FIELD OF THE INVENTION

The present invention relates generally to spools for receiving electrical and communication cable and the like, and specifically, to cable spools that are impervious to the elements, require substantially no maintenance and have a knock-down construction for easy disassembly and shipment as a compact package.

BACKGROUND OF THE INVENTION

Electrical and communication cable is wound on large reels or spools which are transported to the cable installation sites. Such spools, which may carry loads of up to 1-1/2 tons, are usually fabricated of wood treated with a preservative such as creosote, or painted, so as to resist weathering and deterioration. Cable spools made of steel are also known; these, too, are painted so as to provide protection against rusting.

Existing spools have several disadvantages. They are not only heavy but require constant maintenance. Further, wooden spools especially are prone to splintering and breakage and, despite efforts to maintain them and protect them from the elements, they are subject to deterioration. Additionally, nails or bolts projecting from the spools pose a safety hazard. Wooden spools also soak up rain water, increasing their weight by as much as 50%. The dry weight marked on the spool is then meaningless making it impossible for the user to determine how much cable remains on the spool since this determination is usually made by weight. Because existing cable spools are expensive, after all of the cable has been dispensed from a spool it is returned to its point of origin to receive a new load of cable. Because of the space taken up by cable spools, reshipment of empty spools is highly inefficient, limited to relatively few spools per truckload. This inefficiency

and the attendant costs are particularly significant for long distance reshipments.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a cable spool whose main components are fabricated of plastic. Preferably, the plastic is a mixture comprising about 50 to 60% high density polyethylene with the remainder comprising low density polyethylene, a light weight material requiring little or no maintenance and which is impervious to the elements. Moreover, the cable spool of the invention is made of recyclable plastic and therefore helps meet the environmental regulations of a number of states, such as California, encouraging the use of recyclable materials by industry and requiring a certain percentage (for example 10%) of the goods purchased by the state to be fabricated of recyclable material.

Still further, the cable spool according to the present invention is designed to be knocked down and to thereby be easily broken down into several pieces (for example, four) and transported as a compact package. This makes reshipment of empty spools highly efficient, particularly for long shipping distances. Moreover, spools according to the present invention are ultraviolet stable and can be easily cleaned with water. No nails, or other hazardous fastening devices, project from any of the surfaces of the spool of the invention and since the plastic does not absorb water, the dry weight marked on the spool will not vary so as to provide at any time and under any weather conditions an accurate indication of the amount of cable remaining on the spool.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features and advantages of the invention will become evident from the detailed description below when read in conjunction with the

accompanying drawings in which:

Fig. 1 is an exploded perspective view of a cable spool in accordance with the present invention;

Fig. 2 is a side elevation view, in section, of a portion of the spool of Fig. 1; and

Fig. 3 is an end elevation view of the spool, in section.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawings, there is shown a cable spool 10 having a longitudinal axis of rotation 12 and basically comprising a hollow, generally cylindrical center core 14 and substantially identical end disks 16 and 18. In accordance with one aspect of the invention, the center core 14 is divided into two substantially identical half sections 20 and 22 but it will become evident that the core 14 may be subdivided into three or even more sections that are preferably, but are not required to be, substantially identical. The sections 20 and 22 include parallel, longitudinally extending surfaces 24 and 26 which are in abutting relationship in the assembled configuration of the spool 10.

The section 20 of the core 14 includes inwardly directed end flanges 28 and 30 lying generally in planes perpendicular to the axis 12. The end flange 28 has radially extending, inner and outer surfaces 32 and 34, respectively; likewise, the end flange 30 has inner and outer surfaces 36 and 38, respectively. The flange 28 has at least two, and preferably three through-holes 40 in axial alignment with corresponding through-holes formed in the flange 30. Extending between the inner surfaces 32 and 36 of the end flanges are tie rods 44 attached to the inner wall of the center core section 20. Each tie rod 44 lies parallel with the axis 12 and is in axial alignment with corresponding pairs of holes 40 in the end flanges. Thus, three such tie rods are shown in the illustrated embodiment. The ends of the tie rods 44

have threaded bores 46 for receiving bolts 48 adapted to secure the end disks 16 and 18 to the core 14, as will be described in greater detail below.

The section 22 of the core 14 will not be described in detail since it is substantially identical in all respects to the section 20. Similarly, because the end disks 16 and 18 are also substantially identical, only the disk 16 will be described.

The end disk 16 has a diameter substantially larger than the center core 14 so as to define a rim 50 for holding the cable in place on the core. The disk 16 further includes a hole 52, reinforced by a bushing plate 54, centered on the axis 12 for receiving a spindle or axle (not shown) for rotatably supporting the spool 10 while cable is unwound therefrom. A pair of holes 56 positioned along a diameter of the disk 16 is adapted to receive spool drive pins (not shown) in a manner well known in the art. In addition, the disk 16 includes a circular array of bolt holes 58 alignable with the holes 40 in the flange 28 of the core section 20 and the similar holes in the flange of the section 22. The bolts 48 are passed through the holes 58 and 40 and received by the threaded bores in the ends of the tie rods 44 to secure the end disk 16 to the center core sections 20 and 22 which are, as a result, held in abutting relationship thereby. The end disk 18 is attached to the center core sections in an identical fashion. Last, the disk 16 may include several holes 60 adjacent the outer edge of the rim 50 through one of which the end of the wound cable is passed for anchoring by a screw eye 62.

In accordance with another aspect of the invention, the center core 14 and end disks 16 and 18 are fabricated of plastic to minimize weight and maintenance. To conform to government regulations encouraging the use of recyclable plastics, the spool components are made of a mixture of high density polyethylene (HDP) and low density polyethylene (LDP) for strength. Such mixture

may include about 50 to 60% HDP with the remainder comprising LDP.

A cable spool in accordance with the invention may be easily disassembled for shipment as a compact package. All that is required is the removal of the bolts 48. The separated end disks and core sections can then be stacked in various ways to minimize shipping volume. Reassembly of the spool is, of course, equally expeditious.