The present invention relates to a device and method for hanging and dispensing both spooled and non spooled products. In particular, the present invention provides a device that a) rotatingly engages a spool on first and second engagement means, and provides a means for hanging the spool and distributing product therefrom, and b) engages a container on first and second engagement means and provides a means or hanging the container and distributing product therefrom.
Nails, screws, pins, clips and many other loose products are shipped, stored, and distributed in containers such as bags, boxes, buckets and pails. Flexible elongated products, such as wire, tubing, rope, and chain, are commonly sold on spools made of rigid material such as plastic, metal, or wood. Both loose and spooled products are used extensively in building construction, automotive, and many other industries. In the building industry alone, millions of feet of electrical wire and millions of pounds of nails and screws are dispensed each year. Problems associated with handling and dispensing these products negatively impacts both safety and productivity.
Spools can be heavy and difficult for a person to handle. For example a single plastic spool of electrical wire can weigh from twenty to one hundred fifty pounds or more. Many devices currently exist to aid in dispensing such products from their spools. Presently existing dispensing tools typically suspend the spool from a shaft or axle which is inserted into a hole in the center of the spool. The spool rotates about the shaft or axle as product is pulled from the spool. However, suspending the spools from a shaft presents safety and productivity problems that prior art devices fail to overcome.
Many safety problems inherent in existing spooled product dispensing designs can be demonstrated by examining U.S. Pat. No. 5,887,819 to Korn. The Korn patent shows the typical way in which spooled products are supported for distribution: a wire spool rack includes a left side member, a right side member, and a rod; the ends of the rod are disposed in a slot defined in the left side member, and a slot defined in the right side member; spools of coiled wire are rotatingly mounted on the rod; more than one rod may be mounted in the rack, and more or less than three spools may be mounted on the rod(s). When distributing electrical wire four or five spools are typically held on a single rod. To load or change spools on the rods workers must support the weight of three or four spools while loading another. This number of spools can weigh hundreds of pounds, and often exceeds the maximum amount of weight that can be safely handled by available manpower. Each time a spool runs out of wire, each time a wire size needs to be changed, each time a wire color needs to be changed, and each time the distribution location needs to be changed, multiple spools need to be unloaded and loaded on the rods.
The shape of a spool creates another safety problem which prior art devices fail to overcome. While the spool shape may be ideal for dispensing coiled products, it is less than ideal for a worker to grip and carry. In order set up or change the distribution location within a worksite, a worker must pick up each individual spool of wire and carry it to the desired location. Each time a worker carries an unsupported spool of wire he risks physical injury. If a worker looses his grip on a spool and tries to regain control he can easily suffer a muscular or skeletal injury. If a spool falls on a worker's foot, a broken bone is likely to occur. The primary way the prior art addresses the problem of moving spools from one location to another is to adapt a cart to carry spools of wire. U.S. Pat. No. 5,509,671 to Campbell describes one such device wherein a cart includes racks for holding spools. Each rack is sized to typically hold three of four spools. Spools are secured to a main bracket by slipping a tube through openings formed in the center of the spools. The spools and the tube are then raised into position. The racks are releasably secured to and selectively removable from the cart to enable the spools on the racks to be carried to a site which is remote from the cart. Devices such as that described by Campbell suffer from many of the same safety disadvantages as U.S. Pat. No. 5,887,819 to Korn described above: each time a spool runs out of wire, each time a wire size needs to be changed, and each time a wire color needs to be changed, an entire rack must be handled. A loaded rack can easily exceed the amount of weight that can be safely handled with available manpower. Additionally, a fully loaded cart can weigh six hundred pounds or more, be unbalanced, unstable, and prone to overturning. These problems make cart type spool carriers an extreme safety hazard at any work site.
Devices which rely on a shaft to support multiple spools are costly in terms of productivity. On devices such as U.S. Pat. No. 4,869,344 to Peterson, U.S. Pat. No. 5,887,819 to Korn, U.S. Pat. No. 5,509,671 to Campbell and U.S. Pat. No. 4,533,091 to Knight, multiple spools ride against one another on a single axle. Spools tightly adjacent to each other on a single axle can lock together making distribution difficult. The rate at which any individual spool rotates will likely be different than the rotation rate of any adjacent spool. When a heavy spool rotates faster than an adjacent lighter spool, friction between the spools causes the lighter spool to spin too fast. This can cause the product to loop and tangle. Should excess wire become tangled about the axle, the axle must be completely unloaded and reloaded to clear the problem. Even when no problems occur, loading and unloading spools on shafts is time consuming because multiple spools must be unloaded and reloaded on a shaft whenever a single spool needs to be changed.
Another productivity issue is related to spool breakage. Spools are increasingly constructed of rigid plastic. When dropped or banged these plastic spools tend to break. Most existing distribution devices require the user to carry unsupported spools of product to distribution locations. Because spools of wire are heavy and difficult to handle they are frequently dropped and broken. Spools are also frequently broken during transport to and from a work site. Spools are typically transported in open bins in the back of work trucks and vans. There is no way to position a spool so that it will be stable during such transport. Existing distribution tools do nothing to protect spools during transport. Because wire can get hung up on broken spools entire spools of wire are often discarded when the spool breaks. The cost of broken spools adds significant expense to an electrician's overhead.
Another productivity related shortcoming of prior art devices is that they provide no means of distributing wire in multiple directions. In the building construction trade it is often necessary to pull a long length of wire, such as romex wire, in one direction from one location, and to later pull another length of the same wire from the same location but in a different direction. In order to change the direction of wire distribution on existing devices, the spool must be unloaded, the distribution device reoriented, and the spool reloaded on the device.
Workers frequently need to distribute wire, nails, screws, and other products when working on a scaffold. In this situation the worker is presented with a major safety problem. Loose products such as nails and screws are typically distributed from containers such as bags, boxes, buckets or pails which sit on the floor of the scaffolding. Such containers create obstacles which the worker might trip on, causing the products or the worker to fall from the scaffold. There is currently no known product to keep nail, screw, or other product packages secured off the scaffold floor.
When distributing wire from a scaffold, wire spools typically remain on a distribution device on the ground. Wire is then pulled up through the scaffold. Wire pulled in this manner is prone to getting tangled in the scaffold, creating a danger to all workers in the vicinity of the scaffold. Additionally, every time a spool needs to be changed, the electrician must climb off the scaffold, change the spools, and climb back up the scaffold. When climbing up the scaffold, the electrician must pull the wire as he climbs, creating an additional safety hazard. U.S. Pat. No. 6,688,550 to Mullins attempts to overcome problems associated with pulling wire from remote locations by providing a portable supply rack which is stabilized by hanging it at a desired work station. The Mullins supply rack has at least one support rod having opposite ends. Each of the opposite ends of the support rod is insertable through corresponding aligned apertures in a pair of side walls. Each of the opposite ends of the support rod includes an aperture which receives a securing member such as a clip or pin therein. In order to use such a device on a scaffold, the support rod would have to be inserted through the center of a spool. The support rod would then be mounted to the side walls of the supply rack and the securing members secured to the support rod. The supply rack would then be hung from the scaffold. This process would create a safety hazard by causing the electrician to handle pieces such as the support rod, securing members, supply rack, and spool, while on the scaffold. If any one piece is dropped it becomes a danger to those working below. If the supply rack is loaded on the ground, its shape and weight would make it difficult and dangerous to carry up the scaffold.
Space on any work vehicle is limited. Existing wire distribution devices take up valuable space on these vehicles in addition to the space that is used for the spools themselves. Furthermore, current distribution devices are bulky and difficult to handle and must be hauled to and from a work site.
It is therefore an object of the present invention to provide a product hanger that overcomes the above mentioned problems of prior art devices.
Another object of the present invention is to provide a product hanger that allows distribution of product from a spool without the use of a solid axle, shaft, or rod.
Another object of the present invention is to provide a product hanger that is safe to use on scaffolding.
Another object of the present invention is to provide a product hanger that provides omni-directional distribution from a spool.
Another object of the present invention is to provide a product hanger that can support a container.
Another object of the present invention is to provide a product hanger that allows a single spool to be removed and installed for distribution without removing and installing other spools.
Another object of the present invention is to provide a product hanger that can be safely handled, loaded, and unloaded by a single person.
Another object of the present invention is to provide a product hanger that provides a safe and convenient means for a person to carry spools.
Another object of the present invention is to provide a product hanger that protects spools during transport.
Another object of the present invention is to provide a product hanger that conserves space on transport vehicles.
Another object of the present invention is to provide a product hanger that consists of a minimum number of parts.
Another object of the present invention is to provide a product hanger that is inexpensive to manufacture, and simple to use.
The present invention is directed toward a product hanger comprising at least one main support member which defines a longitudinal axis and comprises at least one hanging means for hanging the product hanger from a support. A first end of the main support member comprises a first vertical support arm extending downwardly to a terminating end, and the terminating end comprises a first engagement member. A second end of the main support member comprises a second vertical support arm extending downwardly to a terminating end, and the terminating end comprises a second engagement member.
Another embodiment of the invention is a method of hanging a spool of product, and distributing product from the spool.
The accompanying drawings illustrate a complete embodiment of the invention according to the best modes so far devised for the practical application of the principles thereof, and in which:
Referring now to the drawings where similar elements are numbered the same,
In one embodiment of the invention, the two engagement members 60, 70 engage a hole that resides in the center of a spool without the need for a shaft or axle running through the center of the spool. The spools are mounted and dismounted from the product hanger 10 by flexing the vertical support arms 40, 50, sliding them over the spools until the two engagement members 60, 70 are adjacent to two ends of the hole disposed in the center of the spool, and releasing the vertical support arms 40, 50 so that the two engagement means 60, 70 enter the hole to engage the spool. Alternatively, as seen in
The hanging means 30 is any hanging means known to those of average skill in the art, such as a closed loop section of the main support member 20. A closed loop is used, for example, for transporting large heavy spools: a pipe or rod is inserted through the closed loop and one or more persons carry each end of the pipe or rod. In a preferred embodiment of the invention as shown in
In a most preferred embodiment of the invention as shown in
The open hook hanging means as shown in
Referring back to
The product hanger of the present invention is constructed of rigid material such as metal, pot metal, metal alloy, steel, stainless steel, spring steel, steel wire, extruded plastic, and/or pvc. The preferred material is spring steel or extruded plastic. In a preferred embodiment of the present invention as shown in
In yet another preferred embodiment of the invention as depicted in
The above description and drawings are only illustrative of preferred embodiments which achieve the objects, features and advantages of the present invention, and it is not intended that the present invention be limited thereto. Any modification of the present invention which comes within the spirit and scope of the following claims is considered part of the present invention.
This application claims priority to U.S. Provisional Application 60/58,676 filing date Jul. 6, 2004, for the subject matter contained therein.
Number | Date | Country | |
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60585676 | Jul 2004 | US |