Transportable carrier REEL for pre-coiled unspooled consumable electrical wire

Abstract

A transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire. The carrier reel includes two upright sidewalls and a split spool extending between the two upright side walls. The upright side walls are movable relative to each other so that the carrier reel is transitionable between open and closed states. In the open state, the sidewalls are spread apart thereby splitting the spool so that the electrical wire is loadable onto at least part of the spool. In the closed state, the sidewalls are brought toward each other so that the spool is operably coupled to each sidewall for supporting and dispensing the wire. A handle may be provided that forms at least part of a latch that is movable between secure and release states. The release state enables transitioning the carrier reel between open and closed states.

Description

TRANSPORTABLE CARRIER REEL FOR PRE-COILED UNSPOOLED CONSUMABLE ELECTRICAL WIRECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 720,026 filed November 13, 2024, the entire disclosure of which is hereby incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates generally to a reel for electrical wire, and more particularly to a transportable carrier reel for reusable loading and unrolling an unspooled and pre -coiled consumable electrical wire.BACKGROUND

[0003] Non-metallic (NM) sheathed electrical wire is widely used in residential and light commercial electrical wiring. Such wire typically includes two or more insulated conductors and a bare ground wire, all enclosed in a flexible plastic sheath. This wire commonly is used for interior electrical circuits, such as in walls, ceilings, and floors, and can carry currents for electrical loads including lighting, outlets, and appliances.SUMMARY

[0004] Non-metallic sheathed electrical wire commonly is sold in packs, with the wire being precoiled and unspooled due to the versatility of its use. However, at least one problem with such packaging of this wire is in its dispensability and ability to uncoil the wire easily to provide straightforward routing through structures such as studs and joists. In particular, the uncoiling of the wire from the pack often results in the wire maintaining is permanently deformed coil configuration, with the dispensed wire thereby forming a wire spiral (helix) that needs to be permanently straightened out in segments either at the point of routing or prior to routing through the structures. This is a cumbersome and time-consuming process for the installer of the wire.

[0005] At least one aspect of the present disclosure solves one or more problems associated with unspooled consumable electrical wire, such as conventional non-metallic sheathed electrical wire, by providing a transportable carrier reel that enables reusable loading and unrolling of this electrical wire in an easy and efficient manner, and which may provide such unrolling with permanent deformation of the wire in relatively straight segments at the point of dispensing, thereby facilitating the handling and routing of the wire.

[0006] According to at least one aspect, a transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, includes: two upright sidewalls and a split spool extending between the two upright sidewalls, the upright sidewalls being movable relative toeach other so that the carrier reel is transitionable between open and closed states, wherein when in the open state, the sidewalls are spread apart thereby splitting the spool so that the electrical wire is loadable onto at least part of the spool, and when in the closed state, the sidewalls are brought toward each other so that the spool is operably coupled to each sidewall for supporting and dispensing the wire; the carrier reel further including a handle that forms at least part of a latch that is movable between secure and release states, wherein the release state enables transitioning the carrier reel between its open and closed states, and the secure state secures the first and second sidewalls together thereby containing the wire and enabling transporting of the carrier reel and wire together as a unit by hand.

[0007] According to an aspect, a transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, includes: a base having a first base part and a second base part that are hinged together; a first sidewall extending upright relative to the first base part, and a second sidewall extending upright relative to the second base part, the first and second sidewalls being spaced apart relative to each other to form a gap therebetween; a split spool extending horizontally from the first sidewall to the second sidewall across the gap, the split spool having a first spool part rotatably coupled to the first sidewall and a second spool part rotatably coupled to the second sidewall; a handle movably attached to an upper portion of the first side wall and releasably couplable to an upper portion of the second sidewall; and an opening formed between the first and second sidewalls through which the electrical wire is dispensable; wherein the first and second sidewalls are movable relative to each other via the hinged first and second base parts such that the carrier reel is transitionable between (i) an open state, in which the first and second sidewalls are spread apart thereby splitting apart the first and second spool parts so that the pre-coiled electrical wire is loadable onto one of the first and second spool parts, and (ii) a closed state, in which the first and second sidewalls are brought toward each other thereby co-rotatably coupling together the first and second spool parts to enable supporting the coiled electrical wire in the gap and permit unrolling and dispensing of the electrical wire through the opening; and wherein the handle forms at least part of a latch that is movable between (i) a release state, in which the handle is released from the second sidewall and permits transitioning the carrier reel between the open and closed states, and (ii) a secure state, in which the handle secures the first and second sidewalls together at their respective upper portions to maintain the carrier reel in the closed state thereby containing the pre-coiled electrical wire in the gap and enabling transporting of the carrier reel and wire together as a unit by hand.

[0008] The following description and the annexed drawings set forth certain illustrative embodiments according to the present disclosure. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features according to aspects of the present disclosure will become apparent from the following detailed description when considered in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The annexed drawings, which are not necessarily to scale, show various embodiments according to the present disclosure.

[0010] Fig. 1 is a top, front, left perspective view of an exemplary transportable carrier reel and an unspooled pre-coiled electrical wire which is shown in an uninstalled state on the carrier reel.

[0011] Fig. 2 is a top, front perspective view of the carrier reel.

[0012] Fig. 3 is a top view of the carrier reel.

[0013] Fig. 4 is a right side view of the carrier reel.

[0014] Fig. 5 is a front view of the carrier reel in a closed and secured state.

[0015] Fig. 6 is a front view of the carrier reel in a closed and release / unlocked state.

[0016] Fig. 7 is a top perspective view of the carrier reel in an open state.

[0017] Fig. 8 is a front view of the carrier reel in the open state.

[0018] Fig. 9 is a top, front perspective view of the carrier reel in the open state with electrical wire loaded into the carrier reel.

[0019] Fig. 10 is a top view of the carrier reel in the open state with the wire loaded into the carrier reel.

[0020] Fig. 11 is a top, front view of the carrier reel in a closed and unlocked / release state with the electrical wire loaded in the carrier reel.

[0021] Fig. 12 is a front view of the carrier reel in its closed and locked state with the electrical wire loaded therein.

[0022] Fig. 13 is a top, front, left perspective view thereof.

[0023] Fig. 14 is a top plan view thereof.

[0024] Fig. 15 is a right side view of the carrier reel in its closed and locked state with the electrical wire being dispensed from the carrier reel.DETAILED DESCRIPTION

[0025] The principles and aspects according to the present disclosure have particular application to reels for electrical wire, such as for residential or commercial applications using conventional electrical wire known as non-metallic sheathed electrical wire, type B (NM-B), or more commonly as Romex® wire or cable, and thus will be described herein mainly in this context. It is understood, however, that the principles and aspects of the present disclosure may be applicable to other types of wire for other applications when desirable to provide one or more advantages of the apparatus described herein.

[0026] Referring to Figs. 1 - 15, an exemplary transportable carrier reel 100 for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire 50 is shown. The carrier reel 100 generally includes abase 102, upright sidewalls 104, 106, and a spool 108 extending between the sidewalls 104, 106 to support the electrical wire 50 and permit unrolling and dispensing of the electrical wire through an opening 110 of the carrier reel 100. The carrier reel 100 also includes a handle 120 which may form atleast part of a lockable latch which helps contain the pre-coiled electrical wire 50 in the carrier reel 100 and enables transporting of the carrier reel 100 and wire 50 together as a unit by hand.

[0027] The upright sidewalls of the carrier reel 100 include at least first (e.g., left) upright sidewall 104 and second (e.g., right) upright sidewall 106, which are spaced apart from each other to form a gap 107 therebetween. The spacing of the gap 107 between the sidewalls 104, 106 is sufficient to contain at least one coil of the pre-coiled electrical wire 50. This may include standard NM-B electrical wire with a gauge between 6-gauge and 14-gauge two or three-wire, and lengths in a range from about 25 feet to about 250 feet. Other suitable types of wire include 6-AWG / 3-wire, 8 / 3, 12 / 3 MC (metal clad), or the like. To provide such a gap 107, the spacing between the sidewalls 104, 106 may be in a range from about 6 inches to about 12 inches, more particularly from about 6 inches to 9 inches. In some embodiments, the carrier reel 100 may be configured to hold multiple coils which may be separated by a divider. As such, in some embodiments, the spacing between sidewalls 104, 106 may be greater than in the illustrated embodiment to permit such multiple coils if desired.

[0028] The opening 110 through which the electrical wire is dispensed may be at any suitable location(s) and may be formed in any suitable manner. For example, in the illustrated embodiment, the opening 110 is formed by having at least an open front side of the carrier reel 100 such that there is no front sidewall between the first (e.g., left) and second (e.g. right) sidewalls 104, 106. In other embodiment(s), however, the opening 110 could be formed in a sidewall of the carrier reel 100, such as a window in a front, top, and / or rear sidewall, for example. However, the relatively open nature of the illustrated carrier reel 100 with the first (left) sidewall 104 and second (right) sidewall 106 and without top, front and rear sidewalls, reduces the complexity and cost of the carrier reel while also enabling an ease of visually perceiving the amount of wire 50 remaining, and while enhancing the dispensing capability and transportability of the device.

[0029] The sidewalls 104, 106 extend upright relative to the base 102, such as perpendicularly vertical relative to the base. In the illustrated embodiment, the respective sidewalls 104, 106 are unitary with the base 102, or respective base parts, in which the overall base 102 is laterally enlarged relative to the width of the sidewalls 104, 106. This relatively large, flat base can enhance the stability of the device and reduce tipping when dispensing the wire 50. It is understood, however that the sidewalls 104, 106 could be discrete members that are attached to the base 102, or respective base parts, via suitable fasteners or adhesive. It is also understood that the base 102 could be considered the lower portions of the respective sidewalls 104, 106 with or without being laterally enlarged as compared to the width of the major portions of the sidewalls 104, 106.

[0030] In exemplary embodiments, the base 102 includes a first base part 102a and a second base part 102b which are operably coupled together to provide relative movement between the base parts 102a, 102b. The first upright sidewall 104 is operably coupled (e.g., integral and unitary) with the first base part 102a, and the second upright sidewall 106 is operably coupled (e.g., integral and unitary) with the second base part 102b such that movement of the base parts 102a, 102b results in correspondingmovement of the sidewalls 104, 106 relative to each other. In exemplary embodiments, the first and second base parts 102a, 102b are hinged together via a base hinge 112 to provide a pivot axis 113 about which the upright sidewalls 104, 106 can spread apart relative to each other to transition the carrier reel 100 between open and closed states, as described in further detail below. The hinge 112 may be any suitable type of hinge, such as a continuous (piano) hinge, barrel hinge, butt hinge, pivot hinge, butterfly hinge, or the like which are attached to the base parts 102a, 102b; or the hinge may be a living hinge (in which the base parts are unitary with the living hinge). It is understood that the upright sidewalls 104, 106 may be movably coupled together via another structure at a different location than at the base 102, such as being hinged by rear sidewall parts for example; however, the hinged base 102 provides advantages in the manner in which the wire can be loaded onto the spool 108 in a vertical manner, as described in further detail below.

[0031] The spool 108 extends horizontally between the upright sidewalls 104, 106 and across the gap 107 to support the coil of electrical wire 50 in a manner that permits dispensing through the opening 110. Generally, the spool 108 may be perpendicular relative to the sidewalls 104, 106 and may be at an elevation relative to the base 102 that supports the wire 50 for dispensing without substantial interference with the base 102. In exemplary embodiments, the spool 108, or at least one part thereof, is rotatable relative to at least one of the sidewalls 104, 106. This rotation of the spool 108 facilitates rotation of the wire 50 as it is being dispensed. Although the spool 108 could be stationary relative to the sidewalls 104, 106 and allow the wire 50 to be freely unwound therefrom, such a stationary spool could cause binding as the wire constricts around the spool 108 during rotational dispensing. The rotational spool 108 also can be used for rewinding excess wire 50 back onto the spool 108, which could be facilitated by a handle 114 coupled to a rotational shaft 116 of the spool, as shown in illustration of Fig. 14, for example.

[0032] The spool 108 may have a receiver 118 for receiving an end of the wire 50 which helps the coil of wire co-rotate with the spool 108 during dispensing. This can help generate a counterforce tension as the wire 50 is being dispensed through opening 110, instead of having the wire freely rotate relative to the spool 108. This tension enables the wire to be pulled and permanently deformed from its coiled shape, such as in relatively straight segments at the point of dispensing through the opening 110, which facilitates handling and routing of the wire 50, instead of the wire maintaining its coiled or helical shape as it is unrolled. The receiver 118 of the spool 108 may be any suitable structure, such as a hook, notch, hole, or the like.

[0033] In exemplary embodiments, the spool 108 is a split spool having at least one part that is releasably couplable to at least one of the sidewalls. This releasable nature of the split spool 108 permits the transitioning of the sidewalls 104, 106 between opened and closed states, and also facilitates loading of the pre-coiled electrical wire 50 onto the spool 108 while still in its pre-coiled state.

[0034] In the illustrated embodiment, the split spool 108 includes a first spool part 108a operably coupled to the first sidewall 104, and a second spool part 108b operably coupled to the second sidewall 106. The first and second spool parts 108a, 108b interface with each other to form the overall spool 108that extends across the gap 107. For example, the first and second spool parts 108a, 108b may mate together via a slidable interface engagement as they come together when the carrier reel 100 is transitioned to its closed state. Such a slidable interface engagement may include at least a portion of one of the spool parts (e.g., 108b) being received within at least a portion of the other spool part (e.g., 108a). As shown in the illustrated embodiment, the second (inner) spool part 108b may be tapered toward its free end, such as with a conical shape, which facilitates being received into the first (outer) spool part 108a. The first (outer) spool part 108a may have a cylindrical outer surface for supporting the coiled wire 50.

[0035] The first spool part 108a may be rotatably coupled to the first sidewall 104 and / or the second spool part 108b may be rotatably coupled to the second sidewall 106. When both spool parts 108a, 108b are rotatable, the spool parts may matingly interface with each other so that they co-rotate together. For example, with the illustrated sliding interface engagement of the spool parts 108a, 108b, the width of a portion of the tapered or conical inner spool part 108b may engage an inner surface of the outer spool part 108a to provide a friction fit that permits the spool parts 108a, 108b to co-rotate together. The interface of the spool parts 108a, 108b also may include interlocking elements like stops, grooves, protrusions or the like; however, the spool parts 108a, 108b may be devoid of such interlocking elements to facilitate mating without a specific angular alignment as the carrier reel 100 is transitioned into its closed state.

[0036] It is understood that although the exemplary carrier reel 100 is shown with both spool parts 108a, 108b being co-rotatable, other suitable constructions are possible. For example, the split spool 108 may have only one spool part that is rotatably coupled to one sidewall (e.g., 104) and which can be removably journaled into a receiver of the other sidewall (e.g. 106) when transitioned to the closed state; and which then can be released from the journaled receiver when transitioned to the open state to permit loading of the electrical wire. However, having spool parts 108a, 108b extending from the respective sidewalls 104, 106 and which interface together within the gap 107 may make it easier to connect the split spool 108 when transitioned to the close state (e.g., less tolerance required). The tapered (e.g., conical) construction of the inner (second) spool part 108b also may facilitate this transition to the closed state. In addition, the pivot axis 113 of the hinge being offset relative to center, and more particularly being biased toward the inner spool part 108b also facilitates interfacing the spool parts 108a, 108b together when transitioning to the closed state.

[0037] The handle 120 of the carrier reel 100 may be formed in any suitable manner and at any suitable location. In exemplary embodiments, the handle 120 is formed as a rigid bar that spans the gap 107 to couple respective upper portions of the sidewalls 104, 106 together when in the closed state. The handle 120 is sized to be grippable by an average adult user, for example having a maximum width that fits within a diameter in a range from about 1 to 3 inches. It is understood that other suitable forms of handles 120 may be employed, such as a flexible strap or via suitably sized openings in a top wall of the carrier reel, for example. However, the handle 120 formed as a rigid bar may provide a desired level ofrigidity to secure the device together in its closed dispensing state and enables the carrier reel 100 to be easily transportable.

[0038] To permit opening and closing of the carrier reel 100, the handle 120 may form at least part of a latch that is movable between a release state (see e.g., Fig. 6) and a secure state (see e.g., Fig. 5). In the release state, the handle 120 is released from at least one of the sidewalls (e.g., second sidewall 106) and permits transitioning the carrier reel 100 between its open and closed states. In the secure state, the handle 120 securely couples the first and second sidewalls 104, 106 together to maintain the carrier reel in the closed state thereby containing the pre-coiled electrical wire 50 in the gap 107 and enabling transporting of the carrier reel 100 and wire 50 together as a unit by hand.

[0039] As shown in the illustrated embodiment, the handle 120 forming at least part of the latch may be movably attached to one of the sidewalls (e.g., at an upper portion of first sidewall 104) and is releasably couplable to the other sidewall (e.g., at upper portion of second sidewall 106). Such movable attachment of the handle 120 to the first sidewall 104 may be via any suitable means, such as by being hinged to the first sidewall (e.g., at its top edge) which permits pivoting between the secure / retained and release positions. The handle 120 forming at least part of the latch is configured to releasably interface with a catch to secure the reel 100 in the closed and secured state. The catch is implementable, for example, as a stud or post (pin); or as a receiver such as an aperture, slot, or recess; or the like. As shown, a suitable lock 122 may be implemented latch for locking the carrier reel 100 in the closed state. The lock 122 may include any suitable mechanism, such as a threaded nut on threaded stud, a spring -loaded detent, a toggle, switch, or the like. The lock 122 is releasable to permit releasing the handle 120 from second sidewall 106 thereby enabling the sidewalls 104, 106 to be spread apart so that the carrier reel 100 can be deployed into its open and loadable state.

[0040] Referring particularly to Figs. 5-15, an exemplary operation of the exemplary carrier reel 100 will now be described.

[0041] Fig. 5 shows the carrier reel 100 in its closed and secured state without any electrical wire. As shown, the upright sidewalls 104, 106 are towards each other so that the first and second spool parts 108a, 108b are in co-rotatable engagement with each other. The handle 120 spans across the top edges of the upright sidewalls 104, 106 and interfaces with the catch, which in the illustrated embodiment is a stud received in an aperture of the handle. The handle is latched into its locked state with lock 122, which in the illustrated embodiment is a threaded nut on the stud.

[0042] Fig. 6 shows the latch of the handle 120 in its release state via releasing the lock 122 (e.g., removing the nut) and the handle 120 being pivoted away from the second upright sidewall 106 via its hinged coupling to the first sidewall 104. The release of the handle 120 from the second side wall 106 permits the carrier reel 100 to transition to its open state.

[0043] Figs. 7 and 8 show the carrier reel 100 in an exemplary open state in which the first and second sidewalls 104, 106 are spread apart thereby splitting apart the first and second spool parts 108a, 108b so that the pre-coiled electrical wire 50 is loadable onto one of the first and second spool parts 108a, 108b.As shown in the illustrated embodiment, the hinged coupling of the first and second base parts 102a, 102b via hinge 112 permits the spreading apart of the first and second side walls 104, 106 to the open state. This hinged coupling at the base 102 also provides an ease of tipping the carrier reel 100 onto one side (as shown) so that the first (outer) spool part 108a is pointing upright (e.g., 90-degrees vertical), thereby facilitating loading of the pre-coiled wire 50 while staying in place. As shown, the base hinge 112 may be offset relative to the center of the base 102, for example toward the second upright side wall 106 having the second (inner) spool part 108b. This offset changes the pivot point of the sidewalls 104, 106, which facilitates the separating and coupling together of the spool parts 108a, 108b as they come together.

[0044] Figs. 9 and 10 show the pre-coiled unspooled electrical wire loaded onto the first (outer) spool part 108a when the carrier reel 100 is in its open state. The wire 50 shown is a conventional non-metallic sheathed electrical wire, type B (NM-B), or more commonly known as Romex® wire or cable. This wire in its packaged configuration typically comes in lengths from 15 ft to 250 feet. The weight per foot varies with the gauge of the wire, for example with 6 / 3 (thicker gauge) wire weighing about 0.3 pounds per foot, and 14 / 2 (thinner gauge) wire weighing about 0.05 pounds per foot, for example. To provide an easily transportable carrier reel 100, the wire may be NM-B, MC or any other form of wire. In the illustrated state, one end of the wire 50 can be loaded into the receiver 119 (e.g. opening) of the split spool 108 to help generate tension during the dispensing of the wire.

[0045] Fig. 11 shows the transition of the carrier reel 100 to its closed state, in which the first and second sidewalls 104, 106 are brought toward each other and the first and second spool parts 108a, 108b are co-rotatably coupled together to form the overall spool 108. As noted above, the tapered nature of the second (inner) spool 108b part may facilitate this mating engagement between the first and second spool parts 108a, 108b. The offset of the pivot axis 113 via the hinged first and second base parts 102a, 102b also may facilitate this transition to the closed state. The split spool 108 is elevated relative to the base 102 such that the wire 50 is supported, preferably without interference of the base, and within the gap 107 between the sidewalls 104, 106.

[0046] Fig. 12 shows the handle 120 pivoted about its hinged connection to the first sidewall 104 and latched to the second upright sidewall 106 with the lock 122 so that the carrier reel 100 is in its closed and locked state. In this state, the pre-coiled wire 50 is contained in the gap 107 between the sidewalls 104, 106, as shown, so that the carrier reel 100 and wire 50 can be easily transported together as a unit by hand to the desired location for dispensing the wire through the opening 110.

[0047] Figs. 13-15 show dispensing of the wire 50 through the opening 110 into relatively straight segments 50a of wire that are permanently deformed into this shape by virtue of using the device. Such permanent deformation means that the wire 50 does not spring back automatically and maintains its shape until deformed again. In exemplary embodiments, the carrier reel 100 is configured to provide sufficient tension against the pulling force to cause such permanent deformation into these relatively straight segments. In some embodiments, this may be at least partially achieved by providing the carrierreel 100 with sufficient weight and friction with the ground so that the reel 100 does not slide when the wire 50 is dispensed; or in other words, such that the static coefficient of friction of the carrier reel 100 exceeds the pulling force of dispensing the wire 50 while deforming it into the relatively straight segments. The device 100 also should not be so heavy with the wire 50 that it is too difficult to transport by hand. For example, the carrier reel 100 with the wire 50 loaded may weigh less than about 50 pounds.

[0048] This counterforce provided by the carrier reel 100 may be assisted by the wire 50 being retained in the receiver 119 of the spool 108 which can allow the wire to tighten against the spool 108 while rotating during the dispensing. A tensioner, such as a spring (e.g., coil or compression spring), friction clutch, ratchet and pawl mechanism, or the like, could also be used in the device to provide such counterforce against the pulling force for dispensing. However, in exemplary embodiments, the carrier reel 100 is devoid of such additional tensioning mechanisms, as the ground friction, optionally together with the wire holding by the receiver 119, may provide sufficient counterforce against the pulling force without such additional components that would add extra cost and complexity to the device.

[0049] As an example, a 250 ft. roll of 12 / 2 NM-B wire loaded into the carrier reel 100 may weigh between about 10 lbs to 25 lbs for the wire, and the weight of the device without wire may be about 10 to 20 pounds. A pull force on the wire that provides dispensing with permanent deformation may be in a range from about 2 pounds to about 10 pounds of force, more particularly in a range from 2 to 5 pounds of force. Within these ranges, the carrier reel 100 on a flat (e.g., concrete) ground can provide sufficient tension as a counterforce to the pulling force so that the wire permanently deforms into the relatively straight segments (e.g., uncoils from its previous permanently deformed shape in a coil from its precoiled state). The flat and relatively broad base 102 also helps to restrict tipping of the device when the wire is being dispensed. With only the two sidewalls 104 and 106, the base 102 also provides the connection point for the walls 104, 106 and the pivot axis 113 for spreading apart the walls 104, 106, while enhancing rigidity and stability of the device. The base 102 may include friction pad(s) on its underside that contact with the ground, such as foam or rubber, to also increase its static coefficient of friction when used within the above-noted ranges of weight and force. The carrier reel 100 may provide such features with the walls 104 and 106, base 102, and / or spool 108 being made from suitable plastics to facilitate manufacturing.

[0050] As further shown in Fig. 14, the carrier reel 100 may have an optional crank, for example a handle 114 operably attached to a shaft 116 of the spool 108, which may enable re-coiling excess amounts of the dispensed wire back onto the spool 108.

[0051] According to at least one aspect, a transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, includes: two upright sidewalls and a split spool extending between the two upright sidewalls, the upright sidewalls being movable relative to each other so that the carrier reel is transitionable between open and closed states, wherein when in the open state, the sidewalls are spread apart thereby splitting the spool so that the electrical wire is loadable onto at least part of the spool, and when in the closed state, the sidewalls are brought toward each otherso that the spool is operably coupled to each sidewall for supporting and dispensing the wire; the carrier reel further including a handle that forms at least part of a latch that is movable between secure and release states, wherein the release state enables transitioning the carrier reel between its open and closed states, and the secure state secures the first and second sidewalls together thereby containing the wire and enabling transporting of the carrier reel and wire together as a unit by hand.

[0052] According to an aspect, a transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, includes: a base having a first base part and a second base part that are hinged together; a first sidewall extending upright relative to the first base part, and a second sidewall extending upright relative to the second base part, the first and second sidewalls being spaced apart relative to each other to form a gap therebetween; a split spool extending horizontally from the first sidewall to the second sidewall across the gap, the split spool having a first spool part rotatably coupled to the first sidewall and a second spool part rotatably coupled to the second sidewall; a handle movably attached to an upper portion of the first side wall and releasably couplable to an upper portion of the second sidewall; and an opening formed between the first and second sidewalls through which the electrical wire is dispensable; wherein the first and second sidewalls are movable relative to each other via the hinged first and second base parts such that the carrier reel is transitionable between (i) an open state, in which the first and second sidewalls are spread apart thereby splitting apart the first and second spool parts so that the pre-coiled electrical wire is loadable onto one of the first and second spool parts, and (ii) a closed state, in which the first and second sidewalls are brought toward each other thereby co-rotatably coupling together the first and second spool parts to enable supporting the coiled electrical wire in the gap and permit unrolling and dispensing of the electrical wire through the opening; and wherein the handle forms at least part of a latch that is movable between (i) a release state, in which the handle is released from the second sidewall and permits transitioning the carrier reel between the open and closed states, and (ii) a secure state, in which the handle secures the first and second sidewalls together at their respective upper portions to maintain the carrier reel in the closed state thereby containing the pre-coiled electrical wire in the gap and enabling transporting of the carrier reel and wire together as a unit by hand.

[0053] According to another aspect, a method of using the carrier reel according to any of the foregoing aspects, includes: providing the carrier reel in a closed and secured state; transitioning the carrier reel to a release and open state; loading a pre-coiled unspooled electrical wire onto the spool; transitioning the carrier reel to the closed state; moving the handle and latching the carrier reel into the secured state; transporting the carrier reel and wire by hand via the handle.

[0054] Exemplary embodiment(s) may combine one or more features of the foregoing aspects with each other in any suitable manner; and / or exemplary embodiment(s) may include one or more of the following additional features combined with any of the foregoing, in which one or more of these additional features may be combined separately or in any suitable combination with each other.

[0055] In exemplary embodiment(s), the second spool part is slidably inserted into the first spool part when the carrier reel transitions from the open state to the closed state.

[0056] In exemplary embodiment(s), the second spool part is tapered toward its free end.

[0057] In exemplary embodiment(s), the second spool part has a conical shape.

[0058] In exemplary embodiment(s), when in the closed state, an outer portion of the second spool part interfaces with an inner portion of the first spool part to provide co-rotation of the first and second spool parts.

[0059] In exemplary embodiment(s), the interface between the first and second spool parts is a friction interface.

[0060] In exemplary embodiment(s), the first and second base parts are hinged together at a pivot axis, and the pivot axis is offset relative to a centerline between the first and second sidewalls.

[0061] In exemplary embodiment(s), the pivot axis is biased toward the second sidewall having the second spool part which is insertable into the first spool part.

[0062] In exemplary embodiment(s), when in the open state, the first spool part and the second spool part each point vertically for loading the electrical wire.

[0063] In exemplary embodiment(s), the split spool includes a receiver configured to receive an end of the wire to thereby provide a counterforce when dispensing the wire.

[0064] In exemplary embodiment(s), the handle is a rigid bar that is hinged to the first sidewall.

[0065] In exemplary embodiment(s), a lock is provided to lock the handle in a locked state.

[0066] In exemplary embodiment(s), the opening is at a front side of the carrier reel, along a horizontal plane, and adjacent to the first and second sidewalls.

[0067] In exemplary embodiment(s), the first sidewall is unitary with the first base part and / or the second sidewall is unitary with the second base part.

[0068] In exemplary embodiment(s), the base is laterally enlarged relative to a span of the first and second sidewalls such that the base extends beyond both the first and second sidewalls.

[0069] In exemplary embodiment(s), the carrier reel has a static coefficient of friction with a concrete ground that permits permanent deformation of the wire when it is dispensed from the opening without the carrier sliding on the ground.

[0070] In exemplary embodiment(s), the carrier reel is a self-contained unit with no additional parts required for loading and dispensing the wire.

[0071] The foregoing description of the embodiments has been provided for purposes of illustration and description. Example embodiments are provided so that this disclosure will be sufficiently thorough, and will convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the disclosure, but are not intended to be exhaustive or to limit the disclosure. It will be appreciated that it is within the scope of the disclosure that individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, areinterchangeable and can be used in a selected embodiment, even if not specifically shown or described. Thus, while a particular feature may have been described with respect to only one or more of several embodiments, such feature may be combined with one or more other features of the other embodiments, separately or in any combination. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure, as may be desired and advantageous for any given or particular application.

[0072] Any background information contained in this disclosure is to facilitate a better understanding of the various aspects described herein. It should be understood that any such background statements are to be read in this light, and not as admissions of prior art. Likewise, the description and examples are presented herein solely for the purpose of illustrating the various embodiments of the disclosure and should not be construed as a limitation to the scope and applicability of the disclosure.

[0073] Transitional language such as "including," "comprising," "having," "containing," "involving," or variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, i.e., to be open-ended and meaning including but not limited to.

[0074] Use of "a" or "an" are employed in this disclosure to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of concepts according to the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless otherwise stated.

[0075] The phrase “and / or” as used in this disclosure should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary. Thus, as a non-limiting example, a reference to “A and / or B,” when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A without B (optionally including elements other than B); in another embodiment, to B without A (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0076] The phrases “at least one of [A], [B] and [C];” “at least one of [A], [B] or [C];” “one or more of [A], [B] and [C]”; or “one or more of [A], [B] or [C]” are all synonymous with the phrase “and / or” and are used to mean “one, or more, or all” unless clearly indicated to the contrary. Thus, as a non-limiting example, this could mean (1) A only, (2) B only, (3) C only, (4) A and B, (5) A and C, (6) B and C, or (7) all of A, B and C. Other elements may optionally be present other than the elements specifically identified whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary - e.g., by reciting a closed group of alternatives, such as via conventional “Markush grouping” by stating “selected from the group consisting of [A], [B], and [C].”

[0077] The word “or” as used in this disclosure should be understood as being inclusive and not exclusive. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). Only terms clearly indicating exclusivity should be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”), such as “either,” “only one of,” or “exactly one of.” In other words, such terms of exclusivity refer to the inclusion of exactly one element of a number or list of elements.

[0078] Any references to "one embodiment" or "an embodiment" as used herein is understood to mean that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily referring to the same embodiment.

[0079] The word “exemplary” is used herein to mean “serving as an example or illustration.” Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Likewise, the phrases “particularly,” “preferably,” or the like as used in this disclosure may refer to an element or value that provides advantage(s) in some embodiment(s), however is not intended to limit the scope of the disclosure to those “particular” or “preferable” features.

[0080] It is to be understood that all values, ranges, ratios or the like as described in this disclosure may be combined in any manner. In addition, it is to be understood that a concentration or amount or value range listed in this disclosure is intended to include any and every concentration or amount or value within the range, including the end points, as if each value within the range has been expressly stated, and thus these values are incorporated herein by reference. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific data points, it is to be understood that the inventor(s) appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventor(s) have possession of the entire range and all points within the range, each of which is incorporated herein by reference.

[0081] In addition, each numerical value used in this disclosure should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. The term "about" as used herein refers to any value which lies within the range defined by a variation of up to ±10% of the stated value, for example, ±10%, ± 9%, ± 8%, ± 7%, ± 6%, ± 5%, ± 4%, ± 3%, ± 2%, ±1%, ±0.01%, or ±0.0% of the stated value, as well as values intervening such stated values. When the term “about” is used in describing a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referred to.

[0082] It is to be understood that terms such as “top,” “bottom,” “left,” “right,” “front,” “rear,” or the like may refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Likewise, spatially relative terms, such as “inner”, “adjacent”, “outer,” “beneath,” “below,” “lower,” “above,” “upper,” or the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the article in use or operation in addition to the orientation depicted in the figures. For example, if the article in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0083] Terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, in which it is understood that these elements, components, regions, layers and / or sections should not be limited by these terms unless stated otherwise. In addition, terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed herein could be termed a second element, component, region, layer or section without departing from the teachings of this disclosure.

[0084] Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is apparent that equivalent alterations and modifications will occur to those having ordinary skill in the art upon the reading and understanding this disclosure, and such modifications are intended to be included within the scope of this disclosure as defined in the claims. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. A transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, the carrier reel comprising:a base having a first base part and a second base part that are hinged together;a first sidewall extending upright relative to the first base part, and a second sidewall extending upright relative to the second base part, the first and second sidewalls being spaced apart relative to each other to form a gap therebetween;a split spool extending horizontally from the first sidewall to the second sidewall across the gap, the split spool having a first spool part rotatably coupled to the first sidewall and a second spool part rotatably coupled to the second sidewall;a handle movably attached to an upper portion of the first side wall and releasably couplable to an upper portion of the second sidewall; andan opening formed between the first and second sidewalls through which the electrical wire is dispensable;wherein the first and second sidewalls are movable relative to each other via the hinged first and second base parts such that the carrier reel is transitionable between (i) an open state, in which the first and second sidewalls are spread apart thereby splitting apart the first and second spool parts so that the pre-coiled electrical wire is loadable onto one of the first and second spool parts, and (ii) a closed state, in which the first and second sidewalls are brought toward each other thereby co-rotatably coupling together the first and second spool parts to enable supporting the coiled electrical wire in the gap and permit unrolling and dispensing of the electrical wire through the opening; andwherein the handle forms at least part of a latch that is movable between (i) a release state, in which the handle is released from the second sidewall and permits transitioning the carrier reel between the open and closed states, and (ii) a secure state, in which the handle secures the first and second sidewalls together at their respective upper portions to maintain the carrier reel in the closed state thereby containing the pre -coiled electrical wire in the gap and enabling transporting of the carrier reel and wire together as a unit by hand.

2. The carrier reel according to claim 1, wherein the second spool part is slidably inserted into the first spool part when the carrier reel transitions from the open state to the closed state.

3. The carrier reel according to claim 2, wherein the second spool part is tapered toward its free end.

4. The carrier reel according to claim 3, wherein the second spool part has a conical shape.

5. The carrier reel according to claim 2, wherein when in the closed state, an outer portion of the second spool part interfaces with an inner portion of the first spool part to provide co-rotation of the first and second spool parts; more particularly, wherein the interface between the first and second spool parts is a friction interface.

6. The carrier reel according to claim 1, wherein the first and second base parts are hinged together at a pivot axis, and the pivot axis is offset relative to a centerline between the first and second sidewalls; more particularly wherein the pivot axis is biased toward the second sidewall having the second spool part which is insertable into the first spool part.

7. The carrier reel according to claim 1, wherein when in the open state, the first spool part and the second spool part each point vertically for loading the electrical wire.

8. The carrier reel according to claim 1, wherein the split spool includes a receiver configured to receive an end of the wire to thereby provide a counterforce when dispensing the wire.

9. The carrier reel according to claim 1, wherein the handle is a rigid bar that is hinged to the first side wall.

10. The carrier reel according to claim 1, wherein a manually-releasable lock is provided which is configured to lock the handle.

11. The carrier reel according to claim 1, wherein the opening is at a front side of the carrier reel, along a horizontal plane, and adjacent to the first and second sidewalls.

12. The carrier reel according to claim 1, wherein the first sidewall is unitary with the first base part and / or the second sidewall is unitary with the second base part.

13. The carrier reel according to claim 1, wherein the base is laterally enlarged relative to a span of the first and second side walls such that the base extends beyond both the first and second sidewalls.

14. The carrier reel according to claim 1, wherein the carrier reel has a static coefficient of friction against a concrete ground that permits permanent deformation of the wire when it is dispensed from the opening without the carrier sliding on the ground.

15. A transportable carrier reel configured for reusably loading and unrolling a pre-coiled, unspooled consumable electrical wire, comprising: two upright sidewalls and a split spool extending between the two upright sidewalls, the upright sidewalls being operably coupled together and movable relative to each other so that the carrier reel is transitionable between open and closed states, wherein when in the open state, the sidewalls are spread apart thereby splitting the spool so that the electrical wire is loadable onto at least part of the spool, and when in the closed state, the sidewalls are brought toward each other so that the spool is operably coupled to each sidewall for supporting and dispensing the wire; the carrier reel further including a handle that forms at least part of a latch that is movable between secure and release states, wherein the release state enables transitioning the carrier reel between its open and closed states, and the secure state secures the first and second sidewalls together thereby containing the wire and enabling transporting of the carrier reel and wire together as a unit by hand.

16. A method of using the carrier reel according to claim 1 or claim 15, comprising: providing the carrier reel in a closed and secured state;transitioning the carrier reel to a release and open state;loading a pre-coiled unspooled electrical wire onto the spool;transitioning the carrier reel to the closed state;moving the handle and latching the carrier reel into the secured state;transporting the carrier reel and wire by hand via the handle.

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