and the line may be easily rewound around the spool. With reference to <FIG>, it may be appreciated how the present disclosure innovates over such alternative solutions.

As shown in <FIG>, it is a feature of the present invention that the apertures <NUM> formed in the spool <NUM> are dimensionally sized with a desired relationship relative to a width or thickness of the line <NUM>. In particular, where the line <NUM> is cylindrical with a diameter of X, the apertures <NUM> formed in the illustrated sidewall 140a (and in such embodiments, in the obscured sidewall 140b) are sized such that a maximum dimension thereof in the plane of the sidewall 140a or 140b is a dimension Y, where Y is less than <NUM> times the dimension X. This dimension Y may be the diameter of the aperture <NUM> where the aperture <NUM> has a circular opening (e.g., a generally cylindrical shape), or may be the longest diagonal where the aperture <NUM> has a rectangular opening (e.g., a generally rectangular prism shape), or may be the longest internally bounded line segment that can be drawn in any other appropriately shaped opening for aperture <NUM>. It may be appreciated that the apertures <NUM> may therefore have any appropriate shape, including but not limited to squares, slots, diamonds, rectangles, ovals, star shapes, or may have any other regular or irregular shape.

Accordingly, with this configuration where the dimension Y of the aperture is less than or equal to twice dimension X of the line <NUM>, no loop of the line <NUM>, which would typically be at least <NUM> times X in dimension (unless the line <NUM> is compressed), may form that may fit through the dimension Y of the aperture <NUM>. It may be appreciated that certain sizes of chalk reel <NUM> may be configured with larger or smaller chalk capacities and/or line lengths. As such, in some embodiments, the dimension X of the line <NUM> for a large capacity chalk reel <NUM> may be larger than the dimension X of the line <NUM> for a small capacity chalk reel <NUM>, as a longer intended snap length and thus length of line <NUM> may make desirable a thicker line <NUM> for increased line strength. Accordingly, where a larger dimension X of line <NUM> is utilized (e.g., for a thicker line), a corresponding larger dimension Y of the aperture <NUM> may also be utilized, allowing more chalk to pass through the aperture <NUM> into the inner windings of the line <NUM> on the spool <NUM>, provided that the aperture is not so large that loops of the line <NUM> may pass therethrough.

With regard to a distinction between a large capacity chalk reel and a small capacity chalk reel, it may be appreciated that in some embodiments the outer diameter of the spool <NUM> (e.g., a diameter of the sidewall 140a and/or the sidewall 140b) may range between approximately <NUM> and <NUM> in various embodiments, which may facilitate lengths of line <NUM> between approximately <NUM> meters feet long to approximately <NUM> meters long. In some embodiments, a diameter of the spool <NUM> may be approximately <NUM> in diameter, while in other embodiments the diameter of the spool <NUM> may be approximately <NUM> in diameter, and in still other embodiments, the diameter of the spool <NUM> may be approximately <NUM> in diameter.

Although it may be appreciated that the line <NUM> may be resilient and compressible, in some embodiments the dimension Y in the sidewall 140a may be appropriately sized so as to be less than twice dimension X when the dimension X is of the line <NUM> as uncompressed. In an embodiment, the dimension Y may be approximately <NUM> times the size of dimension X. In an embodiment, the dimension Y may be approximately the same as the dimension X. In some embodiments, the dimension Y may be smaller than the dimension X. In various embodiments, the dimension X of the line <NUM> as uncompressed may be approximately between <NUM> and <NUM>, and in some embodiments may be approximately <NUM>, for a smaller capacity/length line <NUM>. In various embodiments, the dimension X of the line <NUM> as uncompressed may be approximately between <NUM> and <NUM>, and in some embodiments may be approximately <NUM>, e.g., for a larger capacity/length line.

In some embodiments, the dimension Y of the sidewall 140a may be appropriately sized based on a possible compression of the line <NUM>. In an embodiment, the dimension Y may be approximately <NUM> times the size of dimension X as compressed. In an embodiment, the dimension Y may be approximately the same as the dimension X as compressed. In some embodiments, the dimension Y may be smaller than the dimension X as compressed. In an embodiment, compression of the line <NUM> may reduce the dimension X of the line <NUM> to approximately between <NUM> and <NUM>, and in some embodiments may be approximately <NUM>, for a smaller capacity/length line <NUM>. In various embodiments, the dimension X of the line <NUM> as compressed may be approximately between <NUM> and <NUM>, and in some embodiments may be approximately <NUM>, e.g., for a larger capacity/length line.

It may be appreciated in such embodiments though, the dimension Y of the sidewalls 140a or 140b would remain sufficiently large to permit permeation of chalk particles through the apertures <NUM>, and would not be so small as to be functionally the same as having a solid sidewall 140a without apertures <NUM>. Accordingly, in some embodiments the dimension Y of the apertures <NUM> may be as small as <NUM>, in particular where the apertures <NUM> are formed as molded into a plastic spool <NUM>, as smaller sizes may increase molding difficulties. As discussed in greater detail below, however, by using a mesh material or a perforated material to define the apertures <NUM>, the dimension Y of the apertures <NUM> may be significantly smaller, and may be closer in size to (although larger than) the typical size of grains of chalk (e.g., <NUM>). In various embodiments, the dimension Y of the apertures <NUM> may be approximately between <NUM> and <NUM>, and in some embodiments may be approximately <NUM> where the dimension X of the line <NUM> is approximately <NUM>, and may be approximately <NUM> where the dimension X of the line <NUM> is approximately <NUM>.

As shown in <FIG>, by having relatively smaller apertures <NUM>, the sidewalls 140a (and in such embodiments, the sidewalls 140b) may accommodate a large number of such apertures <NUM>. In an embodiment, the sidewall 140a may include at least ten apertures <NUM>. In embodiment, the sidewall 140a may include at least twenty apertures <NUM>. In an embodiment, the sidewall 140a may include at least thirty apertures <NUM>. In an embodiment, the sidewall 140a may include at least forty apertures <NUM>. As shown in the illustrated embodiment, with reference to the view of <FIG>, where a generally planar surface of the sidewall 140a is symmetrical to a generally planar surface of the sidewall 140b (e.g., excluding the axial hub 140c), the spool <NUM> as a whole may contain generally the same number apertures <NUM> on the sidewall 140a and the sidewall 140b. As such, in the illustrated embodiment, the spool <NUM> includes approximately eighty apertures <NUM>.

In some embodiments, the number of apertures <NUM> on each sidewall 140a and 140b may differ. While in the illustrated embodiments the apertures <NUM> are generally symmetrically arranged on the sidewalls 140a and 140b, in other embodiments the apertures <NUM> may be asymmetrically positioned, and in some embodiments may be randomly positioned. In some embodiments, the apertures <NUM> may be appropriately placed on the spool <NUM> so as to align with appropriately placed chalk aeration features <NUM> in the chalk chamber, so as to create a desired movement of chalk from the chalk aeration features <NUM> into the apertures <NUM>.

<FIG> show various views of the spool according to an embodiment of the present disclosure. It may be appreciated that the views therein may be sufficiently appreciated for the ornamental appearance of the spools <NUM> as a whole, or for the arrangement of the apertures <NUM> on a sidewall 140a or 140b. In the view of <FIG>, the extension of the axial hub 140c between the sidewall 140a and the sidewall 140b may be appreciated. As shown in the views of <FIG>, the axial hub 140c may include bars 140d with notches 140e, which may facilitate holding an initial loop of the line <NUM> in the notches 140e. Other arrangements to secure the line <NUM> to the spool <NUM> may be utilized in other embodiments, including but not limited to a through hole extending in the axial hub 140c.

In some embodiments, the apertures <NUM> may be so plentiful on the sidewalls 140a or 140b that the sidewalls 140a or 140b approximate a mesh or perforated screen. In some embodiments, the sidewalls 140a or 140b may comprise a mesh material, including but not limited to metal mesh or plastic mesh, or a perforated material, including but not limited to perforated stainless steel or perforated aluminum. In some embodiments, these materials may define the bulk of the sidewalls 140a and/or 140b. For example, as shown in <FIG>, a spool <NUM>, which may be similar to spool <NUM> as described above in various regards except as discussed herein, may have sidewalls 220a and/or 220b that are joined by a hub 220c. The hub 220c may be similar to the hub 140c as described above. The sidewalls 220a and/or 220b may comprise or be formed from a mesh or perforated material 220d as described in greater detail below, forming a multitude of apertures <NUM> therein. As shown in the illustrated embodiment, the sidewalls 220a or 220b may include reinforcements <NUM>, such as rims 230a or spokes 230b, to support the mesh or perforated material 220d. The reinforcements <NUM> may be formed from any appropriate material, including but not limited to metal or plastic, and in some embodiments may be formed from the same material as the hub 220c. In some embodiments, the mesh or perforated material 220d may be sufficiently rigid as to avoid the need for such reinforcements <NUM>, as shown in the embodiment of the spool <NUM> illustrated in <FIG>, where mesh or perforated material 220d defines the sidewalls 240a and 240b thereof extending from a hub 220c which may be similar to that described as to the spool <NUM>.

The mesh or perforated material 220d may be of any appropriate construction or configuration, including but not limited to metal or plastic mesh. As a non-limiting embodiment, a metal mesh configuration may comprise stainless steel. It may be appreciated that chalk grain particles are typically approximately <NUM> microns, or <NUM> in size. In some embodiments, the aperture size of the mesh may be larger than such size so as to permit movement of chalk particles therethrough. For example, 635x635 mesh with a wire diameter of <NUM> may define an aperture of <NUM>, while 400x400 mesh with a wire diameter of <NUM> may define an aperture of <NUM>. In an embodiment, a mesh material 220d may be similar to 200x200 mesh, which generally has apertures of <NUM>. It may be appreciated that larger meshes may be utilized to accommodate larger dimensions X of lines <NUM>. For example, a 5x5 mesh having a wire diameter of <NUM> has a larger aperture of approximately <NUM>, which may be utilized with a line <NUM> having a dimension X of approximately <NUM>. The weave method of the mesh material 220d may vary across embodiments, and may be configured as a plain weave, twill weave, Dutch weave, Dutch twill, or any other appropriate method of construction. Further, the mesh construction may be woven wire, welded wire, crimped wire, or so on. In still other embodiments, where the material 220d is a perforated material, the material be formed as perforated aluminum, perforated stainless steel, or perforated carbon steel.

In various embodiments, the chalk reels and components thereof described herein may be formed of metal, plastic, ceramic, or any other appropriate material. It may be appreciated that the components described herein may be of different constructions or configurations, including but not limited to one or more being comprised of different material choices. For example, the components described herein may each be constructed from a variety of materials, including but not limited to one or more of fabrics, plastics, metals, rubbers, elastomers, or any other appropriate material choice. For example, in an embodiment one or more of the components (e.g., the housing <NUM>, the spool <NUM>) may be formed of aluminum (e.g., machined aluminum), iron (e.g., steel), or any other appropriate material. Similarly, portions of the chalk reels may be formed from molded plastic, metal, or combinations thereof (e.g., plastic with metal supports or fasteners coupling portions tougher). In some embodiments, structural and functional components may be formed from metal or hard plastic, while gripped components positioned to engage the palm of a gripping hand to provide the palm with a comfortable gripping surface may be made of a suitable molded plastic material or elastomeric material, and may be generally formed as a bi-material suitable molded plastic material coated with a layer of an elastomeric material, such as a rubber based material. In some embodiments, the material choices may differ from component to component (e.g., a metal housing <NUM> and a plastic spool <NUM>). In various embodiments, some components may be integrally formed together, while other components may be assembled by any appropriate mechanism, including but not limited to fastened, welded, snap-fit, friction fit, adhesive bonding, or other appropriate securements.

Claim 1:
A chalk reel (<NUM>) comprising:
a housing (<NUM>) defining a chalk chamber and an opening from the chalk chamber;
a spool (<NUM>) positioned within the chalk chamber; and
a line (<NUM>) wound on the spool (<NUM>) and extending through the opening, the line (<NUM>) having a width of dimension X;
wherein the spool (<NUM>) comprises an axial hub (140c) and a sidewall (140a);
wherein the sidewall (140a) comprises a plurality of apertures (<NUM>) extending through the sidewall (140a) from a first face distal from the axial hub (140c) to a second face proximal to the axial hub (140c); and
characterized in that each of the plurality of apertures (<NUM>) has a maximum width of dimension Y, and wherein the dimension Y is less than or equal to twice dimension X.