FIELD OF ART
The present invention relates to spools for holding and dispensing wire rope, cable and the like. The present invention more particularly relates to a modular design enabling individual wire spool racks to be connected in linear and/or two-dimensional arrays.
BACKGROUND OF THE INVENTION
Traditional wire spool supports consist of a smaller diameter rod through a larger central opening in the spool axle and two supports for the rod. To change a spool, the rod must be taken off the supports and removed, then reinstalled with the new spool, which involves wasted time and energy. During rotation of the spool, the mismatch between the rod diameter and the spool axle diameter causes bouncing and irregular playing out of the wire, as well as difficulty spooling the wire initially. Traditional spool racks have a fixed length that limits the number of spools per rack.
SUMMARY OF THE INVENTION
The present invention provides a modular wire spool rack that enables spools to be easily and quickly changed. Spool bearings are included to ensure smooth rotation of the spool without bouncing. Multiple modular wire spool racks may be connected by spools to form linear and two-dimensional arrays of spool racks so any number of spools may be accommodated. The modular wire spool rack is portable and self-contained, and so may be taken where needed. Optional attachment to a slat wall to avoid tipping of tall combinations of modular wire spool racks is provided. Optional rack bars for additional strength and stability are also provided.
DESCRIPTION OF THE FIGURES OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
FIG. 1 is a front/side perspective view illustrating an exemplary embodiment of a modular wire spool rack, according to a preferred embodiment of the present invention;
FIG. 2 is a side elevation view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 3 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 4 is an exploded perspective view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 5 is a front elevation view illustrating the exemplary embodiment of a spool of the exemplary modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 6 is a right side elevation view illustrating the exemplary embodiment of the spool of the exemplary modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 7 is an exploded perspective view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 8 is an exploded perspective view illustrating a second exemplary embodiment of the spool of the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 9 is a front/side perspective view illustrating an exemplary embodiment of the modular wire spool rack of FIG. 1 in a linear array, according to a preferred embodiment of the present invention;
FIG. 10 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1 in the linear array shown in FIG. 9, according to a preferred embodiment of the present invention;
FIG. 11 is a front/side perspective view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1 in a two-dimensional array, according to a preferred embodiment of the present invention;
FIG. 12 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack of FIG. 1 in the two-dimensional array of FIG. 11, according to a preferred embodiment of the present invention;
FIG. 13 is a front/side perspective view illustrating an exemplary embodiment of optional rack bars of the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention; and
FIG. 14 is a top/front perspective view illustrating an exemplary optional connection to a slat wall of the exemplary embodiment of the modular wire spool rack of FIG. 1, according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used and defined herein, words of relative position such as “front”, “bottom”, etc. refer to the apparatus in the operational orientation shown in FIG. 1. The hundred(s) digits of reference numbers refer to the drawing number in regard to which the referenced item is first shown and discussed. As used and defined herein, “wire spool” refers to a large hollow cylindrical axle 116 having first and second ends with first and second opposing disc-shaped end pieces 120 and 304, respectively, as shown in FIG. 8 and identified be reference number 806. Wire spools may be used for storing and dispensing wire, rope, chain, hose, or the like.
FIG. 1 is a front/side perspective view illustrating an exemplary embodiment of a modular wire spool rack, according to a preferred embodiment of the present invention. Modular wire spool rack 100 includes first modular spool rack panel 101, second modular spool rack panel 103, wire spool axle 116, wire spool left end piece 120, and wire spool right end piece 304 (see FIG. 3). First modular spool rack panel 101 and second modular spool rack panel 103 are identical and so like reference numerals are shared in describing parts. Further, the left and right sides of first modular spool rack panel 101 and second modular spool rack panel 103 are preferably made of injection molded plastic. In some embodiments, other materials of sufficient strength may be used. The left and right sides of first modular spool rack panel 101 are mirror images of one another, so reference numerals are shared for like items. The left and right sides of second modular spool rack panel 103 are mirror images of one another, so reference numerals are shared for like items. First modular spool rack panel 101 includes a ridge-reinforced spool rack panel body 114. First modular spool rack panel 101 includes alignment features including: rear alignment pin 104, middle alignment ridge 106, and front alignment pin 108 on spool rack panel top side 102 to assist in vertical stacking of additional modular wire spool racks 100. First modular spool rack panel 101 includes wire spool rack bar sockets 124 (one of three visible labeled), with four wire spool rack bar sockets 124 shown on second modular spool rack panel 103. First modular spool rack panel 101 includes first spool rack panel horizontal slot 110 which receives an axle extension in the form of a right bearing assembly 802 (see FIG. 8) and a second spool rack panel horizontal slot 112 which may receive an axle extension in the form of a right bearing assembly 802 (see FIG. 8) when making a linear array of modular wire spool racks 100 (see FIGS. 9-10). First spool rack panel horizontal slot 110 terminates in a vertical slot which serves as a wire spool bearing rest 118. First modular spool rack panel 101 includes a slat wall connector receiver 122 for mounting the modular wire spool rack 100 on a slat wall 1402 (see FIG. 14).
FIG. 2 is a side elevation view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. The left side of second modular spool rack panel 103 is shown and is similar to the right side, as seen in FIG. 1. Reinforcement ridges 202 (one of twenty-three labeled) increase the strength of the ridge-reinforced spool rack panel body 114. Both the left and right sides of second modular spool rack panel 103 are ridge-reinforced as shown in FIG. 1 and FIG. 2.
FIG. 3 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. The outer edges of the bottom side alignment feature receiver 302 can be seen in this view. Bottom side alignment feature receiver 302 includes cavities that receive rear alignment pin 104, middle alignment ridge 106, and front alignment pin 108 when modular wire spool racks 100 are stacked vertically. Wire spool right end piece 304 can be seen in this view
FIG. 4 is an exploded perspective view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Assembled wire spool 402 includes right axle bearing outer race 404 that slides into First spool rack panel horizontal slot 110 and then downward into wire spool bearing rest 118 of second modular spool rack panel 103 to form modular wire spool rack 100. Left axle bearing 708 (see FIG. 7) is similar to right axle bearing 726 having right axle bearing outer race 404. Left axle bearing 708 slides into First spool rack panel horizontal slot 110 and is retained by slot retainer flange 126, which prevents horizontal separation of the assembled wire spool 402 from the first modular spool rack panel 101. Left axle bearing 708 slides further into wire spool bearing rest 118 and is retained there by slot retainer flange 126. Thus, the assembled wire spool 402 connects to first modular spool rack panel 101. Similarly, right axle bearing outer race 404 slides into second spool rack panel horizontal slot 112 and wire spool bearing rest 118 of second modular spool rack panel 103 and is retained by a slot retainer flange 126 there. Thus, the assembled wire spool 402 connects to second modular spool rack panel 103.
FIG. 5 is a front elevation view illustrating the exemplary embodiment of a spool of the exemplary modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Assembled wire spool 402 includes right axle bearing outer race 404 and left axle bearing outer race 502. The right and left axle bearing outer races 404 and 502 are held by gravity in wire spool bearing rests 118 to enable the assembled wire spool 402 to rotate freely for dispensing wire, rope, etc. from modular wire spool rack 100. Left axle bearing assembly pillar 504 spaces the left axle bearing 708 (see FIG. 7) apart from the axle-distal side of the wire spool left end piece 120. The right axle bearing 726 configuration is similar the left axle bearing 708 configuration. The bearing offset space 506 accommodates the slot retainer flanges 126 to connect first modular spool rack panel 101 and second modular spool rack panel 103 to assembled wire spool 402.
FIG. 6 is a right-side elevation view illustrating the exemplary embodiment of the spool of the exemplary modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Right bearing assembly 614 rests within circumferential end piece rib 612 and on right bearing assembly bracket 610. Right bearing assembly bracket 610 is part of a bearing holder 722 (see FIG. 7). Right bearing assembly bracket 610 is fastened to wire spool right end piece 304 with right bearing holder fasteners 606, illustrated here as screws 606. Right axle bearing inner race 608 rotationally engages right axle bearing outer race 404. Right axle bearing inner race 608 is secured to bearing holder 722 with a right bearing washer 602 and a right bearing assembly fastener 604, illustrated here as screw 604.
FIG. 7 is an exploded perspective view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Circumferential axle fitting 724 fits frictionally within wire spool axle 116 and may be secured thereto with adhesive, set screws, or similarly effective means. Wire spool right end piece 304 has an identical circumferential axle fitting (not shown). Bearing holder 722 is secured to wire spool right end piece 304 with right bearing holder fasteners 606 (one of two labeled). Right axle bearing 726 includes right axle bearing inner race 608 and right axle bearing outer race 404. Right axle bearing 726 is secured to bearing holder 722 with right bearing washer 602 and right bearing assembly fastener 604, illustrated here as a screw 604. Left bearing holder 710 attaches to wire spool left end piece 120 with fasteners 706 (one of two labeled). Left axle bearing 708 is secured to left bearing holder 710 using left bearing washer 702 and left bearing assembly fastener 704, illustrated here as screw 704. Optional lower wire spool rack bar 712 fits into opposing wire spool rack bar sockets 124. In some embodiments, anti-slip gaskets 716 (one of four labeled) may be used on the ends of lower wire spool rack bar 712 and upper wire spool rack bar 714. Left slat wall connector 718 has a lower end configured to engage a slat wall connector receiver 122 and an upper end configured to engage a slot 1404 in a slat wall 1402 (see FIG. 14). Right slat wall connector 720 is similarly configured.
FIG. 8 is an exploded perspective view illustrating a second exemplary embodiment of the spool of the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Left and right bearing assemblies 804 and 802 are attached to wire spool 806. Right bearing assembly 614 is shown completely assembled and delivered to manufacturing as a unit. Right bearing assembly 614 is fastened to wire spool right end piece 304 using right bearing holder fasteners 606 (one of two labeled). Left bearing assembly 804 is shown completely assembled and delivered to manufacturing as a unit. Left bearing assembly 804 is fastened to wire spool left end piece 120 using left bearing attachment screws 706 (one of two labeled).
FIG. 9 is a front/side perspective view illustrating an exemplary embodiment of the modular wire spool rack 100 of FIG. 1 in a linear array 900, according to a preferred embodiment of the present invention. Assembled wire spool 402 connects first modular spool rack panel 101 to second modular spool rack panel 103. Assembled wire spool 906 connects second modular spool rack panel 103 to third modular spool rack panel 902. Assembled wire spool 908 connects third modular spool rack panel 902 to fourth modular spool rack panel 904.
FIG. 10 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1 in the linear array shown in FIG. 9, according to a preferred embodiment of the present invention. The centerline 1002 of wire spool axles 116 (one of three labeled) aligns with wire spool bearing rest 118.
FIG. 11 is a front/side perspective view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1 in a two-dimensional array 1100, according to a preferred embodiment of the present invention. Modular wire spool racks 100 (eight of nine labeled) have three linear arrays from FIG. 9 stacked vertically. Using the rear alignment pin 104, middle alignment ridge 106, and front alignment pin 108 to engage complimentary features in bottom side alignment feature receiver 302 (one of nine labeled). Two-dimensional arrays of any height and length may be made with modular wire spool racks 100, but practicality may limit heights to those accessible to consumers of wire. In a particular embodiment, the rear side of the two-dimensional array 1100 may be presented to the consumer and the front side accessible only to store staff for changing or removing assembled wire spools 402 (one of nine labeled).
FIG. 12 is a front elevation view illustrating the exemplary embodiment of the modular wire spool rack 100 of FIG. 1 in the two-dimensional array 1100 of FIG. 11, according to a preferred embodiment of the present invention. A rear view of two-dimensional array 1100 would not show First spool rack panel horizontal slot 110 (one of none labeled) or second spool rack panel horizontal slot 112 (one of none labeled), but would show slat wall connector receivers 122.
FIG. 13 is a front/side perspective view illustrating an exemplary embodiment of optional spool rack bars 712 and 714 of the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Lower wire spool rack bar 712 fits snugly in a wire spool rack bar socket 124 at each end. In some embodiments, anti-slip gaskets 716 are added to the ends of lower wire spool rack bar 712. Upper wire spool rack bar 714 fits snugly in a wire spool rack bar socket 124 at each end. In some embodiments, anti-slip gaskets 716 are added to the ends of upper wire spool rack bar 714. Up to four wire spool rack bars may be used. Lower wire spool rack bar 712 and upper wire spool rack bar 714 assist in lifting and handling the modular wire spool rack 100 and also add structural stability to linear arrays 900 and two-dimensional arrays 1100. In various embodiments, from one to four spool rack bars may be installed in the modular wire spool rack 100.
FIG. 14 is a top/front perspective view illustrating an exemplary optional left and right slat wall connectors 718 and 720 to a slat wall 1402 of the exemplary embodiment of the modular wire spool rack 100 of FIG. 1, according to a preferred embodiment of the present invention. Left slat wall connector 718 engages a left slat wall connector receiver 122 at a lower end and engages a slot 1404 of slat wall 1402 at an upper end of left slat wall connector 718. Right slat wall connector 720 engages a right slat wall connector receiver 122 at a lower end and engages a slot 1404 of slat wall 1402 at an upper end of right slat wall connector 720. Slat wall 1402 may be used to stabilize tall two-dimensional arrays 1100 or to present smaller linear arrays 900, or individual modular wire spool racks 100 at a convenient height.
The following claims may contain functional claim language and do not contain statements of intended use.