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`a2) United States Patent
`US 7,121,501 B1
`(0) Patent No.:
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`Oct. 17, 2006
`(45) Date of Patent:
`Lea
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`US007121501B1
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`(54) WIRE SPOOLING SYSTEM
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`(76)
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`Inventor: Frederick L. Lea, 9445 Old Needville
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`Fairchilds Rd., Needville, TX (US)
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`77461
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`(*) Notice:
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`Subject to any disclaimer, the term ofthis
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`patent is extended or adjusted under 35
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`U.S.C. 154(b) by 210 days.
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`(21) Appl. No.: 10/985,223
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`(22)
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`(51)
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`Nov. 9, 2004
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`Filed:
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`Int. Cl.
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`(2006.01)
`BO5H 75/14
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`(2006.01)
`BO5H 75/18
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`(52) U.S. Ch cece 242/608.2; 242/608.5;
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`242/608.6; 242/609.1; 242/609.3; 242/608.3
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`(58) Field of Classification Search ................ 424/607,
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`424/608, 608.1-608.3, 608.5—-608.6, 609,
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`424/609.1, 609.3, 601, 118.4, 118.6, 118.61
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`See application file for complete search history.
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`References Cited
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`U.S. PATENT DOCUMENTS
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`(56)
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`3,830,445 A
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`3,836,093 A
`3,837,597 A
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`4,151,963 A *
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`4,667,897 A
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`4,765,560 A
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`4,844,376 A
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`4,973,011 A
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`8/1974 Moore oo. eeeeeee 242/118.4
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`9/1974 Mozina et al. 0... 242/118.6
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`9/1974 Bourhenne ..........0..... 242/129
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`5/1979 Ruiz-Barbotteau ....... 242/608. 1
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`5/1987 Burrow et al... 242/129
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`8/1988 Branback «0.0... 242/129
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`7/1989 Maraman,Sr.
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`11/1990) Wilson ...... eee eee eeee 242/129
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`6/1993 Blackshire ..........0.0.. 242/137.1
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`9/1993 Branback .........00:cceeee 242/129
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`12/1993 Hofrichter et al.
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`9/1994 Huette 0... weve 242/597 .5
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`9/1996 Browning......
`weve 242/578.2
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`9/1998 Shea «oe wee 242/559.1
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`8/2000 Ripplinger ........
`wee 242/609.1
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`9/2001 Peterson et al.
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`2/2002 Oppmann et al.
`.......... 242/580
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`5,222,683 A
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`RE34,376 E
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`5,267,705 A
`5,348,241 A
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`5,551,647 A
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`5,810,283 A
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`6,102,327 A *
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`6,289,570 B1*
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`2002/0023984 Al*
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`* cited by examiner
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`Primary Examiner—William A. Rivera
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`Assistant Examiner—Sang Kim
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`(74) Attorney, Agent, or Firm—Michael S. Neustel
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`ABSTRACT
`(57)
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`A wire spooling system for spooling and dispensing wire.
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`The wire spooling system includes a first spool member,
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`having a tubular member with a locking cap andfirst collar,
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`and a second spool member, having an engagementaperture
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`and second collar. The tubular member extends through the
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`first spool membersubstantially transverse to thefirst spool
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`member. The locking cap is positioned at the end of the
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`tubular member opposite the first spool member. The first
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`collar protrudes from the first spool member in the same
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`plane and direction as the tubular member. The secondcollar
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`protrudes from the second spool memberandfits within the
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`first collar. The spool members thereby form a spool shape.
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`Upon fitting the second collar within the first collar, the
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`engagementaperture receives the locking cap of the tubular
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`member, securing the first spool member and second spool
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`memberin a locked position.
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`20 Claims, 8 Drawing Sheets
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`30
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`32
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`20
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`Page 1 of 13
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`PPC Exhibit 1041
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`Page 1 of 13
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`PPC Exhibit 1041
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`Oct. 17, 2006
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`Sheet 1 of 8
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`US 7,121,501 B1
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`FIG.1
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`U.S. Patent
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`U.S. Patent
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`Oct. 17, 2006
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`Sheet 2 of8
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`US 7,121,501 B1
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`U.S. Patent
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`Oct. 17, 2006
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`Sheet 3 of 8
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` FIG.4
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`Page 5 of 13
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`U.S. Patent
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`Oct. 17, 2006
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`Sheet 5 of8
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`US 7,121,501 B1
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`Oct. 17, 2006
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`Sheet 6 of8
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`US 7,121,501 B1
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`FIG.6
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`U.S. Patent
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`U.S. Patent
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`Oct. 17, 2006
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`Sheet 7 of8
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`US 7,121,501 B1
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`FIG.7
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`U.S. Patent
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`Sheet 8 of 8
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`1
`WIRE SPOOLING SYSTEM
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`US 7,121,501 B1
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`CROSS REFERENCE TO RELATED
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`APPLICATIONS
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`Not applicable to this application.
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`STATEMENT REGARDING FEDERALLY
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`SPONSORED RESEARCH OR DEVELOPMENT
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`Not applicable to this application.
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`BACKGROUND OF THE INVENTION
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`1. Field of the Invention
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`Thepresent invention relates generally to wire dispensing
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`spool devices and more specifically it relates to a wire
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`spooling system for efficiently spooling and dispensing
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`previously unspooled wire.
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`2. Description of the Related Art
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`Wire dispensing spool devices have been in use for years.
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`Typically, wire spools were only sold in large sizes with
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`gigantic amounts of wire wound around the spool. These
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`types of spools of wire were only usable with large equip-
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`ment and were difficult to effectively manage and transport.
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`Morerecently, wire spools came in smaller portions that
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`were more manageable for smaller companies’ needs for
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`spooled wire. The smaller spools and lessened amounts of
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`wire have proved a great help to smaller contractors and
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`electricians. However, a main existing problem was that
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`there were certain types of wire that still only came on a
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`spool in gigantic quantities. These types of wire werestill
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`difficult to manage and required heavy machinery move
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`Additionally, unspooled wire that was sold in smaller
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`quantities required a user to unravel the wire from the inside
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`out. This caused twisting of the wire thereby reducing its
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`quality.
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`In these respects, the wire spooling system according to
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`the present invention substantially departs from the conven-
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`tional concepts and designsofthe prior art, and in so doing
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`provides an apparatus primarily developed for the purpose
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`of efficiently spooling and dispensing previously unspooled
`wire.
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`BRIEF SUMMARY OF THE INVENTION
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`2
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`stantially transverse to the first spool member. The locking
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`cap is positioned at the end of the tubular memberopposite
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`the first spool member. The first collar protrudes from the
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`first spool member in the same plane and direction as the
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`tubular member. The second collar protrudes from the
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`second spool memberandfits within the first collar, wherein
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`the first and second spool members thereby form a spool
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`shape. Upon fitting the second collar inside the first collar,
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`the engagement aperture receives the locking cap of the
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`tubular member, thereby securingthefirst spool member and
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`the second spool memberin a locked position.
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`There has thus been outlined, rather broadly, the more
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`important features of the invention in order that the detailed
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`description thereof may be better understood, and in order
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`that the present contribution to the art may bebetter appre-
`ciated. There are additional features of the invention that
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`will be described hereinafter and that will form the subject
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`matter of the claims appendedhereto.
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`In this respect, before explaining at least one embodiment
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`of the invention in detail,
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`invention is not limited in its application to the details of
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`construction and to the arrangements of the components set
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`forth in the following description or illustrated in the draw-
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`ings. The invention is capable of other embodiments and of
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`being practiced and carried out in various ways. Also,it is
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`to be understood that
`the phraseology and terminology
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`employed herein are for the purpose of the description and
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`should not be regarded as limiting.
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`A primary object of the present invention is to provide a
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`wire spooling system that will overcome the shortcomings
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`of the prior art devices.
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`A second object is to provide a wire spooling system for
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`efficiently spooling and dispensing previously unspooled
`wire.
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`Another object is to provide a wire spooling system that
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`prevents twisting wire when trying to unravel it.
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`An additional object is to provide a wire spooling system
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`that simplifies work with unspooled wire traditionally used
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`in home improvementprojects.
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`A further object is to provide a wire spooling system that
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`is easily assembled.
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`Another object is to provide a wire spooling system that
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`provides a “split spool” that can be easily transported from
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`one job to another.
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`Other objects and advantagesofthe present invention will
`become obviousto the reader and it is intended that these
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`objects and advantages are within the scope of the present
`invention.
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`To the accomplishment of the above andrelated objects,
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`this invention may be embodiedin the form illustrated in the
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`accompanying drawings, attention being called to the fact,
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`however, that the drawings are illustrative only, and that
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`changes may be madein the specific construction illustrated
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`and described within the scope of the appended claims.
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`In view of the foregoing disadvantages inherent in the
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`known types of wire dispensing spool devices now present
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`in the prior art, the present invention provides a new wire
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`spooling system construction wherein the same can be
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`utilized for efficiently spooling and dispensing previously
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`unspooled wire.
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`The general purpose of the present invention, which will
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`be described subsequently in greater detail, is to provide a
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`new wire spooling system that has many of the advantages
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`of the wire dispensing spool devices mentioned heretofore
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`and many novel features that result in a new wire spooling
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`Various other objects, features and attendant advantages
`system which is not anticipated, rendered obvious, sug-
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`of the present invention will becomefully appreciated as the
`gested, or even implied by any oftheprior art wire dispens-
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`same becomes better understood when considered in con-
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`ing spool devices, either alone or in any combination
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`thereof.
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`junction with the accompanying drawings,
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`reference characters designate the same or similar parts
`To attain this, the present invention generally comprises a
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`throughout the several views, and wherein:
`first spool member, having a tubular member with a locking
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`cap andafirst collar, and a second spool member, having an FIG.1 is an exploded upperperspective view illustrating
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`engagementaperture and a secondcollar. The tubular mem-
`the components located on the facing sides of each wire
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`ber extends from the first spool member in direction sub-
`spooling system component.
`Page 10 of 13
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`DETAILED DESCRIPTION OF THE
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`INVENTION
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`3
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`C. Second Spool Member
`FIG.2 is an exploded upper perspective view illustrating
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`The second spool member 30 hasafirst side 32 and a
`the positioning of the wire spooling system components
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`second side 34 that are preferably substantially circular as
`prior to assembling the wire spooling system.
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`shown in FIGS. 1 through 4. The second spool member30
`FIG.3 is an exploded upper perspective view illustrating
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`is preferably disc shaped. As shown in FIGS. 4 through 8,
`the positioning of the previously unspooled wire with
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`the first side 32 is substantially flat. The first side 32 also has
`respect to each wire spooling system component.
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`an engagement aperture 76 to receive the locking cap 72
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`FIG. 4 is an upper perspective view of the present
`whensecuring thefirst spool member 20 to the second spool
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`invention in a fully assembledstate.
`member 30 as shown in FIGS. 1, 2, 3 and 8.
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`FIG. 5 is an exploded front view of the present invention
`The second spool member 30 has a second collar 50
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`protruding substantially transverse to the second side 34 as
`illustrating the unspooled wire with respect to the wire
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`shown in FIGS. 1 through 3, 5, 7 and 8. The second side 34
`spooling system components.
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`of the second spool member 30 has guide sleeves 62 that
`FIG. 6 is a front view of the present invention in an
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`protrude from the same side and in the sameplane as the
`assembledstate.
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`second collar 50 and are preferably found within the perim-
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`FIG. 7 is an exploded front cutaway view of the present
`eter of the second collar 50 as shown in FIGS. 1, 7 and 8.
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`invention illustrating the alignment of the internal compo-
`The second spool member 30 also has a wire-retaining
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`nents of the wire spooling system prior to assembly.
`aperture 36 through the second spool member 30 and
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`FIG. 8 is a front cutaway view of the present invention in
`positioned outside of the perimeter of the second collar 50
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`an assembledstate.
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`as shown in FIGS. 1 through 4, 7 and 8.
`D. Tubular Member
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`The tubular member 70 is positioned on the second side
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`24ofthefirst spool member 20 as shown in FIGS. 1 through
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`3, 7 and 8. The tubular member70 has a hollow channel 74
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`A. Overview
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`that extends through the middle of the tubular member 70
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`and spans the entire length of the tubular member 70,
`in which
`Turing now descriptively to the drawings,
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`thereby spanning the entire width of the assembled wire
`elements
`reference
`characters denote
`similar
`similar
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`spooling system 10 as shownin FIG.8. The tubular member
`throughout the several views, FIGS. 1 through8illustrate a
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`30
`70 also has a locking cap 72 positioned upon the end of the
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`wire spooling system 10, which comprises a first spool
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`tubular member 70 opposite the first spool member 20. The
`member 20, having a tubular member 70 with a locking cap
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`tubular member70 is the connection thatlinks thefirst spool
`72 andafirst collar 40, and a second spool member 30,
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`member20 to the second spool member 30 when the wire
`having an engagement aperture 76 and a second collar 50.
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`spool system 10 is fully assembled as shownin FIG. 8.
`The tubular member 70 extends through the first spool
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`member20 in direction substantially transverse to the first
`E. Locking Cap
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`spool member 20. The locking cap 72 is positioned at the
`The locking cap 72 has an aperture that is an extension of
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`end of the tubular member 70 opposite the first spool
`the hollow channel 74 positionedat the end furthest from the
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`member20. The first collar 40 protrudes from thefirst spool
`second side 24 of the first spool member 20 as shown in
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`member 20 in the same plane and direction as the tubular
`FIGS. 1 through 8. The locking cap 72 is an expanded
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`member 70. The second collar 50 of the second spool
`preferably mushroom-shaped end portion of the tubular
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`member30 fits snugly within thefirst collar 40, wherein the
`member 70 that is used to secure the first spool member 20
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`first spool member 20 and second spool member 30 thereby
`and the second spool member30 together as shown in FIGS.
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`form a spool shape. Upon fitting the first collar 40 and
`4 and 8. The locking cap 72 must be small enough to fit
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`second collar 50 together,
`the engagement aperture 76
`through the engagement aperture 76, but large enough to
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`receives the locking cap 72 of the tubular member 70,
`frictionally secure the first spool member 20 to the second
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`thereby securing the first spool member 20 and the second
`spool member 30 via the tubular member 70 as shown in
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`spool member30 in a locked position.
`FIGS. 4, 6 and 8.
`F. First Collar
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`B. First Spool Member
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`Thefirst collar 40 is positioned on the second side 24 of
`Thefirst spool member 20 hasa first side 22 and a second
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`the first spool member 20 as shown in FIGS. 1 through 3.
`side 24 that are preferably substantially circular as shown in
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`The first collar 40 is preferably circular shaped and pro-
`FIGS. 1 through 4. The first spool member 20 is preferably
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`trudes substantially transverse to the second side 24 of the
`disc shaped. As shown in FIGS. 4 though8, thefirst side 22
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`first spool member 20. A notch 42 is carved out ofthefirst
`is substantially flat. The first side 22 also has an aperture that
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`collar 40 on the edge opposite the second side 24 ofthe first
`provides access to a hollow channel 74 that extends through
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`spool member20 as shown in FIGS. 1 through 3 and 5. The
`the center of the wire spooling system 10 and out of the
`first collar 40 is of sufficient size that the second collar 50
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`locking cap 72 opposite the first side 22 of the first spool
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`member 20 as shown in FIGS. 7 and8.
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`may fit within it as shown in FIG.8.
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`G. Second Collar
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`The second side 24 is substantially flat and hasafirst
`60
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`collar 40, a plurality of guide members 60, and a tubular
`The second collar 50 is positioned on the secondside 34
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`member 70 attached thereto as shown in FIGS. 1 through3,
`of the second spool member 30 as shown in FIGS. 1 and 5.
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`7 and 8. The plurality of guide members 60, first collar 40
`The second collar 50 is preferably circle shaped and pro-
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`and tubular member 70 all protrude substantially transverse
`trudes substantially transverse to the second side 34 of the
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`to the secondside 24 ofthe first spool member 20 as shown
`second spool member 30 as shown in FIGS. 1 and 2. A recess
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`in FIGS. 1 through 3, 7 and 8. The guide members 60 and
`52 is defined in the second collar 50 as extending across the
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`entire width of the second collar 50 from a first side of the
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`tubular member 70 are preferably located within the perim-
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`eter of the first collar 40 as shown in FIGS. 1 through 3.
`second collar 50 in a plane transverse to that ofthe first side
`Page 11 of 13
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`US 7,121,501 B1
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`US 7,121,501 B1
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`22 of said second spool member30 as shownin FIG. 1. The
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`second collar 50 is preferably capable offitting within the
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`first collar 40. When aligning the guide members 60 of the
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`first collar 40 with the corresponding guide sleeves 62 of the
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`second collar 50, the second collar 50 fits within the confines
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`of the first collar 40 as shown in FIG.8. Additionally, upon
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`alignmentthe notch 42 aligns with a portion of the recess 52
`as shown in FIG. 6
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`H. Engagement Aperture
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`The engagement aperture 76 preferably passes through
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`the first side 32 and second side 34 of the second spool
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`member 30 as shown in FIGS. 1 through 4 and 7. The
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`engagementaperture 76 is large enough to allow the locking
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`cap 72 and end of the tubular member 70 to pass through, but
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`small enoughto frictionally retain the locking cap 72 after
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`the locking cap 72 is inserted through the engagement
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`aperture 76 as shown in FIGS. 4 and 8.
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`I. Operation of Invention
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`In use, a user places an unspooledroll of wire 12 over the
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`first collar 40 of the first spool member 20. The user may
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`crimp one portion of the wire 12 that can be inserted into the
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`notch 42 positioned on the first collar 40. Placing the
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`crimped portion of the wire 12 within the notch 42 allows for
`the recess 52 of the second collar 50 to secure the roll of wire
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`12 in place following assembly of the wire spooling system
`10. The secured wire 14 is retained between the notch 42 and
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`the recess 52, thereby disallowing the roll of wire 12 to
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`rotate about the first collar 40 independentofthe rotation of
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`the assembled wire spooling system 10.
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`Upon placement of the wire 12 on thefirst collar 40, the
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`user then preferably aligns the guide members 60 with their
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`corresponding guide sleeves 62, and the tubular member 70
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`35
`with the engagement aperture 76 as shown in FIG. 7. When
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`the guide members 60 and guide sleeves 62 are mated,
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`forcing the first spool member 20 and the second spool
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`member30 towards each other forces the locking cap 72 to
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`pass through the engagementaperture 76 as shown in FIGS.
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`4, 6 and 8. Thefirst spooling member 20 and the second
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`spooling member 30 then retain the wire 12 between their
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`respective second sides 24, 34 as shown in FIGS. 4 and 6.
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`The wire spooling system 10 is then assembled as shown in
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`FIGS. 4 and 6. The wire spooling system 10 is then fully
`assembled as shown in FIGS. 4 and6.
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`To efficiently unspool an amount of wire 12, a user may
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`place the hollow channel 74 over a nail or other appendage
`to facilitate a smooth removal of wire 12 that was not
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`previously on a spool. The user then pulls on the unsecured
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`end of the wire 12, thereby causing the spool to rotate and
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`the wire 12 to be dispensed accordingly. When the wire
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`spooling system 10 is not in use, the user may place the loose
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`end of the wire 12 through the wire-retaining aperture 36 and
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`crimp the wire 12,
`thereby securing the unused,
`loose
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`portion of wire 12 shown as secured wire 16 in FIGS. 4 and
`6.
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`What has been described and illustrated herein is a
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`preferred embodimentof the invention along with some of
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`its variations. The terms, descriptions and figures used
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`herein are set forth by way ofillustration only and are not
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`meantas limitations. Those skilled in the art will recognize
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`that many variations are possible within the spirit and scope
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`of the invention, which is intended to be defined by the
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`following claims (and their equivalents) in which all terms
`are meant in their broadest reasonable sense unless other-
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`wise indicated. Any headings utilized within the description
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`are for convenience only and havenolegalor limiting effect.
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`I claim:
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`1. A wire spooling system, comprising:
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`a first spool member;
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`a tubular member, wherein said tubular memberprotrudes
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`transversely from said first spool member;
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`a locking cap positioned at an end of said tubular member
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`opposite of said first spool member;
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`a first collar protruding from said first spool member;
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`a second spool member;
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`a secondcollar protruding substantially transversely from
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`said second spool member, wherein said second collar
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`fits within said first collar;
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`an engagement aperture within said second spool mem-
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`ber; and
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`wherein said engagement aperture receives said locking
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`cap of said tubular member, thereby securing saidfirst
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`spool member and said second spool member in a
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`substantially spool-shaped locked position.
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`2. The wire spooling system of claim 1, wherein saidfirst
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`spool member has a first side and a second side that are
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`substantially coplanar.
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`3. The wire spooling system of claim 1, wherein saidfirst
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`collar is capable of retaining an unspooled amount of wire
`aroundits exterior.
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`4. The wire spooling system of claim 1, wherein saidfirst
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`collar and said second collar are substantially the same
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`shape.
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`5. The wire spooling system of claim 1, wherein saidfirst
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`collar and said tubular member protrude transverse to said
`second side.
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`6. The wire spooling system of claim 1, wherein saidfirst
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`collar has a notch through an edge of said first collar
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`opposite ofa side of saidfirst collar that is positioned on said
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`first spool member.
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`7. The wire spooling system of claim 1, wherein saidfirst
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`spool memberhasa plurality of guide members protruding
`transverse to said secondside.
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`8. The wire spooling system of claim 1, wherein said
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`second spool memberhasa first side and a secondside that
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`are substantially coplanar.
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`9. The wire spooling system of claim 1, wherein said
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`second spool member has a plurality of guide sleeves
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`protruding substantially transverse to said second side of
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`said second spool member.
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`10. The wire spooling system of claim 9, wherein said
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`second collar has a recess that extends substantially across
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`the entire width of said second collar in a plane transverse
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`to said of said second spool member.
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`11. The wire spooling system of claim 9, wherein each of
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`said plurality of guide membersfits within a corresponding
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`one of said plurality of guide sleeves.
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`12. The wire spooling system of claim 11, wherein upon
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`alignment and insertion of said plurality of guide members
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`within said plurality of guide sleeves, said notch on saidfirst
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`collaris substantially aligned with said recess on said second
`collar.
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`13. The wire spooling system of claim 12, wherein a
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`predetermined portion of said wire is secured between said
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`notch and said recess to prevent a roll of wire positioned
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`radially about said first collar from rotating independent of
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`the wire spooling system.
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`14. The wire spooling system of claim 13, wherein upon
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`insertion of said plurality of guide members into each
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`corresponding said plurality of guide sleeves, subsequently
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`forcing said first spool member toward said second spool
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`Page 12 of 13
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`US 7,121,501 B1
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`20
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`25
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`8
`7
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`wherein said first collar and said second collar have
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`member causes said engagement aperture to receive said
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`substantially the same shape;
`locking cap, thereby securing said first spool memberto said
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`wherein said second collar fits within said first collar;
`second spool member.
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`15. The wire spooling system of claim 14, wherein upon
`a plurality of guide sleeves protruding substantially trans-
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`securing said first spool member to said second spool
`verse to said second side of said second spool member;
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`member, the wire positioned radially about the exterior of
`wherein eachof said plurality of guide memberfits within
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`said first collar is retained on said first collar between said
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`a corresponding one ofsaid plurality of guide sleeves;
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`second side of said first spool member and said second side
`a recess that extends substantially across the entire width
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`of said second spool member.
`of said secondcollar in a plane transverseto that of said
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`16. The wire spooling system of claim 1, wherein said
`second spool member;
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`second spooling memberhas a wire-retaining aperture posi-
`wherein upon alignment andinsertion of said plurality of
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`tioned through said second spool member.
`guide members within said plurality of guide sleeves,
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`17. The wire spooling system of claim 16, wherein the
`said notch on said first collar is substantially aligned
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`loose end of the wire may be secured