Abstract
A cable caddy with a portable housing stores cable reels. Each reel includes a drum coupled to end caps. Plugs inserted in the end caps are irrotatable with respect to the housing and rotatable with respect to the drum. During transport reels are stacked vertically atop one another with a plug of a first reel inserted in a plug of a second reel.
Claims
1. A caddy system for enclosing, transporting and dispensing cable, the caddy system comprising: a clamshell housing for enclosing a tubular drum that holds a coil of electrical cable; inserted in each end of the drum is a tubular projection of an end cap; opposite the tubular projections are receivers within each end cap; rotatably inserted in the receivers are first and second plugs; a key irrotatably inserted in the housing is irrotatably inserted in the first plug; and, the second plug is irrotatably inserted in the housing such that the drum and end caps rotate about the plugs.
2. The caddy system of claim 1 further including: a drum first end with latching holes and a drum second end with latching holes.
3. The caddy system of claim 2 further including: tubular projection spring tabs that mate with the latching holes.
4. The caddy system of claim 1 wherein the housing includes molded V shaped hangers for receiving the key and the second plug.
5. The caddy system of claim 1 wherein the end caps have six sides.
6. The caddy system of claim 5 wherein the key has six sides.
7. The caddy system of claim 6 wherein the second plug has six sides.
8. The caddy system of claim 1 further comprising a slot located along a top edge of the housing near a housing handle for dispensing cable therethrough.
9. The caddy system of claim 1 wherein a key cross section is shaped like a rectangle with a triangle at either end.
10. A caddy system for enclosing, transporting and dispensing cable, the caddy system comprising: a clamshell housing for enclosing a tubular drum for holding a coil of electrical cable; inserted in each end of the drum is a tubular projection of an end cap; the drum and end caps included in a reel; opposite the tubular projections are receivers within each end cap; for rotatably insertion in the receivers are first and second plugs; for irrotatable insertion in the housing is a key for irrotatable insertion in the first plug; and, for irrotatable insertion in the housing is the second plug such that the drum and end caps rotate about the plugs.
11. The caddy system of claim 10 wherein reels holding electrical cable are stacked with a second plug of first reel inserted in a first plug of a second reel.
12. The caddy system of claim 11 wherein housings that are opened are stacked with a first housing fitting substantially within a second housing.
13. The caddy system of claim 12 wherein closed housings having reels within are stacked such that indentations on a first housing top receive feet on a second housing bottom.
14. A method of providing a caddy for enclosing, transporting and dispensing cable, steps of the method comprising: providing a clamshell housing for enclosing a tubular drum that holds a coil of electrical cable; inserting in each end of the drum is a tubular projection of an end cap the drum and the end caps forming a reel; providing in each end cap a receiver opposite the tubular projections; rotatably inserting in the receivers first and second plugs; irrotatably inserting a key in the housing and irrotatably inserting the key in the first plug; and, irrotatably inserting the second plug in the housing such that the reel rotates about the plugs.
15. The method of claim 14 wherein the reel is removed from the housing when the key and the second plug are no longer within molded V shaped slots in a lower half of the housing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
(2) FIG. 1 is a frontal isometric view of an embodiment of our cable reel caddy, with the caddy closed;
(3) FIG. 2 is a rear isometric view of the closed cable caddy;
(4) FIG. 3 is a front elevational view of the closed caddy;
(5) FIG. 4 is a rear elevational view of the closed caddy;
(6) FIG. 5 is a top plan view of the closed caddy;
(7) FIG. 6 is a bottom plan view of the closed caddy;
(8) FIG. 7 is a left side elevational view of the closed caddy;
(9) FIG. 8 is a right side elevational view of the closed caddy;
(10) FIG. 9 is a frontal isometric view of a loaded and opened caddy;
(11) FIG. 10 is a rear isometric view of the loaded and opened caddy;
(12) FIG. 11 is a front plan view of the loaded and opened caddy;
(13) FIG. 12 is a rear plan view of the loaded and opened caddy;
(14) FIG. 13 is a top plan view of the loaded and opened caddy;
(15) FIG. 14 is a right side elevational view of the loaded and opened caddy;
(16) FIG. 15 is a left side elevational view of the loaded and opened caddy;
(17) FIG. 16 is a right, frontal isometric view of a cable reel;
(18) FIG. 17 is a left frontal isometric view of the cable reel;
(19) FIG. 18 is an exploded isometric view of the cable reel;
(20) FIG. 18A is an exploded isometric view of a caddy and reel assembly;
(21) FIG. 19 is an enlarged plan view of a reel end cap;
(22) FIG. 20 is an enlarged, exploded isometric view of a multi-part spindle;
(23) FIG. 21 is an enlarged, isometric view of the inside hub socket associated with the multi-part spindle of FIG. 20;
(24) FIG. 22 is an enlarged isometric view of a unitary spindle;
(25) FIG. 23 is an enlarged isometric view of the spindle of FIG. 22, but showing the inside;
(26) FIG. 24 is an isometric view showing a plurality of stacked reels on a pallet;
(27) FIG. 25 is an isometric view showing a plurality of stacked and nested cases disposed on a pallet;
(28) FIG. 26 is a frontal isometric view of an alternative embodiment of our cable reel caddy, with the caddy closed.
DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(29) Referring initially to FIGS. 1-12 of the appended drawings, a system for housing and carrying reels of coaxial cable or wire, and for dispensing cable or wire, has been generally designated by the reference numeral 40. The system 40 comprises a protective, portable caddy 50 for housing a reel 52 (FIGS. 9, 10) containing wound coaxial cable (or other filamentary wire or cable) that may be rotatably disposed. Ideally, the caddy 50 is disposed upon a suitable available supporting surface 54 proximate to a work site where various types and lengths of cable are to be installed. Bottom caddy feet 59 (FIGS. 3, 4) provide support and stability. The impact resistant, plastic caddy 50 comprises a lower base 56 that forms an enclosure in which reel 52 sits, and a cooperating top 58 that is pivotally coupled to base 56 with an elongated hinge 60 (FIG. 2). Base 56 and top 58 are both generally in the form of an open parallelepiped. When caddy 50 is closed, as in FIGS. 1-5, it may be conveniently transported by grasping a front handle 62 that is formed by abutting handle portions of the base 56 and top 58 when the caddy is closed, as explained in detail hereinafter. Each of top 58 and base 56 are preferably formed of impact resistant plastic and can be created in various combinations of colors to aid in identification of the caddy 50.
(30) Base 56 forms a box-like enclosure comprising a front panel 70 and an integral rear panel 72 (FIG. 7) which are integral with right end panel 74 (FIG. 8) and left end panel 76 (FIG. 7). Front panel 70 has a plurality of spaced part, generally parabolic indentations 80 that reinforce the caddy 50 and add to aesthetic styling. Similar stylistic reinforcement indentations 82 (FIG. 4) are spaced apart on the rear caddy panel 72. At the top of the center indentation 80 on front panel 70 there is a spring-biased button 86 that releasably mates with a similarly contoured, complementary opening 88 formed in the interior of top 58 (FIG. 9, 10) to form a latch. Button 86 may be manually depressed to unengage the opening 88 and allow top 58 to rotate away from base 56 to open the caddy and expose the caddy interior. As seen in FIGS. 1, 2, and 13, top 58 has an upper, slotted front mouth 57 through which cable wound about the enclosed, interior reel 52 may be withdrawn. Mouth 57 is preferably bounded by a peripheral, generally rectangular lip 61 (FIG. 13) of generally cylindrical cross section that lessens friction or resistance as cable is withdrawn through the mouth 57. Other embodiments of mouth 57 have lip 61 covered by a smooth, low-friction grommet, or a plurality of rollers, or other mechanisms (not shown) to reduce friction on cable or wire being drawn from the caddy 50. Still other embodiments of mouth 57 have an alternative lip (not shown) that is curved slightly inwardly or outwardly to reduce friction on cable or wire being drawn from the caddy 50.
(31) The base 56 also comprises an integral, stylized, frontal ledge 90 (FIGS. 1, 9) that reinforces the structure of the caddy to enable the base to retain its critical dimension and forms its upper periphery. The frontal ledge midportion 92 (FIGS. 9, 11) is offset from button 86 forming a lower half of the handle 62 (FIG. 1) extending integrally across the upper edges of the front panel 70. Ledge 90 comprises spaced apart, lateral triangular portions 93, 95 (FIG. 9) that nest within similarly styled recesses 99, 100 formed in the underside of top 58 (FIG. 9) when the caddy 50 is closed. The rear panel 72 hinge structure (FIG. 4) has a plurality of spaced apart pairs of upper hinge ferrules 102 integrally formed in rear peripheral ledge 104. Each pair of ferrules 102 on the base 56 is coupled to a barrel 106 from the top 58 disposed between it by a clevis pin 103 (FIG. 6). The ferrules 102 and barrels 106 are axially aligned, and form hinge 60 to allow the top 58 to pivot relative to the base 56.
(32) Each integral end panel 74, 76 (FIGS. 7, 8, 14, 15) of the base 56 also includes an upper peripheral ledge that extends from the rear hinge 60 to the front shelf 90 previously described. For example, left end panel 76 (FIG. 15) has a curved ledge 108 with the higher midpoint 109 centered on panel 76 and disposed above an outwardly projecting bearing housing 111. The opposite, spaced apart right end panel 74 (FIGS. 8, 14) has a complementary curved ledge 114 with a higher midpoint 115 centered on panel 74 above an outwardly projecting bearing housing 116. Ledges 108 and 104 can be utilized as lifting handles when the caddy 50 is closed. The bearing housings 111, 116 define interior gudgeons 111A and 116A respectively that mate with the spindles projecting from the reel 52 (FIG. 13) to rotatably mount the reel 52 as explained hereinafter. The plastic spindles (FIGS. 21-23) discussed later comprise hub portions seated within the receptive inner gudgeons 111A and 116A (FIG. 13) defined by the bearing housings 111, 116 when the reel 52 is disposed within caddy 50.
(33) The caddy top 58 sits atop the base 56 and is pivoted thereto with hinge 60 at the rear as discussed earlier. Top 58 has a front panel 122 (FIGS. 1, 12) with a recessed center portion 124 disposed between integral side portions 126, 127 (FIG. 1). A complementary front ledge 129 projects outwardly from panel portion 127 and a similar opposite ledge 132 projects from panel 122 (FIGS. 1, 3). Preferably there is a wire end catch 131 defined in ledge 129 (FIGS. 1, 5) to temporarily hold loose wire ends. Peripheral borders 140, 141 form the front of ledges 132, 129 and are joined by a handle portion 146 which is part of handle 62. Borders 140, 141 are complementary with and substantially cover the projecting ledge 90 on the base 56 discussed earlier.
(34) End panels 160 (FIG. 7) or 161 (FIG. 1) of the top 58 have arcuate peripheries 164, 162 (i.e., FIGS. 10, 14-15), respectively that mate with and are complementary to base side ledges 108 (FIG. 15) and 114 (FIG. 14) discussed above when the caddy 50 is closed. Importantly, the upper surface 166 (FIGS. 1, 2) of the top 58 has a plurality of generally cubicle indentations 169 disposed generally at the comers of the rectangular surface 166. Indentations 169 are aligned with the feet 59 (FIG. 4) in the base 56. Thus when caddies are vertically stacked atop one another, when for example two or more caddies are transported at the work site on a conventional hand truck or dolly, the feet 59 from an upper caddy can register with the indentations 169 in a lower unit to stabilize the vertical stack. Beneath the upper surface 166 of the top, at the underside 170 (FIG. 13) the indentations have projecting nubs 169B. When empty caddies are stacked in the open position for shipping, as discussed later, the indentations 169 (FIG. 2) in one caddy can register with the projecting indentations 169B (FIG. 13) in a lower stacked caddy for stability.
(35) Referring now to FIGS. 16-18, wire or coaxial cable 180 is wound about and stored upon reels 52. Referring to FIG. 18, the reel 52 preferably comprises a spool 182 of cable 180 that is coaxially mounted by a central axle 184 when reels are mounted within a caddy or clamshell housing 50. Opposite ends 187, 189 of axle or drum 184 are coupled to similar, spaced apart end caps 190, 192 (i.e., FIGS. 18, 19). These flange-like end caps 190, 192 restrain wire, cable or other filamentary material wound about the spool 182 and enable rotation. The inner centers of each end cap include circular coupling rings or end cap tubular projections 194 that mate with ends 187, 189 of axle 184 in assembly. The axle ends include projecting notches 199 that register with locks 198 in coupling rings 194. The axle ends include latching holes 1950 for mating with the end caps 190, 192. On their opposite outer ends, the coupling rings 194 have generally circular, recessed bearing races or receivers 200 (FIG. 18) to which spindles or plugs 202, 204/1940 may be fitted. Extending from each bearing race is a race inner lip 1999. A wire end slot 331 is shown in FIG. 16 and provides access to the starting end of the cable 180 on spool 182.
(36) There are two spindles employed in a preferred embodiment, a unitary, single piece spindle 202, and a multi-piece spindle 204. Each preferably molded plastic spindle includes a bearing portion, and a hub. The spindle bearing portions are fitted to the end cap races 200 to journal the reel 52 for rotation. Spindle hub structures are supported within complementary gudgeons 116A or 111A (FIG. 13) respectively to support the associated reels 52 within the case and enable rotation. The inner axle 184 and end caps 190, 192 thus rotate relative to the spindle hubs to enable reel rotation. Referring to FIG. 19, a preferred embodiment of end cap 190 or 192 is detailed. Spindle 204 is seen mated within the coaxially centered race 200 of the end cap discussed above. Preferably each end cap is polygonal so that the reel is stable when placed on a substantially flat surface and will not roll away. In a preferred embodiment the end caps are either hexagonal or octagonal. Each of the outer facets 210 of the end cap are integral with curved and radially spaced apart spokes 212 that project from the inner hub of the end cap 190. Periodic radially spaced apart voids 213 lighten the end caps. The orientation of of spokes 212 and voids 213 add to the durability of the end cap 190 or 192 by allowing it to more flex on impact and thereby resist permanently deforming or breaking.
(37) Referring mainly now to FIGS. 20 and 21, the preferably two-piece spindle 204 comprises a bearing portion 205 comprising a circular, peripheral bearing ring 206. Bearing ring 206 is segmented, comprising curved, peripheral portions 208, 209 that are separated by relief slots 211 to enable resilient bending. Ring 206 engages and yieldably frictionally fits into end cap race 200 (FIG. 19) forming the bearing connection, allowing the end cap and reel to rotate relative to the hub. In an embodiment of the invention, the width of bearing ring 206 in contact with end cap race 200 is preferably between one-half and one inches. The width of the bearing ring 206 is important in providing variable braking as cable is removed, for durability and to sufficiently support the weight of a full reel 52. Ring 206 is integral with a projecting cap portion 219 (FIG. 20) that interiorly defines a recessed socket 217 (FIG. 21) at its opposite end. A separate, removable key 218 (FIGS. 18, 18A, 20) is removably fitted to spindle bearing portion 205 (FIG. 20), being received within socket 217 (FIG. 21).
(38) Key 218 (FIG. 20) comprises a pair of adjoining, preferably similarly shaped portions 221 and 223. The key's hub 221 is designed to seat within a gudgeon 111A in assembly when a reel is placed within the caddy. The neighboring plug 223 (FIG. 20) is adapted to fit within socket 217 provided by the spindle bearing portion 205 (FIGS. 20, 21). With a reel disposed within the caddy, the projecting key 218 now coupled to socket 217 by plug 223 projects its hub 221 towards bearing gudgeon 111A (FIG. 13). Alternatively, when reels are shipped from the factory, or when reels are moved or stored about a work site, the key 218 can be removed from spindle 204, exposing hub socket 217 (FIG. 21) that can now receive the hub 239 (FIGS. 18, 22) from a unitary spindle 202 projecting upwardly from another reel below it, as when multiple reels are vertically stacked. When reels are to be mounted in the caddy for use, the removable key 218 is reconnected to spindle 204 and seats within a gudgeon to establish reel rotation.
(39) The security key 218 can be adapted to allow only specific reels to fit within a caddy. In other words, the configuration of the plug 223 (FIGS. 18, 20) can be matched to specific, complementary sockets 217 (FIG. 21), so that specific reels cannot be rotatably disposed within a caddy unless the user has a properly configured key 218 (i.e., the proper key) to fit within the given socket 217. Alternatively, the design of the receptive case gudgeons 111A or 116A can be custom configured so that a given caddy will receive and mount only a specific reel with specifically configured keys 218, associated with spindled 204, or hubs 239 (FIG. 22) associated with spindle 202. As a result, specific reel designs can be custom defined for specific customers or specific jobs using specific caddies, enabling rapid identification, reducing mistakes, and reducing the likelihood of theft.
(40) In FIGS. 22 and 23 the permanently attached, unitary spindle 202 is detailed. An integral, outer, peripheral bearing ring 226 is also segmented, comprising separated curved portions 228, 229 for example, that are separated by relief slots 231 to enable resiliency. The width of bearing ring 226 is preferably the same as the width of bearing ring 206.
(41) Preferably there are four radially spaced apart, barbed tabs 233 comprised of outwardly facing barbs 236 that engage with a inner lip of the race 200 (FIG. 18) and snap into place. Barbs 236 axially lock the spindle 202 within the race 200 for rotation of the spindle. Thus bearing ring 226 journals the spindle for rotation. The resilient plastic construction enables yieldable frictional fitting of the spindle 202 to the end cap (FIG. 18) where it is permanently seated. Ring 226 borders a frontal, recessed interior 237. Recess 237 forms the underside of an integral projecting hub 239 (FIG. 22) at an opposite end that is normally seated within a caddy inner gudgeon 111A or 116A (FIG. 13) to enable reel rotation. The removable key 218 (FIG. 18) that is associated with spindle 204 may have its hub portion 221 geometrically configured similarly to hub portion 239 on spindle 202; however, both hub portions 221 and 239 have the same function, and both are seated within caddy inner gudgeons 111A and 116A. Alternatively, when reels are shipped or moved, hub portion 239 of a spindle 202 can engage another spool above it, nesting within an exposed socket 217 (FIGS. 18, 21) in another spindle 204 whose key 218 (FIG. 20) has been removed. Normally, hub portion 239 will seat within a gudgeon 116A (FIG. 13) when a reel is disposed within a caddy, and the spool can thus rotate relative to the hub and its receptive gudgeon.
(42) FIG. 24 illustrates how a plurality of separate reels 300 may be conveniently stacked in a pallet. Here the reels 300 are arranged in multiple, spaced-apart vertical stacks forming columns upon floor 303 of the pallet 304. For most of the reels, their upwardly projecting, permanent spindles 202 mate with upper reels. Specifically, the hubs 239 of spindles 202 fit within an exposed socket 217 (FIG. 21) that are unblocked and exposed by removal of the security key 218 of spindle 204 (FIG. 18) discussed earlier. However, the uppermost reels 321 (FIG. 24) have their spindles 202 seated within suitable spaced apart orifices defined in the roof 328 of pallet 304. FIG. 24 also illustrates how stability of the stacks is increased and volume required is decreased by the polygonal shape of reel endcaps 190 (FIG. 19) and 192 (FIG. 18A). The flat edge of the polygonal endcaps 190, 192 abut with a greater contact area than a circular shaped endcap.
(43) FIG. 25 illustrates how empty caddies 50 can be stacked for shipment. The caddies are opened as illustrated and stacked such that the lower base 56 of an upper unit is nested within the lower base of a lower unit. Similarly the top 58 of one unit, inverted by folding, is nested within the top of a similarly folded lower caddy. This minimizes shipping volume.
(44) FIG. 26 shows an alternative embodiment of a portable caddy 350. Caddy 350 has an alternative top 358 and is otherwise similar to caddy 50 shown in FIG. 1. The caddy top 358 has a front panel 322 with a mouth 357. Mouth 357 is approximately centered on front panel 322 and extends preferably eighty percent of the width of front panel 322 and preferably fifty percent of the height of front panel 322. Other embodiments of mouth 357 may be larger or smaller.
(45) From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
(46) It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations.
(47) As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
